MX2007003734A - Tow-based absorbent articles with a single casing sheet. - Google Patents

Abstract

An absorbent article is provided that includes a liquid pervious top layer and anabsorbent core of synthetic tow fibers. A casing layer is disposed to surround thecore such that super absorbent particles are disposed therebetween. The casinglayer is bonded with the core to form a predetermined pattern. The pattern is configuredfor containment of super absorbent particles. A liquid impervious back layeris also included, wherein the casing layer is disposed between the top layer andthe back layer. Alternatively, the absorbent article has an absorbent core ofpolypropylene tow fibers and a polypropylene casing sheet that encloses thecore such that super absorbent particles are disposed therebetween. The casingsheet is ultrasonically bonded, or embossed, to the core to form a predetermined pattern.The pattern defines pockets that are configured for containment of the superabsorbent particles.

Description

ABSORBENT ARTICLES BASED ON CABLE FIBER WITH AN INDIVIDUAL PACKAGING SHEET CROSS REFERENCE TO RELATED REQUESTS This patent application is: a continuation in part of Utility Patent Application Serial No. 10 / 394,588, filed with the United States Patent and Trademark Office (USPTO) on March 24, 2003 by Walter et al., which is a continuation in part of Utility Patent Application Serial No. 10 / 046,279 filed at the USPTO on January 16, 2002 by Delzer et al, now US Patent No. 6,832,905; a continuation in part of the Utility Patent Application of E.U.A. No. Series 10/951, 791, filed at the USPTO on September 29, 2004 by Waksmundzki et al., Which is a continuation in part of the Utility Patent Application of E.U.A. No. Series 10/411, 376 filed at the USPTO on April 11, 2003 by Litvay, now the Publication of the Patent Application of E.U.A. No. 2004/0204697; and a continuation in part of the Utility Patent Application of E.U.A. No. Series 10/951, 792, filed with the USPTO on September 29, 2004 by Waksmundzki et al., The full contents of each of these descriptions being incorporated for reference in this document.

BACKGROUND OF THE INVENTION TECHNICAL FIELD The present disclosure is generally related to absorbent articles and, more particularly, the present disclosure relates to absorbent articles based on cable fiber having an individual sheet of liner, and absorbent articles having centers of superabsorbent material.

BACKGROUND OF THE RELATED ART Absorbent articles or garments such as, for example, disposable diapers, training pants, adult incontinence pads, sanitary napkins, underpants lining, incontinence garments, etc. They are generally used in cooperation with clothing and disposed against a body surface for incontinent infants or adults. The absorbent article is used to collect and absorb discharges of fluid from the body, such as, for example, blood, menstruation, urine, watery body fluids, mucus and cell debris. For example, the absorbent article may be disposed between the legs of an individual adjacent to a crotch area. The absorbent article is placed with a garment and tensioned on the garment with a body surface of the crotch area to collect fluid discharge. As is known, absorbent articles typically include a fluid permeable cover material for coupling the surface of the body, a backing sheet impermeable to the fluid and an absorbent center supported therebetween. The backing sheet serves as a moisture barrier to prevent leakage of fluid into the garment. The absorbent center usually includes a liquid retention material that faces the body surface. The absorbent center may include, for example, loosely formed cellulosic fibers, such as, for example, wood pulp, fluff pulp, etc. acquiring and storing body discharge. Elastic regions may be provided around the edges of the article to secure the article around the waist and legs of the wearer. Much effort has been expended to find cost-effective materials for absorbent centers that exhibit good absorbency and liquid retention. Particles of superabsorbent materials (SAP) in the form of granules, beads, fibers, film chips, globules, etc., have been favored for such purposes. Such SAP materials are generally polymeric gelling materials that are capable of absorbing and retaining even under moderate pressure large amounts of liquid, such as water and body wastes, relative to their weight. SAP particles have typically been distributed within a fibrous web of spongy pulp material, which may comprise natural or synthetic fibers. Such structures are commonly referred to as spongy pulp / SAP centers. The superabsorbent material is generally a polymeric substance insoluble in water but capable of swelling with water capable of absorbing water in an amount that is greater than the weight of the substance in its dry form. In another type of superabsorbent material, the particles can be chemically described as having a center of natural or synthetic polymers with hydrophilic groups or polymers containing hydrophilic groups being chemically linked to the back center or in intimate admixture therewith. Included in this class of materials are modified polymers such as neutralized crosslinked sodium polyacrylates and polysaccharides including, for example, cellulose and starch and regenerated cellulose which are modified polymers to be carboxylated, phosphonoalkylated, sulfoxylated or phosphorylated, causing the SAP to be highly hydrophilic Such modified polymers can also be crosslinked to reduce their solubility in water. The ability of a superabsorbent material to absorb liquid depends on the shape, position and / or manner in which the particles of the superabsorbent material are incorporated in the fibrous web of the absorbent center. At any time when a particle of the superabsorbent material is wet, it swells and forms a gel. Gel formation can block the transmission of fluid into the absorbent center, a phenomenon called "gel block". Gel blocking prevents the liquid from being rapidly spread or absorbed beyond the "blocking" particles of the superabsorbent, causing portions of a partially hydrated center to be inaccessible for multiple doses of urine. Additional absorption of liquid by the absorbent center must then occur via a diffusion process. This is typically much slower than the speed at which the liquid is applied toward the center. Gel blocking frequently leads to leakage from the absorbent article before all absorbent material in the center is completely saturated. Despite the incidence of gel blockage, superabsorbent materials are incorporated into absorbent centers because they absorb and retain large amounts of liquid, even under load. However, for the superabsorbent materials to work, the liquid being absorbed in the absorbent structure must be transported to the unsaturated superabsorbent material. In other words, the superabsorbent material must be placed in a position to be connected by the liquid. In addition, when the superabsorbent material absorbs the liquid, it must be allowed to inflate. If the superabsorbent material is prevented from swelling, such as by being tightly enclosed within the fibrous web or by pressure exerted by the swelling of the adjacent superabsorbent particles, it will cease to absorb liquids. Adequate absorption of liquid by the absorbent center at the point of contact with initial liquid and rapid distribution of liquid far from this point are necessary to ensure that the absorbent center has sufficient capacity to absorb liquids deposited subsequently. Previous absorbent centers have thus attempted to rapidly absorb and distribute large quantities of liquids through the absorbent center while minimizing gel block during the absorption of multiple doses of liquid. Some of the most important performance attributes of an absorbent center of a diaper (or any other absorbent garment) are the functional capacity, absorption speed, and stability of the center in use. The absorption under load or AUL is a good measure of the functional capacity and the speed at which that absorption occurs. AUL is a function of both SAP basis weight (mass per unit area) and the composition of SAP used in the compound. Conventional baby diaper centers containing only a fluffy pulp fibrous web and high gel strength SAP typically maintain adequate SAP efficiency if the center contains less than about 50% SAP. Spongy diaper / SAP centers that contain more than 50% SAP generally result in lower SAP efficiency due to gel blocking. Although spongy centers / SAP with more than 50% SAP can provide adequate absorbency, the overall base weight of the center should typically be increased to compensate for the lower efficiency of the SAP. Increasing the base weight decreases the performance / cost ratio of the absorbent core, making it non-economic. Also, increased base weights tend to affect the fit and comfort of the garment, as well as impact packaging and shipping costs. Attempts to increase the relative weight of the SAP by reducing the basis weight of the conventional fluff pulp have resulted in failure because the low density fluff pulp mats have been unable to withstand the stress loads placed on them during the manufacturing processes. Such centers also exhibit poor moisture resistance, making them unstable during use, and fail to adequately secure the SAP in place. The introduction of centers of fibrous structure of relatively high integrity, however, has allowed the basis weight of the fibrous web to be decreased without compromising the manufacture and moisture resistance of the absorbent center. These structures absorbent center. SAP efficiency and a decrease in integral basis weight have been improved. Such absorbent centers are described, for example, in the Statutory Invention of E. U. A. Registration No. H1, 565 of Brodof et al., Which is incorporated herein by reference in its entirety and in a manner consistent with the present invention. These high integrity fibrous structure centers, referred to herein as "fiber in cable / SAP" centers or "fiber-in-cable" centers, typically use a continuous cable or crimped filaments. The cable fiber can be provided by the manufacturer of the absorbent center in a compact and "open" (ie, "grown" or softened) form prior to being assembled into an absorbent core.

In some cases, the fibrous web of the cable fiber center / SAP can be treated with an adhesive agent to adhere the SAP particles to the fibrous web. In other cases, the SAP particles may be introduced into the fibrous web without any adhesive, binder or tackifier, such as described in US Patent No. 6,068,620 published by Chmielewski et al., Which is incorporated herein by reference. in the present document for full reference and in a manner consistent with the present invention. Such a construction has been referred to as a dry formed composite center (DFC). A DFC center may be surrounded by a layer of tissue or multiple tissue layers to form a DFC laminar structure containing the fibrous web and SAP. A potential disadvantage with the DFC centers, however, is that the known methods and apparatuses for producing such centers typically require two separate sheets of tissue to be used during manufacturing to enclose the cable fiber and SAP. The use of these two sheets of fabric can, for example, increase the cost or complexity of the manufacturing operation. A problem with fibrous cores containing SAP has been to provide the SAP within the fibrous web in a controlled manner. Typical processes known to create a conventional SAP / sponge pulp core use a large forming chamber to mix the SAP with the comminuted pulp, then this mixture is transported on a drum or grid using vacuum. The drum or grid has molded cavities that mold the sponge / SAP material into the desired shape and the molded cores are then deposited for integration into the absorbent products. Such methods have been found to be inefficient during startup and speed transitions of the manufacturing line because they require a relatively long period of time to provide a stabilized blend of SAP and fluff pulp, leading to the creation of a large number of products. scrap until stabilization. Other conventional processes for molding fluff pulp cores / SAP immerse the minced pulp into a fluid mixture containing SAP particles, then dry the fluff pulp / SAP before integration into the absorbent article. Such wet molding processes typically require more manufacturing steps and are more expensive than dry molding methods. Other power systems use fixed-sized movable mechanical doors that provide a uniform amount of SAP to the absorbent core, such as described in US Patent No. 6,139,912 to Onuschak et al, which is incorporated herein by reference. complete and in a manner consistent with the present invention. Although such devices may be suitable for providing a uniform flow of SAP and other powder and particulate additives for absorbent cores, they are based on relatively complex feed machinery, including a positive valve which uses a pneumatic SAP conveyor to return the SAP not distributed to a supply container.

SAP conveyors typically require relatively long time to be pressurized and to transport the SAP, causing inefficiencies during transition phases, such as when the machine's operating speed varies, such as during the start and stop of the machine, or when You want to change the amount of SAP being fed to the core. Additional parts of such feeders can also be expensive and subject to wear and other service problems. Similar devices, which have similar deficiencies, are described in U.A. Patent No. 4,800,102 to Takada, which is incorporated herein by reference in its entirety and in a manner consistent with the present invention. Still other power systems use pneumatic particle projectors that use pressurized gas to transport the SAP to the surface of the absorbent core. Such devices are described, for example, in U.S. Patent Nos. 5,614,147 to Pelley and 5,558,713 to Siegfried et al., which are incorporated herein by reference in their entirety and in a manner consistent with the present invention. Such systems are based on relatively complex air conveyors, which may be susceptible to blockage and which may not efficiently accommodate a wide variety of particles, dust and fibrous materials as other systems due to their relatively small pitch sizes. In fact, it has been found that the compressed air used in such pneumatic conveyors is frequently contaminated with oil which can cause blockage, degradation of SAP, and other problems. Such systems may also require a relatively long time to stabilize, leading to inefficiencies during the transition phases. Other SAP power systems are disadvantageous for a variety of reasons. First, the blend of fiber and SAP is still subject to local concentrations and lack of SAP. Second, these power systems typically can not be controlled with sufficient precision to provide concentrations and deficiencies of SAP when these are desired. Third, such feeding systems can not be controlled to accurately provide quantities of reduced SAPs that are necessary during transition phases, leading to inappropriately loaded cores during those phases of operation. Therefore, it may be desirable to overcome the disadvantages and drawbacks of the prior art by providing an absorbent article based on cable fiber having a single wrapping sheet. Such an absorbent article desirably defines a predetermined pattern containing superabsorbent material. It may also be desirable to provide absorbent articles having cores of superabsorbent material. ES contemplates that such absorbent articles are easily and efficiently manufactured. Thus, manufacturing methods are also described.

BRIEF DESCRIPTION OF THE INVENTION Accordingly, an absorbent article based on fiber in cable having an individual wrapping sheet is described. Such an absorbent article can define a predetermined pattern containing superabsorbent material. Absorbent articles having cores of superabsorbent material are also described. It is contemplated that such absorbent articles are easily and efficiently manufactured. Thus, manufacturing methods are also described. Objects and disadvantages of the present disclosure are published in part in the present document and in part will be obvious from these, or can be learned by the practice of the present description that is realized and achieved by the instrumentation and combinations indicated in the claims appended by the devices and methods of the present description consisting of their constituent parts, constructions, arrangements, combinations, steps and improvements shown and described herein. In a particular embodiment, an absorbent article is provided which includes a liquid pre-top layer and an absorbent core of synthetic cable fibers. A wrapping layer is arranged to surround the core such that the superabsorbent particles are disposed therebetween. The wrapping layer is attached to the core to form a predetermined pattern. The pattern is configured for containment of superabsorbent particles. A liquid impermeable reinforcing layer is also included, wherein the wrap layer is disposed between the top layer and the backing layer. In an alternative embodiment, the absorbent article has an absorbent core of polypropylene cable fibers and a polypropylene wrap sheet that encloses the core such that the superabsorbent particles are disposed therebetween. The wrapping sheet is ultrasonically joined to the core to form a predetermined pattern. The pattern defines cavities that are configured to contain the superabsorbent particles. The absorbent article also includes a liquid impervious reinforcing layer, wherein the wrapping sheet is disposed between the upper layer and the reinforcing layer. The superabsorbent particles can be adhered to the wrapping sheet. In another alternative embodiment, the absorbent article includes a wrap layer that is bonded to the core to form a patterned pattern. The embossed pattern defines cavities that are configured to contain the superabsorbent particles. In another alternative embodiment, the absorbent article includes an absorbent core of synthetic fibers from a suitable roll product. In an alternative embodiment, the absorbent article includes a prior top layer of liquid and an absorbent layer comprised of 100% by weight superabsorbent particles. A wrapping layer is arranged to surround the absorbent layer. A liquid impermeable reinforcing layer is also included, wherein the wrapping layer is disposed between the upper layer and the reinforcing layer. Alternatively, the absorbent article may include an absorbent core of synthetic cable fibers, wherein the absorbent layer is separated from the adjoining and adjacent disposed absorbent core. The wrapping layer is attached to the core. An acquisition layer may be disposed between the upper layer and the wrapping layer.

BRIEF DESCRIPTION OF THE DRAWINGS The objects and features of the present disclosure are published with particularity in the appended claims. The present description, regarding its organization and manner of operation, together with additional objectives and advantages can be understood by reference to the following description, taken in combination with the attached drawings, in which: FIG. 1 is a plan view of a diaper-type absorbent article, shown with the effect of elastics removed for clarity; FIG. 2 is a cross-sectional view of the article of FIG 1, as seen from reference line 1-1; FIG. 3 is a partial sectional side view of a system for dry molded absorbent cores and other structures and machine in accordance with a preferred embodiment of the present invention, shown in operation and in relation to a portion of a manufacturing line of the absorbent article; FIG. 4 is a partial sectional view of a feeding tray in accordance with a preferred embodiment of the present invention, shown at one end of its range of motion and showing the other end of its range of motion in dashed lines; FIG. 5A is a sectional view of a portion of a feed tray in accordance with a preferred embodiment of the present invention; FIG. 5B is a view is a sectional view of a portion of another feed tray in accordance with a preferred embodiment of the present invention; FIG. 6 is a side view in partial section of a feed tray, motor and side plates in accordance with a preferred embodiment of the present invention; FIG. 7 is an isometric view of the outlet portion of a feed tray in accordance with a preferred embodiment of the present invention; FIG. 8 is an isometric view of a combination drum in accordance with a preferred embodiment of the present invention; FIG. 9 is a cross-sectional view of the vacuum surface of a combination drum according to a preferred embodiment of the present invention, showing the operation with the composite core adjacent to the vacuum surface; FIG. 10 is an isometric view in partially exploded view of another combination drum in accordance with a preferred embodiment of the present invention; FIG. 11 is an isometric view of yet another combination drum in accordance with a preferred embodiment of the present invention; FIG. 12 is a cross-sectional view of a combination drum assembly in accordance with a preferred embodiment of the present invention as seen from reference line 3-3 of FIG. 13; FIG. 13 is a cross-sectional view of the combination drum assembly of FIG. 12, as seen from the reference line 2-2; FIG. 14 is a partial sectional view of the assembly of the combination drum of FIG. 12 shown with the outer drum partially removed; FIG. 15 is an isometric view of the outlet portion of a feed tray in accordance with another embodiment of the present invention; FIG. 16A is a cross-sectional view of one embodiment of an absorbent article having a single wrapping sheet; FIG. 16B is a cross-sectional view of another embodiment of an absorbent article having a single wrapping sheet; FIG. 17 is a side view of one embodiment of a system for molding absorbent articles based on cable fiber with a single wrapping sheet; FIG. 18A is a cross-sectional view of an embodiment of an absorbent core assembly during processing in the apparatus of FIG. 17 as seen along reference line 4-4 of FIG. 17, shown with the machine removed for clarity; FIG. 18B is a cross-sectional view of an embodiment of an absorbent core assembly during processing in the apparatus of FIG. 17 as seen along reference line 5-5 of FIG. 17, shown with the machine removed for clarity; FIG. 18C is a cross-sectional view of one embodiment of an absorbent core assembly during processing in the apparatus of FIG. 17 as seen along reference line 6-6 of FIG. 17, shown with the machinery extracted for clarity; FIG. 19 is an illustration of one embodiment of a tapered cutting roller of the embodiment of the apparatus of FIG. 17; FIG. 20 is an illustration of an angled surface embodiment and a non-tapered cutting drum that can be used with the embodiment of FIG. 17; FIG. 21 is a side view of another embodiment of a system for molding absorbent articles based on fiber in cable with a single wrapping sheet; FIG. 22 is a side view of yet another embodiment of a system for molding absorbent articles based on cable fiber with a single wrapping sheet; FIG. 23 is a top view of an embodiment of a staggered configuration on the roller that can be used with a tapered vacuum drawing cylinder in a system for modeling absorbent articles based on cable fiber with a single wrapping sheet; FIG. 24 is an isometric view of an embodiment of a tapered vacuum drawing roll that can be used in a system for molding fiber-based absorbent structures in cable with a single wrap sheet; FIG. 25 is a sectional side view of the embodiment of a tapered combination drum of FIG. 24; FIG. 26 is a front view in partial section of the embodiment of a tapered combination drum of FIG. 24; FIG. 27 is a front view in partial section in detail illustrating the embodiment of a tapered combination drum of FIG. 24; FIG. 28 is a side view of another embodiment of a system for molding tow-based absorbent articles with a single wrapping sheet; FIG. 29 is a side view of yet another embodiment of a system for molding tow-based absorbent articles with a single wrapping sheet; FIG. 30 is a side view of yet another embodiment of a system for molding tow-based absorbent articles with a single wrapping sheet; FIG. 31 is a sectional plan view illustration of the components of an alternative embodiment of the absorbent article in accordance with the principles of the present disclosure; FIG. 32 is a side cross-sectional view of the absorbent article shown in FIG. 31; FIG. 33 is a perspective view of the absorbent article shown in FIG. 31 illustrating the pattern of the point of attachment; FIG. 34 is an alternative lateral cross-sectional view of the absorbent article shown in FIG. 31 illustrating a predetermined pattern of cavities; FIG. 35 is an illustration showing the formation of the attachment points shown in FIG. 33; FIG. 36 is a plan view of an alternative embodiment of the junction point pattern shown in FIG. 33; FIG. 37 is a plan view of another alternative embodiment of the junction point pattern shown in FIG. 33; FIG. 38 is a plan view of another alternative embodiment of the junction point pattern shown in FIG. 33; FIG. 39 is a plan view of another alternative embodiment of the junction point pattern shown in FIG. 33; FIG. 40 is a sectional illustration plan view of the components of another alternative embodiment of the absorbent article; FIG. 41 is a side cross-sectional view of the absorbent article shown in FIG. 40; FIG. 42 is a plan view with sectional illustration of the components of another alternative embodiment of the absorbent article; FIG. 43 is a side cross-sectional view of the absorbent article shown in FIG. 42; FIG. 44 is a plan view with illustration in section of the components of another alternative embodiment of the absorbent article; FIG. 45 is a side cross-sectional view of the absorbent article shown in FIG. 44; FIG. 46 is a sectional plan view illustration of the components of another alternative embodiment of the absorbent article; FIG. 47 is a side cross-sectional view of the absorbent article shown in FIG. 48; FIG. 48 is a side view of an alternative embodiment of a system for molding tow-based absorbent articles with a single wrapping sheet; and FIG. 49 is a side view of another alternative embodiment of a system for molding tow-based absorbent articles with a single wrapping sheet.

DETAILED DESCRIPTION OF THE INVENTION The exemplary embodiments of the absorbent article and methods of use described are discussed in terms of absorbent articles, and more particularly, in terms of an absorbent article based on tow having an individual wrapping sheet. Such an absorbent article desirably defines a predetermined pattern containing superabsorbent material. Absorbent articles having cores of superabsorbent material are also described. Manufacturing methods are also described. As used herein, the terms "absorbent article" or "absorbent garment" refer to articles that absorb and contain extruded mixture, and more specifically, refer to articles that are placed against or in close proximity to the wearer's body. to absorb and contains several extruded mixtures discharged from the body. A non-exhaustive list of examples of absorbent articles includes diapers, diaper covers, disposable diapers, training underpants, femienine hygiene products and adult incontinence products. The term absorbent article includes all variants of absorbent garments, including disposable absorbent garments that are intended to be discarded or partially discarded after a single use (ie, they are not intended to be washed or otherwise restored). or reused) and unitary disposable absorbent garments having essentially an individual structure (ie, they do not require separate manipulated parts such as a diaper cover and insert). Absorbent articles and diapers can have a variety of different constructions. These constructions may have an absorbent core disposed between a top sheet facing the body, permeable to liquid and a rear sheet facing outward, impervious to liquid. One or both of the upper sheet and the back sheet can be molded to form a garment similar to a brief. The topsheet, backsheet and absorbent core can also be formed as a discrete assembly that is placed on a main frame layer that is molded to form a panty-like garment. The garment can be provided to the consumer in a similar way to a fully assembled briefs, or it may be partially similar to short and require the consumer to make the final final steps necessary to create the similar form to similar shorts. In the case of training-type garments and most adult incontinence products, the garment completely formed with factory-made side seams and the garment placed by pushing it up the legs of the wearer. . In the case of diapers, a caregiver wraps the diaper around the wearer's waist and joins the side seams manually by adhering one or more adhesives or mechanical tabs, thus forming a structure similar to panties. Through this description, the expressions "top layer", "bottom layer", "top" and "bottom", which refer to the various components of the absorbent article (including the layers surrounding the absorbent core), as well as the illustration in the drawings of certain layers of materials that are "up" or "down" from each other, are used merely to describe the spatial relationship between the respective components. The top layer or "up" component of the other component does not always need to remain vertically above the core or component, and the bottom layer or "down" component of the other component does not always need to remain vertically below the core or component. In fact, the embodiments of the invention include various configurations by means of which the core can be bent in such a way that the upper layer finally turns into the uppermost layer vertically and lower vertically at the same time. Other configurations are contemplated within the context of the present invention.

The term "component" may refer, but is not limited, to designate selected regions, such as edges, corners, sides or the like; the structural members, such as elastic bands, absorbent pads, stretchable layers or panels, layers of material, or the like; or a graphic, embossed pattern, or the like. Through this description, the term "arranged" and the expressions "disposed about", "disposing about", "disposed within", "disposed between" and variants thereof (for example, a description of the article being "arranged" is interposed between the words "arranged" and "on") are meant to mean that an element can be integral with another element, or that an element can be a separate structure attached to or placed with or placed near another element. Thus, a component that is "arranged on" an element of the absorbent article can be formed or applied directly or indirectly to a surface of the element, formed or applied between the layers of a multiple layer element, formed or applied to a substrate that is placed with or near the element, formed or applied within a layer of the element or other substrate, or other variants or combinations thereof. Through this description, the terms "top sheet" and "back sheet" denote the relationship of these materials or layers with respect to the absorbent core. It is understood that additional layers may be present between the absorbent core and the topsheet and the backsheet, and that additional layers and other materials may be present on the opposite side of the absorbent core of the topsheet or housing reinforcing. Throughout this description, the term "fibrous material" denotes any fibrous material that can be used in an absorbent garment, including without limitation, various fluff pulps of hardwood and softwood, fabrics, cottons, and any other materials. fibroses described herein. The "fibrous material" used in the context of the present invention is not intended to limit the invention to any particular type of fibrous material. Throughout this description, the expression "fibers in cable" is generally related to any continuous fiber. Cable fibers are typically used in the manufacture of staple fibers, and are preferably comprised of synthetic thermoplastic polymers. Usually, numerous filaments are produced by melt extrusion of the melted polymer through a multiple orifice die during the manufacture of staple fibers from synthetic thermoplastic polymers in order to achieve reasonably high productivity. The groups of filaments from a plurality of rows are typically combined into a cable which is then subjected to a delineation operation to impart the desired physical properties to the filaments comprising the fiber in cable. A preferred embodiment of the present invention comprises a disposable absorbent article 10 of the diaper type, as shown, for example, in FIG. 1. It should be understood, however, that the present invention is applicable to other types of absorbent garments. With reference to FIG. 1, the diaper 10 in accordance with a first embodiment is shown in a relaxed condition with the effects of the elastics removed for purposes of clarity in the description. The diaper 10 has a shape generally similar to hourglass and can be defined generally in terms of a front waist region 22, a rear waist region 24, and a crotch region 26. Those skilled in the art will recognize that " "front" and "rear" are relative terms, and those regions may be transpuntos without deviating from the scope of the present invention. Alternatively, the diaper can be configured in a generally rectangular or "T" shaped. A pair of leg openings 28a, 28b extend along at least a portion of the crotch region 26. The diaper preferably comprises a top sheet 2, a back sheet 4, which can be substantially limited with the top sheet 2, and an absorbent core 6. arranged between at least a portion of the topsheet 2 and backsheet 4. One or more pairs of leg elastics 8 (3 pairs shown in Figure 1) may be arranged to extend adjacent the leg openings 28a, 28b , respectively. Of course, in other embodiments, the leg elastics 8 can be omitted completely. The diaper may further include a front waist elastic system 30a, a rear waist elastic system 30b, a fastening system 32 (e.g. tape and other appropriate mechanical fastener) and a waste containment system in the form of waste containment flaps 12 (also known as upright leg gathers). The waste containment flaps 12 (FIG 2) preferably extend from the front waist region 22 to the rear waist region 24 along opposite sides of a longitudinal center line or axial center line 60 of the diaper 10, or alternatively only along a portion thereof. The front waist region 22 and the rear waist region 24 may include ear portions 38, 34 extending outwardly from the leg openings 28a, 28b. A variety of backsheet and top sheet constructions and materials are available and are known in the art, and the invention is not intended to be limited to some specific materials or constructions of these components. The backsheet 4 is of any suitable foldable liquid impervious material known in the art. Typical backsheet materials include polyethylene, polypropylene, polyester, nylon, and polyvinyl chloride films and mixtures of these materials. For example, the backsheet may be a pigmented polyethylene film having a thickness in the range of 0.02-0.04 mm. The moisture permeable backsheet 2 can be of any relatively suitable liquid-permeable material known in the art that allows liquid to pass therethrough. Nonwoven backsheet materials are exemplary because such materials readily allow the passage of liquids to the underlying absorbent core 6. Examples of such suitable top sheet materials include spun or carded non-woven webs of polypropylene, polyethylene, nylon, polyester and mixtures of these materials. The backsheet 4 and the top sheet 2 are preferably "associated" with each other. The term "associated" includes configurations by means of which the top sheet 2 is directly attached to the back sheet 4 by attaching the top sheet 2 directly to the back sheet 4, and configurations by means of which the top sheet 2 is indirectly bonded to the backsheet 4 fixing the upper sheet 2 to the intermediate members which in turn are fixed to the back sheet 4. While the back sheet 4 and the upper sheet 2 in the preferred embodiment have substantially the same dimensions, they can also have different dimensions. In addition, the backsheet 4 can be covered with a non-woven, fibrous web as described for example in U.S. Patent No. 4,646,362, which is incorporated herein by reference in its entirety and in a manner consistent with the present invention. Materials for such a fibrous outerliner include a non-woven web spun from synthetic fibers such as polypropylene, polyethylene or polyester fibers; a non-woven web of cellulosic fibers, textile fibers such as rayon fibers, cotton and the like, or a mixture of cellulosic and textile fibers; a non-woven web spins synthetic fibers such as polypropylene; polyethylene or polyester fibers blended with cellulose, pulp, or textile fibers; or melt blown thermoplastic fibers, such as macro fibers or micro fibers of polypropylene, polyethylene, polyester or other thermoplastic materials or blends of such macro fibers or thermoplastic micro fibers with cellulosic, pulp or textile fibers. The backsheet 4 may comprise multiple panels, such as three panels wherein a central rear poly sheet panel is placed adjacent to the absorbent core while non-woven breathable side rear sheet panels are attached to the side edges of the poly panel central back sheet. The backsheet can also be formed from microporous poly cover to add breathability. In other embodiments, the backsheet may be a laminate of several sheets. The backsheet may also be treated to render it hydrophilic or hydrophobic, and may have one or more visual indicators associated therewith, such as labels indicating the front and back of the diaper or other characters or colorations. The present invention is not limited to any particular backsheet material 4 or construction. The top sheet 2 can be formed from one or more panels of material and can comprise a laminated sheet construction. In the embodiment of FIG. 1, the top sheet comprises three separate portions or panels. A three panel top sheet may comprise a central top sheet panel 2a (FIG 2) which is preferably formed of a liquid permeable material that is hydrophobic or hydrophilic. The central top sheet panel 2a can be manufactured from any variety of materials, including synthetic fibers (e.g., polypropylene or polyester fibers), natural fibers (e.g., wood or cellulose), plastic films with holes, cross-linked foams and foams porous to name a few. A preferred material for a central top sheet panel 2a is a conventional laminated nonwoven cover which can be made of carded, adhesively or thermally bonded fibers, perforated plastic film, spunbond nonwoven fibers, or water-entangled fibers which are generally they weigh from 0.3-0.7 oz / yd2 and have proper and effective machine direction and transverse direction resistance of the machine suitable for use as a classic baby diaper cover material, as is known in the art. The central top sheet panel 2a preferably extends from substantially the front waist region 22 towards the rear waist region 24 or a portion thereof. The second and third top sheet panels 2b, 2c in this embodiment can be placed laterally outside the central top sheet panel 2a. The outer top sheet panels 2b, 2c are preferably substantially liquid impervious and hydrophobic, preferably at least in the crotch area. The outer edges of the outer top sheet panels can substantially follow the corresponding outer perimeter of the back sheet 4. The material for the outer top sheet portions or panels is preferably polypropylene and can be woven, nonwoven, spun nonwoven, carded or similar, depending on the application.

An inner region 34 (FIG.2) of the outer top sheet portions or panels 2b, 2c is preferably fixed with, for example, an adhesive, to the outer edges 36 of the inner top sheet portion or panel 2a. At this point of connection with the outer edges 36 of the inner top sheet portion or panel 2a, the inner regions 34 of the outer top sheet portions or panels 2b, 2c extend upwardly to form waste containment flaps 12. Scrap containment flaps 12 may be formed of the same material as the outer top sheet portions or panels 2b, 2c, as in the embodiment shown. The waste containment flaps 12 may also be formed of elasticized bands separated from the material that are associated with the topsheet, backsheet or both, or otherwise integrated into the garment. The waste containment flaps 12 can be treated with an appropriate surfactant to modify their hydrophobicity / hydrophilicity or impregnated with surface products in good condition as desired. The central top sheet portion or panel 2a can extend beyond the point of connection with the waste containment flaps 12 and still extend to the periphery of the backsheet. Still further, the central top sheet portion or panel 2a could be completely extended between the outer top sheet portions or panels 2b, 2c and even further such that the outer edges 36 of the central top sheet portion or panel are coextensive and interleaved between the outer top sheet portions or panels 2b, 2c and the back sheet 4. The waste containment flaps 12 each preferably includes a portion that bends over itself to form a housing. One or more elastic members 14 (FIG 2) can be secured in the housing in a stretched condition. As has been known at least up to the description of Tetsujiro, Japanese Patent Document 40-11543, when the flap elastic 14 attempts to assume the relaxed, unstretched condition, the waste containment flaps 12 rise above the surface of the portion. of central top sheet or panel 2a. Various other configurations of top sheets 2 and waste containment systems, such as flaps 12, are known in the art, and the present invention is not intended to be limited to any particular design for these components. The waist elastics 30a, 30b (FIG 1) can be similar or different structures to impart similar or different elastic characteristics to the front and back waist portions 22, 24 of the diaper. In general, the waist elastics can comprise elastically stretchable foam strips placed in the front and back waist sections 22, 24. The foam bands are preferably from approximately 1.27 centimeters (0.50 inches) to approximately 3.81 (1.50 inches) wide. and approximately 7.62 centimeters (3 inches) to 15.24 centimeters (6 inches) in length. The foam bands are preferably placed between the upper sheet portions or panels and the backsheet 4. Alternatively, a plurality of elastic yarns may be employed as waist elastics instead of foam bands. The foam webs are preferably made of polyurethane, but could be of any other suitable material that preferably decreases the web roll on the waist, reduces leakage on the waist ends of the absorbent garment, and generally improves comfort and fit. . The front and rear waist foam bands 30a, 30b are stretched 50-150%, preferably 100% before being adhesively secured between the backsheet 4 and the top sheet 2. Waist elastics are known in the art, and the present invention is not limited to the use of a particular waist elastic system, or the inclusion of waist elastics in any way. The leg openings 28a, 28b may be provided with a leg elastic restraint system 8, sometimes referred to as conventional leg gathers. In a preferred embodiment, three strands of elastic yarns are positioned to extend adjacent to the leg openings 28a, 28b between the outer top sheet portions or panels 2b, 2c and the backsheet 4, the selection of appropriate elastics and the construction of the Elastic leg restraint systems are known in the art. For example, the leg elastics 8 can be ultrasonically bonded, sealed with heat / pressure using a variety of bonding patterns, or glued to the diaper 10.

Various commercially available materials can be used for the leg elastics 8 and elastic members 14, such as cacucho, butyl rubber or other synthetic rubber, urethane, elastomeric materials such as spandex, which is marketed under various names, including LYCRA (DuPont), GLOSPAN (Globe) and SYSTEM 7000 (Fuiflex), and so on. The present invention is not limited to any particular elastic. The diaper fastening system 10 can be attached to the rear waist region 24, and preferably comprises tape tabs or mechanical fasteners 32. However, any fastening known in the art will be acceptable. In addition, the fastening system can include a reinforcing patch below the front waist portion such that the diaper can be checked for dirt without compromising the ability to reuse the fastener. Alternatively, other diaper fastening systems are also possible, including safety pins, buttons, and snaps. Clamping systems are known in the art, and the present invention is not limited to using any particular fastener, and can be constructed without some fastening system in any way, such as in training pants. As previously stated, the invention has been described in combination with a diaper. The invention, however, is not intended to be limited to application only in diapers. Specifically, the present invention can be easily adapted for use in other garments in addition to diapers, including, but not limited to, training pants, feminine hygiene products and adult incontinence products. The underlying structure beneath the top sheet 2 may include, depending on the construction of the diaper, various combinations of elements, but in each embodiment, it is contemplated that the absorbent article will preferably include an absorbent core 6. For example, an additional layer 20 may be disposed between the top sheet 2 and the absorbent core 6, as shown in FIG. 2, and / or other additional layers may be disposed between these layers, or between the absorbent core 6 and the backsheet 4. The additional layer 20 or layers may comprise any useful layer known in the art or developed hereinafter, such as a fluid acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, an absorbent layer, a storage layer, or combinations and fragments of those layers. Such layers can be provided to assist in the transfer of fluids to the absorbent core 6, by manipulating the emergence of fluid, preventing rewetting, containing absorbent material, improving core stability, or for other purposes. Skilled artisans are familiar with several additional layers that can be included in an absorbent article, and the present invention is not intended to be limited to any particular type of materials used for those layers. Instead, the invention includes all types of absorbent layers, all types of distribution layers, etc., up to the extent to which that type of layer 20 is used. The dimensions of the additional layer (s) 20 can be the same as or different from the dimensions of the absorbent core 6 and / or top sheet 2 and backsheet 4. It is preferred that the additional layer (s) 20 have a width in the direction side (102) anywhere from about 10 mm to about 100 mm, and preferably from about 25 mm to about 80 mm. Although the absorbent core 6 illustrated in FIG. 1 has a substantially rectangular shape as seen in the plant view, other shapes can be used, such as "T" shape or a shape similar to hourglass. The absorbent core 6 may extend into either or both of the front and rear waist regions 24, 22. The shape and construction of the absorbent core 6 may be selected to provide greater absorbency in the target areas where body fluids are more likely. that affect the diaper 10, which are referred to as the absorbency zone. The absorbent core 6 may also comprise a number of layers of similar or different construction. The absorbent core may be associated with the topsheet 2, backsheet 4, or any other appropriate part of the garment 10 by any method known in the art, to secure the absorbent core 6 in place. Generally, in a preferred embodiment, the absorbent core 6 comprises superabsorbent polymer particles distributed within a fibrous structure. Additional fibers or particle additives may be disposed within the absorbent core 6 to add core strength and SAP efficiency or to otherwise improve the performance of the garment. The absorbent core 6 may be partially or completely surrounded by a fabric layer 16, 18, and additional layers 20 may be added to provide additional benefits. The various components of the absorbent core 6 are now described in greater detail. Certain fibrous materials are preferably used to form the fibrous structure of the absorbent core 6 of the present invention. These fibrous materials maintain high SAP efficiencies when the SAP weight concentration is in the range of about 50-95%, more preferably about 65-95%, and more preferably about 80-95% (as measured in the absence of tissue, adhesive or other core components). For example, the fibrous structure of the absorbent core 6 can be manufactured with cellulose acetate fibers, polypropylene fibers, rayon fibers, LYOCELL fibers by Courtauld, polyacrylonitrile fibers, polyester fibers (hydrophilic) with modified surface, bicomponent polyolefin fibers / polyester with modified surface, bicomponent polyester / polyester fibers with modified surface, cotton fibers, mixtures of the preceding materials, and the like. From the foregoing, the most preferred materials are cellulose acetate or polyolefin cable fibers (e.g., polypropylene or polyethylene) for use as the fibrous structure. In addition, rayon, LYOCELL de Courtauld, polyacrylonitrile, cotton fibers and cotton linters have properties similar to cellulose acetate and are alternatively preferred. The remaining fibers, bicomponent polyolefin / polyester fibers with modified surface, and bicomponent polyester / polyester fibers with modified surface are also believed to be effective as a fibrous structure or as fibrous additives. Of course, other fibers can also be used. To maintain high SAP concentrations, the weight concentration of fibrous material forming the absorbent core 6 of the invention is preferably about 5-50%, more preferably about 5-35%, and more preferably about 5-20% (as measured in US Pat. the absence of tissue, adhesive or other core components). More preferably, the absorbent core 6 comprises from about 80-95% SAP and from about 5-20% fibrous structure material chosen from the above group. In accordance with the present invention, improved absorbent articles are advantageously based on continuous crimped filament cable, and consequently, the central fibrous structure of the core 6 is advantageously prepared therefrom. This fiber structure has high structural integrity, and as such, is distinct from a discontinuous fiber matrix, often described as spongy pulp or fluff, which is commonly used in the prior art. The high structural integrity allows the production of more resistant wefts than those formed of discontinuous fibers, which in turn is believed to allow the production of thinner absorbent pads. In addition, the use of such fibers allows the production of absorbent cores of ultra low density, when purchased with absorbent cores prepared by dispersing SAP particles in the fluff. The reduction in density is mainly attributable to the reduced weight of the fibrous structure. The absorbent cores 6 constructed from a mixture of such materials and SAP are referred to herein as "fiber in cable / SAP" cores or "fiber-in-cable" cores. Beneficially, fiber in cellulose ester cable is used to form the fibrous structure. Non-limiting examples of suitable cellulose esters include cellulose acetate, cellulose propionate, cellulose butyrate, cellulose caproate, cellulose caprylate, cellulose stearate, highly acetylated derivatives thereof such as cellulose diacetate, cellulose triacetate and tricaproate. of cellulose, and mixtures thereof such as cellulose acetate butyrate. A suitable cellulose ester will preferably have the ability to absorb moisture, is biodegradable and is influenced not only by the substituent groups but also by the degree of substitution. The relationship between substituent groups, degree of substitution and biodegradability is discussed in W. G. Glasser et al, BIOTECHNOLOGY PROGRESS, vol 10, pp. 214-219 (1994), the description of which is incorporated in this document for full reference. Alternatively, polyolefin cable fiber can also be used with the present invention. Polyolefin fibers offer certain advantages, for example, they are typically available in a wider denier range than other materials and are thermoplastic and thus can be embossed or ultrasonically bonded. In addition, the polyolefin fibers have a relatively high elasticity, allowing them to be able to open after they have been placed under pressure. Such elasticity is beneficial because it creates a cushion between the person who uses it and the dampened SAP that reduces the rewet values and makes the garment more comfortable. Typically, the fiber denier (dpf) of the cable fiber will be in the range of about 1 to 30, preferably about 4 to 15, and more preferably about 7. For the same product weight, the filaments with lower dpf can provide Increased surface area and increased moisture absorption. The total denier of the cable may vary within the range from about 5,000 to 80,000, depending on the process and material used, and is preferably about 30,000. Lower total deniers provide a more open structure that allows free fluid transfer, while larger total deniers tend to obstruct fluid movement and rely more on capillary fluid transport. The total denier should not be excessively reduced, however, as this can result in inadequate core strength, reduced elasticity (leading to increased soaking), and reduced comfort. The previous dpfs and total deniers are beneficial for cellulose acetate cables and polyolefin fiber cables. Of course, other total dfsfs and deniers may be selected in accordance with the particular material used for the fiber. The fibers can have a circular, oval, rectilinear or any other cross section. In one embodiment, the fibers have a cross section of three lobes with an area of approximately 3.36 x 10"6 cm 2. Such a cross-sectional shape can provide bending stiffness, increased absorbency, or other beneficial properties. as a relatively dense matrix, and it is often desirable to "open" (also known as "crumble" or "expand") the fiber into wire in a bulkier cotton-like matrix Several methods and devices are known in the art to open fiber For example, US Patent No. 4,468,845 to Harris discloses a jet to form fiber in cable having a portion of jet that injects gases into a fiber in cable that causes the fiber in cable to separate when gases escape, and a portion of pad that collects the fiber in cable in a mass similar to cotton, thus essentially completing the expansion operation. or in the Patent of E. U. A. No. 6, 253,431, operates without a club (ie, tension plate). These and any other cable fiber opening device can be used with the present invention. Fiber in cable having crimped filaments may be used with the present invention, since the crimps help the cable fiber opening. The filament separation resulting from the opening procedure advantageously results in increased available filament surface area for immobilization of superabsorbent material and increased moisture absorption. The gel block can also be reduced by using crimped cable fiber in the absorbent core 6. As can be understood, more curl is typically better, with an excess of about 20 loops per 2.54 centimeters (inch) being usually preferred. Fiber in continuous filament cellulose ester cable having crimped filaments with approximately 25 to 40 crimps per 2.54 centimeters (inch) is commercially available from Hoechst Celanese Corporation of Charlotte, N.C. However, it should be understood that non-crimped cable strands or filaments having relatively few loops can also be used with the present invention, and can provide a cost advantage without substantially reducing the performance of the garment. If desired, an absorbent core 6 with multiple layer thickness can be provided. For this purpose, the cable fiber can be, for example, folded or folded transversely in accordance with conventional procedures. In this manner, a superabsorbent, absorbent material of a desired weight and / or thickness can be provided. The specific weight or thickness will depend on factors including the particular end use. Any superabsorbent polymer (SAP) known now or recently discovered can be used in the absorbent core 6, provided that it is capable of absorbing liquids. In addition, the SAP can be omitted from the core 6 in some circumstances, such as when a garment for swimming is produced. Useful SAP materials are those that are generally insoluble in water but also polymeric substances capable of swelling with water capable of absorbing water in an amount that is at least ten times the weight of the substance in its dry form. In a type of SAP, the particles or fibers can be chemically described as having a major center of natural or synthetic polymers with hydrophilic groups or polymers containing hydrophilic groups being chemically linked to the main center or in intimate admixture therewith. Included in this class of materials are modified polymers such as polyacrylates and crosslinked sodium neutralized polysaccharides, eg, cellulose and starch and regenerated cellulose which are modified to be carboxylated, phosphonoalkylated, sulfoxylated or phosphorylated, causing SAP to be highly hydrophilic. Also included are polymers capable of swelling with water of water-soluble acrylic or vinyl monomers cross-linked with a polyfunctional reagent. Such modified polymers can also be crosslinked to reduce their solubility in water, and it has been found that such cross-linked SAPs provide superior performance in some sorbent cores. A more detailed description of superabsorbent polymers is found in U.S. Patent No. 4,990,541 to Nielsen, the disclosure of which is incorporated herein by reference in its entirety. The SAP is preferably selected to provide an absbinding performance ata for the particular application. The measurement of SAP absorbency performance can be evaluated in a variety of ways, as will be understood by those skilled in the art. For example, it may be desirable, in some cases, to provide an SAP having a high measure of saline flow conductivity (SFC), as described in the Patent of E. U. A. No. 5, 562,646 to Goldman et al, which is incorporated herein by reference in its entirety and in a manner consistent with the present invention. However, the present invention is also suitable for providing low salt flow conductivity, which may also provide certain benefits, such as higher capacity and absorbency under load. Of course, the SAP can be selected to also provide other properties or combinations of properties. Commercially available SAPs include a starch-modified superabsorbent polymer available under the tradename SANWET from BASF of Portsmouth, Va. SANWET is a sodium salt of polyacrylate grafted with starch. Other commercially available SAPs include a superabsorbent derivative of polypropenoic acid, available under the tradename DRYTECH 520 SUPERABSORBENT POLYMER from The Dow Chemical Company, Midland Mich.; AQUA KEEP manufactured by Seitetsu Kagaku Co., Ltd .; ARASORB manufactured by Arakawa Chemical (U. S. A.) Inc .; and FAVOR manufactured by Stockhausen Inc. Still other commercially available SAPs include SA55SX, available from Sumitomo Chemical Co. Ltd.

From Osaka, Japan, and 3900, 8400 and 8600 provided by BASF of Portsmouth, Va. The SAP can be provided in any particle size, and appropriate particle sizes vary depending mainly on the ultimate desired properties. Preferably, a fine particle instead of a coarse particle is used in the invention, and preferably a fine particle passing through a mesh screen of approximately 200 is used. It is known to prepare absorbent cores comprising fiber in cellulose acetate or other polymeric fibers and SAP, as described in the Statutory Invention of US Record H1565, and U.S. Patent Nos. 5,436,066, and 5,350,370, the description of each. of which is incorporated herein by reference in its entirety and in a manner consistent with the present invention. It was conventional to add tackifiers, fibers of specific size, or fibers in combination with fluff, to prepare the absorbent core and immobilize the SAP particles. These additional materials may add density to the core, or otherwise adversely affect the overall performance of the absorbent garment manufactures thereof. Thus, the use of such additives (any other additives, adhesives, bonding agents or the like) should be controlled to minimize any negative effects caused by their inclusion.

The total basis weight of the absorbent core 6 including fibrous materials, SAP, fabric, additional layers, and additives, typically can typically be anything from about 50 grams per square meter (gmc) to about 1,000 gmc. The most preferred total basis weight of the absorbent core 6 is about 250 gmc to about 700 gmc. Additional particles of fibrous additives can be added to the absorbent core 6 to help maintain high SAP efficiency, to reduce the cost of the garment, or to provide other benefits. The fibrous additives may be introduced as part of the fiber supply in unopened wire or they may be added to the wire fiber after it has been opened. In a preferred embodiment, the particulate additives can generally be added to the cable fiber after it has been opened to allow practical manufacture of the cable fiber and to avoid losses of the particulate additives during processing. In one embodiment, about 1-10%, and preferably about 5%, by weight of thermally bonded synthetic fibers can be added to the absorbent core 6 to impart additional moisture resistance to the laminate. These additive fibers can improve the stability of the core during the use of the diaper. Preferred synthetic fibers for such an embodiment are polyolefin / polyester fibers and bicomponent polyester / polyester fibers.

In another embodiment, the fibrous structure may comprise a combination of preferred cable fiber materials or a combination of a cable fiber material and a fluff pulp material, such as a mixture of cellulose ester and soft or hard wood fibers. conventional Such combinations may be useful in maintaining the improved SAP efficiency available from the fiber-based fibrous structure in crimped filament cable while providing additional benefits. For example, it has been found that an absorbent core 6 having a compound of 150 g / m2 comprised of 80% SAP, 10% cellulose acetate, and 10% conventional fluff pulp has an SAP efficiency of about 85%, while an absorbent core 6 comprised of 80% SAP and 20% fluff pulp SAP has an efficiency of about 70%. The particulate additives that can be added to the absorbent core 6 are preferably hydrophilic, insoluble polymers with particle diameters of 100 mu.m or less. These particle additives may be chosen to impart optimum separation of the SAP particles. Examples of preferred particle additive materials include, but are not limited to, potato starch, corn, wheat, and rice. Starches partially boiled or chemically modified (ie, modifying hydrophobicity, hydrophilicity, softness, and hardness) may also be effective. More preferably, the particulate additives comprise corn starch or wheat cooked partially because in that state, the maize or wheat are supplied larger than the unfired starch and in the cooked state remain harder than still swollen SAP. In some event, regardless of the chosen particulate additive, one of the most important criteria is to use particulate additives which are hard hydrophilic materials relative to swollen SAP or which are organic or inorganic polymeric materials of approximately 100 microns in diameter. Fibrous and particulate additives can be used together in these absorbent laminates. Examples of SAP additives / particles and SAP / fiber / particles include those described in, for example, U.S. Patent No. 6,068,620. Other particulate or powder additives may also be deposited within the absorbent core 6 to provide odor control, softness to the skin, and improved appearance. For example, zeolites, sodium bicarbonate and perfumes can be added to reduce or mask odors, and titanium dioxide and other color-impregnable compounds can be added to provide the absorbent core 6 with a more pleasing color. The absorbent core 6 preferably comprises a tissue wrap that at least partially encloses the preferred fiber-in-cable mix and SAP, such as is described in US Patent No. 6,068,620. This tissue wrap is useful, for example to contain the SAP within the absorbent core 6 and provide resistance to the core during manufacture and use. In a preferred embodiment the tissue wrap comprises the first and second fabric layers 16, 18 enclosing the absorbent core 6, and may also enclose one or more additional layers 20. Preferably, the first fabric layer 16 is generally located between upper sheet 2 and the absorbent core 6, and it is hydrophilic and permeable to the fluid. It is also preferred that the second layer of fabric be placed between the backsheet 4 and the absorbent core 6 and be hydrophobic and impermeable to the fluid. The tissue wrap may also comprise an individual fabric layer which has been folded to enclose the absorbent core, and which may be treated in the area to provide the hydrophobic, fluid impermeable lower fabric layer portion 18. Modes having an individual tissue layer are described in more detail below, but generally can have all the features described herein with reference to modalities having multiple tissue layers. The fabric layers 16, 18 or the entire core 6 can be crimped, bent, sealed or joined to help contain the SAP particles. In one embodiment, the fabric, fibrous structure and SAP of the absorbent core may be adhesively or thermally bonded to improve the moisture resistance of the absorbent core and core stability. This may, in some cases, result in slower speeds than adequate SAP absorption and poor efficiency. In another embodiment, the SAP and the fibrous structure can be bound with hydrogen to the additional fabric layers 16, 18. When a fibrous fiber-based structure in cable having a high concentration of SAP is hydrogen bonded to the first and second fabric layers 16, 18 to form an absorbent core 6, the efficiency of SAP is not deteriorated, it increases moisture resistance and the first and second fabric layers 16, 18 add stability to the core 6 during manufacture. It has been found that when the fibrous structure of the absorbent core 6 bound with hydrogen using water to the fabric layers 16, 18, good "core utilization" is unexpectedly performed. "Core utilization" is the percentage of the total capacity of a core that can be absorbed in a demand test for absorbency. This improvement in unexpected performance is believed to be the result of the beneficial liquid distribution provided by the close bond between the fibers of the fibrous structure and the tissue layers., 18. In another preferred embodiment, the first and second fabric layers 16, 18 are coated with adhesive prior to being placed on either side of the absorbent core 6, thereby providing strength to the core and adhesively supporting a portion of the SAP in place during use. The fabric layers 16, 18 can be provided having a width greater than the fibrous structure of the absorbent core 6, and the portions of the fabric layers 16, 18 extending beyond either side of the fibrous structure of the core 6 can be attached to each other to also provide SAP retention capacity. In yet another embodiment, if the fibrous structure contains about 1-5% by weight of thermally bondable synthetic fibers, bonding to the fabric layers 16, 18 can be achieved using thermal bonds. The absorbent core 6 of the present invention can be flat or folded when it is fixed in its press between the top sheet 2 and the back sheet 4. The folded cores can provide additional performance benefits, such as improved fluid redistribution, higher efficiency SAP, and others. The absorbent core 6 can be folded in any appropriate manner, including any and all of those described in the Patent of E. U. A. No. 6,068,620. Those skilled in the art will appreciate that the absorbent core 6 can be folded such that adjacent sides touch each other, or such that channels are formed in certain areas. For example, the absorbent core 6 can be folded into the shape of a "C" where the crimped ends can be spaced apart to form a channel therebetween, and the lower edges of the crimped ends can be disposed adjacent the upper edges of the ribs. the lower portion of the folded article. Alternatively, another absorbent material, or other absorbent core 6 may be disposed in the space formed by the standard "C" fold. The same considerations can be given to the embodiments having a "G" fold or "U" fold where the spaces formed by those folds can be filled with another absorbent material, another absorbent core 6, left open to form water handling channels. fluid, or the folds can be manufactured tight enough that little or no space is formed. Other possible arrangements include a "Z" fold, and a pleated absorbent core 6, and other folded shapes, as will be appreciated by those skilled in the art. The absorbent core 6 is formed using preferably a dry process. Dry processes have numerous benefits over wet processes. For example, in wet processes, the core material is typically submerged in a fluid that has superabsorbent particles mixed or suspended in it, and the core material may require additional drying steps and other steps that add complexity and cost to the process. core formation. In addition, wet processes often require that the absorbent core be manufactured outside of the main assembly line. Dry processes typically have lower operating costs than wet processes because equipment used in dry processes is typically less complex and can run at higher line speeds. In addition, dry molding processes can be frequently adapted for use directly in the line of conventional diaper machines. A preferred embodiment of the present invention is particularly involved with the use of a dry molding process to manufacture absorbent cores having relatively high SAP and base weights, while overcoming or avoiding the deficiencies of dry molding processes and machines, as described elsewhere in this document. A challenge with the manufacture of absorbent cores that have high concentrations of SAP and fibrous structures with relatively low basis weight, as described above, is to achieve the desired distribution of SAP within the core. In many cases it may be desirable to achieve a uniform distribution of SAP within the core to provide the absorbent garment with uniform absorption capacity. In such a case, the SAP should not only be distributed evenly along the length and width of the absorbent core, but should also be properly distributed across the thickness of the core to ensure that the SAP is not subject to gel blocking or other inefficiencies during use. It is also desirable to provide a controlled amount of SAP to the core to avoid overuse of the SAP, which is typically relatively expensive. It may be additionally desirable to precisely control the SAP distribution to provide local regions of the core that have higher SAP concentrations than others to provide zone absorbency. Such concentrations may be along one or more of the length, width and thickness of the absorbent core. With reference now to FIG. 3, a preferred embodiment of an apparatus and method for dry-molded composite cores is shown. In the preferred embodiment, a cable fiber supply 302, which may be partially unopened or open, is provided along a first path to enter a molding jet assembly 304. The fiber supply in cable may be comprising any material that is desired to be used as the fibrous structure of the absorbent core 6 of the garment and is suitable for use in the process described herein, such as those described herein. Those skilled in the art will appreciate that if fluff fibers or pulp in addition to cable fibers are used, assembly of the molding jet 304 could be replaced by an appropriate fiber or fluff molding apparatus, as is well known in the art. A preferred material for cable fiber supply 302 is a cellulose acetate supply having a basis weight of about 30 g / m2 to about 100 g / m2, and more preferably about 66 g / m2. The tension, speed and trajectory of the cable fiber supply 302 can be adjusted by one or more movable pulleys 306, guides (not shown) and / or festoons (not shown), as are known in the art. The cable fiber supply 302 enters the molding jet assembly 304 and is opened in preparation for incorporation into the absorbent cores. The molding jet assembly 304 comprises a cable fiber entry port 308 at one end within which the cable fiber supply 302 is fed. One or more high velocity jets 310 of air or other gas are projected into the molding jet assembly to impinge on the fiber supply in cable 302 to thereby separate the fibers and "expand" or open the fiber in cable. Preferably, two jets 310 are used and each jet 310 is located proximate the entry port of the cable fiber 308 and on opposite sides of the cable fiber supply 302. Each of the jets 310 preferably comprises an air flow moving to approximately 0.5 cubic meters (17.5 cubic feet) per minute through a slot-shaped port that has a length of approximately 10.0 centimeters (3.94 inches) and a width of approximately 0.076 millimeters (0.003 inches). Similar devices for opening fiber in cable are known in the art, and are described, for example in U.S. Patent No. 5,331, 976 to St. Pierre, which is incorporated herein by reference in its entirety and in a manner consistent with the present invention. Other devices and methods for opening the cable fiber supply 302 may also be used with the present invention, as will be understood by those skilled in the art. Fiber in open or "expanded" cable 312 is accumulated within the molding jet assembly 304 as it is being used, and the amount of fiber in open cable 312 being consumed can be measured by a level 314 meter (also known as a "club"). The level meter 314 can be any suitable electromagnetic, optical, or other device capable of measuring the amount of fiber in open cable 312 being consumed. In a preferred embodiment, the level meter 314 is a plate that is rotatably attached to a rotary position detector (such as a commonly known variable potential or resistance device). When the level of open cable fiber 312 increases or decreases, the plate rotates up and down, thus changing the output of the rotary position detector. In a preferred embodiment, the level meter 314 is used as part of a closed-loop feedback algorithm or open cycle algorithm for measuring the rate at which the cable fiber supply 302 is fed into the jet assembly. molding 304, and can be integrated into a 320 control system.

The control system 320 may comprise any electrical control apparatus that can be configured to control one or more variables based on the measurement of one or more inputs. Although the control system 320 is referred to in the present document in the singular, it should be understood that a number of independent control systems 320 can be used for various parts of the machinery, and these various systems are referred to collectively herein as a system individual control 320. The control system 320 can control any number of variables and have any number of inputs, and can use an open cycle or closed cycle algorithm. Exemplary control systems 320 include programmable logic control (PLC) devices that have machine interfaces easily used by humans, as is known in the art. Of course, the control system 320 may simply comprise a human operator that monitors the various inputs and adjusts the various system variables. The open cable fiber 312 is preferably pulled out of the molding jet assembly 304 by a vacuum drawing cylinder 322, such as the combination drum 800 described elsewhere herein in combination with FIG. 8, or similar stretching device. The open cable fiber 312 leaves the molding jet assembly 304 at a fiber breakage angle in TB cable, which can be adjusted to alter the position of the vacuum drawing cylinder 322 (or similar device), or, more preferably, adjusting the height and angle of the molding jet assembly 304 using adjustable assemblies 324. Increasing the fiber breakage angle in cable TB, increases the drag on the open cable fiber 312 and thus increases the amount of stretch that the Vacuum drawing cylinder 322 imparts on open cable fiber 312. Further stretching reduces the basis weight of the fiber in open cable 312 which is pulled over vacuum drawing cylinder 322. The fiber molding jet in cable 304 preferably it is aligned such that its outlet point is tangential to the vacuum drawing cylinder 322 or slightly on a tangent to the vacuum drawing cylinder 322. In a preferred embodiment, the exit point of the cable fiber molding jet 304 is located at a tangent to the vacuum drawing cylinder 322 at approximately 2.54 centimeters (1 inch) on a tangent to the vacuum drawing cylinder 322. In a most preferred mode the outlet admission access of the fiber molding jet on cable 304 is less than about 1.91 centimeters (0.75 inches) on a tangent to the vacuum drawing cylinder 322, and in a more preferred embodiment, the The outlet of the fiber molding jet on cable 304 is located less than about 1.27 centimeters (0.5 inches) on a tangent to the vacuum drawing cylinder 322. In another embodiment, the amount of stretch on the open cable fiber 312 may instead of (or additionally) being regulated by operating the club 314 as a circulation reducer (instead of using it as a level 314 meter) to compress ab garlic on the open cable fiber 312 when it is pulled over the vacuum drawing cylinder 322, and thereby increase the stretch of the open cable fiber 312. Using the club as a circulation reducer, it is expected that the adjustments of +/- 10% can be made to fiber stretch in cable or base weight. Adjustable mounts of the cable fiber molding jet 324 may be fixed in a desired position during the operation of the machine, or may be actively operated by a control system 320 during operation in response to core weight measurements of the core and other feedback agreed during the operation. Mechanical adjustment devices, electromechanical, pneumatic, hydraulic, or other suitable can be used to drive the adjustable assemblies 324, such as photorepeat engines, solenoids and hydraulic or pneumatic pistons or pistons, and the like. Alternatively or in addition, the basis weight of the open cable fiber 312 can be adjusted by increasing or decreasing the speed of the vacuum drawing cylinder 322, with generally faster speeds resulting in a lower base weight of the open cable fiber 312. After the open cable fiber 312 leaves the molding jet assembly 304, a supply of superabsorbent particles 326 is sent to open cable fiber 312, and the fiber composite in cable / SAP is enclosed between the supplies of the first and second wrap sheets 316, 318. Alternatively, the wire / SAP fiber composite can be enclosed within a fold in a single wrap sheet. Preferably, as shown in FIG. 3, the open cable fiber 312 lies on a first wrap sheet supply 316 before the SAP 326 is fed to the open cable fiber 312 to help contain the SAP 326 and control the distribution of SAP, then the second wrapping sheet supply 318 lies on the cable / SAP fiber composite to form a sub-assembly of the absorbent core that can be processed into absorbent garments. The first and second wrapping sheet supplies 316, 318 enclose the open cable fiber composite and SAP. The first and second wrapping sheet supplies 316, 318 preferably form the first and second fabric layers 16, 18 of the completed garment, but may also form the upper sheet 2 and the back sheet 4 of the absorbent garment. 10, or any other layers. The first and second wrapping sheet supplies 316, 318 are preferably wider than the open rope fiber 312 that forms the absorbent core 6 and their side portions are preferably sealed with each other by bonding or crimping to prevent fiber release in open cable 312 and SAP particles. The absorbent core composite 348, comprising the assembly of the first and second wrap sheet supplies 316, 318 and the open cable fiber 312 and the SAP core 326, can be further processed when the latter is transported through the line assembly for inclusion in the absorbent garments 10. For example, in a preferred embodiment, the absorbent core composite 348 is divided into individual absorbent cores 6, and the split ends can be bent or joined to prevent the SAP 326 from coming off of the extremes. In all cases, at least one of the first and second wrapping sheets 316, 318 should be permeable to liquid and placed on the garment facing the body of the quine using it to allow the flow of fluid within the core 6. another supply of wrapping sheet may optionally be impermeable to the liquid. The impermeability or permeability to the liquid of any of the wrapping sheet supplies 316, 318 may be provided by chemical or physical treatment, or by the appropriate selection of materials, as is known in the art. In a preferred alternative embodiment, the first and second wrapping sheets 316, 318 can both be formed from a single sheet of material that is folded to enclose the open cable fiber 312 and the SAP 326. In such embodiment, the structure of various parts of the system may be optionally modified to facilitate the manufacture of an absorbent core composite having a single wrapping sheet, as will be explained in more detail hereinafter. It may be desirable to apply an adhesive to one or both of the first and second wrapping sheet supplies 316, 318 prior to bonding these with the open cable fiber 312 or cable fiber / SAP combination. For example, in a preferred embodiment, an adhesive is applied to the full width of one or both of the wrapping sheet supplies 316, 318 by adhesive applicators 328 before they are attached to the open cable fiber 312 to provide a better bond between the wrapping sheets 316, 318 and the fiber composite in cable / SAP. In such an embodiment, the adhesive can also function to fix a portion of the SAP 326 particles in place. In another preferred embodiment, the envelope sheet material supplies 316, 318 are broader than the cable / SAP composite fiber, and the adhesive is applied along the side edges of one or both of the sheet supplies wrapping to join these with each other, sealing in the composite cable fiber / SAP. Other uses of adhesives will be apparent to those skilled in the art based on the teachings provided herein. • A preferred adhesive for these and other embodiments is hot melt construction adhesive H2561 U, available from Ato Findley, Inc. of Wauwatosa, Wis. Other suitable adhesives, known in the art, can be used provided they do not excessively deteriorate the desired properties of the wrapping sheet material (as described elsewhere herein), or add excessive stiffness to the absorbent core. For example, other adhesives may include HL-1258 by H. B Fuller Company of St. Paul, Minn.; Findley 2031 and H2587-01 by Ato Findley Inc. of Wis .; and NS34-5665 by National Starch Co. of Bridgewater, NJ Other adhesives that may be used include 34-578A by National Starch Co. of Bridgewater, NJ In another preferred embodiment, the adhesive may be selected to impart the desired properties to the supplies of wrapping sheet 316, 318. For example, an adhesive can be used to supply one of the wrapping sheet supplies 316, 318 with fluid impermeability, opacity, which is hydrophobic (or hydrophilic), etc., the adhesive can also be soluble in water or have other beneficial properties. Adhesive applicators that can be used with the present invention include spray applicators, such as those provided by Nordson Corporation of Westlake, Ohio, and other appropriate applicators, as are known in the art. Still with reference to FIG. 3, in a preferred embodiment the absorbent core composite 348 is assembled into four processes that occur when the various parts of the assembly are pulled on the rotary vacuum cylinder 322 rotating. In the first step, which occurs at location A, the first wrapping sheet supply 316 is stretched over the vacuum drawing cylinder 322. In the second step, at location B, the open rope fiber 312 is stretched on the vacuum drawing cylinder 322 to lie on top of the first wrap sheet supply 316 after being pulled out of the molding jet assembly 304. In the third step, at the location C, a supply of SAP 326 is deposited on the open cable fiber 312 by the vibratory feeder 332, as described herein. And in the fourth step, at location D, the second wrap sheet supply 318 is carried inside to lie on top of the first wrap sheet supply 316, open wire fiber 312 and SAP deposited. Those skilled in the art will appreciate that these steps can be performed using other equipment in addition to those specifically described herein, and can also be performed in several different orders, with some of the steps being arranged differently, omitted or combined, or with additional steps being made. Such variants are generally within the scope of the present invention. Also in a preferred embodiment, a configuration on the roll is used to press the second wrap sheet supply 318 against the wire / SAP fiber composite and the first wrap sheet supply 316. The configuration on the roll 330 helps flatten the assembly of the core and improves the edge seals between the first and second wrapping sheet supplies 316, 318. The configuration on the roller 330 can also be equipped to provide ultrasonic, heat, and other connections between one or more of the first and second wrapping sheets 316, 318 and the fiber composite in cable / SAP. In such an embodiment, the configuration on the roller 330 may cooperate with the vacuum drawing cylinder 322 or other device to create the desired connections. For example, portions of the configuration on the roller 330 can form ultrasonic horns, while the corresponding portions of the vacuum drawing cylinder 322 form anvils that, together, form an ultrasonic joint between the first and second wrapping sheet supplies 316, 318. The superabsorbent particles are preferably provided by a vibratory feeder 332, however any other suitable SAP feeding device, such as drill-type feeders and SAP atomizers can also be used. The vibrating feeder 332 comprises a feed tray 334 which is fixed and driven by a motor 340. The motor 340 vibrates the feed tray 334, moving it back and forth in the direction of vibration V, as indicated by the double headed arrow in FIG. 3. The feed tray 334 is supplied from above by a hopper 336 by means of a flexible coupling 338 which helps to isolate the hopper 336 from the movement of the feed tray 334. The vibratory feeder is preferably suspended over one or more, and more preferably three, scales 342 weighing the vibratory feeder 332 and its contents. The vibrating feeder 332 is preferably positioned such that none of its moving parts, particularly the motor 340 and the feed tray 334, strike other parts of the machinery during operation. The hopper is preferably selected to provide consistent flow characteristics for a variety of superabsorbent polymers and other particles and fibrous additives. In particular, it is preferred that the hopper 336 should allow the flow of all its contents in a regular manner, described as "mass flow", such that few or none of the particles adhere to the hopper 336, and do not experience sudden increases in the flow velocity. The mass flow is present when essentially all the material in the hopper is in motion at any time when some material is removed. This type of flow pattern is also described as the first-come-first-out flow. To provide the desired mass flow, the hopper 336 is preferably designed to avoid "bridging" (ie, when the particles become embedded in the hopper by forming a "bridge" or arc-like structure that resists the flow), and to avoid "deflection" (ie, when a particle column flows through the center of the hopper 336, but those particles along the walls do not flow). When the hopper 336 provides mass flow, it is not necessary to provide undesirable external forces, which can damage or redistribute the particles, to shake the non-moving particles and release them. The mass flow can be obtained by providing the hopper 336 with relatively smooth inner walls and avoiding the use of surface flow angles within the hopper 336. The design may vary depending on the particulate matter or SAP 326 being kept in the hopper 336, and it may be desirable to test the properties of the material, such as the slip angle of the material and angle of repose, to obtain an appropriate hopper pattern. The design of mass flow hoppers is generally known in the art, and a skilled worker will be able to design an appropriate hopper without undue experimentation based on the teachings provided herein. In one embodiment, the hopper has a capacity of about 0.04 m3 (1.5 ft3) to about 0.28 m3 (10 ft3), and more preferably 0.06 m3 (2.25 ft3) to about 0.17 m3 (6 ft3), and more preferably about 0.08 m3 (3 feet3). Also, in a preferred embodiment, the hopper 336 discharges through an outlet point that has a diameter of about 10J6 centimeters (4 inches) to about 30.48 centimeters (12 inches), and more preferably from about 12.7 centimeters (5 inches) to approximately 22.86 centimeters (9 inches), and more preferably approximately 17.78 centimeters (7 inches). The hopper 336 can be supplied and filled with SAP using any device and method known in the art. In a preferred embodiment, the hopper 336 is filled by a screw (or "screw feeder") conveyor type that moves the SAP from a power source into the hopper 336. The design of such hoppers 336, conveyors and sources of feeding is known in the art, and a skilled worker will be able to provide a hopper 336 for use with the present invention without undue experimentation based on the teachings provided herein. In a preferred embodiment, hopper 336 is derived from a SOLIDSFLOW MODEL 5007 DRY MATERIAL FEEDER. Also in a preferred embodiment, the hopper 336 is provided and filled from a SOLIDSFLOW MODEL SBS BULK BAG DISCHARGE STATION using a flexible screw conveyor (screw feeder) FLEXICON, which is controlled by a SOLIDSFLOW MODEL 1200 LOSS- IN-WEIGHT CONTROLLER. All of these devices are available from SolidsFlow Corporation of Fort Mili, S.C. The vibratory feeder 332 may be suspended from one or more, and more preferably three, scales 342 that measure the weight of the vibratory feeder 332 and its contents. The scales can be used to calculate the amount of SAP 326 that is distributed over open cable fiber 312. Such systems are commonly known as "weight loss" systems, since they continuously measure the reduction in weight of the vibratory feeder 332 since its contents are being emptied. The conveyors and supply sources that are fed into the hopper 336 can also be suspended on scales such that the SAP can be added to the hopper during the operation, while still being able to calculate the amount of SAP being deposited on the fiber at open cable 312. In a preferred embodiment, the weight loss measurements of the scales 342 are used with a closed cycle feedback loop to control the amount of SAP 326 that is deposited on the open cable fiber 312. Such circuit is preferably integrated into a control system 320 that can control other features and operation of the vibratory feeder 332 and related devices. The scales 342 can also be used to determine when it is necessary or desirable to fill the hopper. The scales 342 are preferably capable of reading with an accuracy that allows the useful determination of the amount of SAP being deposited on the open cable fiber 312. In a preferred embodiment, the scales 342 read with an accuracy of approximately +/- 10 grams , and more preferably of about +/- 1 gram, and more preferably of about +/- 0.1 gram. In a preferred embodiment, the scales 342 comprise load measuring type strain gauge cells, such as those available under the designation SOLDSFLOW MODEL 1000 SCALE ASSEMBLY from SolidsFlow Corporation of Fort Mili, S.C. The design, construction, and use of appropriate scales for use with the present invention is known in the art. A flexible coupling 338 preferably attaches the hopper 336 to the feed tray 334. The flexible coupling 338 is used by passing SAP or other additives from the hopper 336 to the feed tray 334, while simultaneously isolating the hopper 336 from the vibratory movement of the feed. feed tray 334 and motor 340. Flexible coupling 338 may comprise any durable flexible material, such as scrim and other fabrics, or natural or synthetic rubbers. It is preferred that the flexible coupling does not dampen or impede the desired vibration movement of the feed tray 334 and motor 340, and thus impair the ideal SAP feed. For example, if the flexible coupling 338 is too rigid, it will reduce the ability of the motor 340 to vibrate the feed tray 334 because it will resist deformation, effectively increasing the mass of the feed tray 334. Also, if the flexible coupling 338 is too elastically resistant, it will tend to store energy created therein when the feed tray 334 and the motor 340 are vibrating, and return this stored energy in an uncontrolled manner (i.e., vibrate on its own) thus creating additional uncontrolled vibrations in the power tray 334 and motor 340. It is also preferred that the flexible coupling 338 be as light as possible to reduce the inertia which must be overcome by the motor 340 during operation. In a preferred embodiment, the flexible coupling 338 comprises a rubber material having a diameter and shape selected to join the outlet outlet of the hopper 336 with the entrance access conduit 402 of the feed tray 334. The feed tray 334 and the motor 340 are preferably suspended below the hopper 336 by flexible mounts 344 which allow the motor 340 and the feed tray 334 to move relative to the hopper 336. The flexible mounts 344 may comprise rods having flexible or rotatable couplings joining these, in each end, to the hopper 336, motor 340 and feed tray 334. In a preferred embodiment, the flexible assemblies 344 are designed to convey a minimum amount of vertical movement or vibration to the hopper 336, which may cause the scales 342 read without precision. In such a preferred embodiment, the flexible assemblies 344 may be attached to one or more of the hopper 336, motor 340 and feeder tray 334 by an elastomeric bearing filled with liquid or dry or coupling. The design and selection of such wet movement and vibration couplings are known in the art, and a skilled person will be able to select or produce an appropriate coupling system based on the teachings provided herein.

With reference now to FIG. 4, the feed tray 434 preferably comprises an inlet access conduit 402 which is fixed to the flexible coupling 338 to receive the SAP 326 from the hopper 336. A plate 404 extends away from the inlet access conduit 402 at a downward angle to an outlet outlet edge 406 of the feed tray 334. The plate 404 may also comprise multiple sections descending to varying angles. The feed tray 334 is preferably covered over most of its length to avoid alterations of the SAP 326 or other particulate additives. The portion preferably covers an adjustable door 408 located near the outlet outlet edge 406 of the feed tray 334. The adjustable door 408 is spaced over the plate 404 and generally divides the feed tray into an upstream portion from which SAP 326 flows and a portion downstream. The adjustable door 408 can be manually operated, or it can be opened and closed by a drive device, such as an electromechanical, mechanical, pneumatic, or hydraulic device. Such a drive device may optionally be controlled by a control system 320 using a closed cycle feedback algorithm or open cycle algorithm. Such actuators are known in the art, and a skilled person will be able to employ an appropriate actuator without undue experimentation. Of course, in one mode the door can be a fixed door, instead of an adjustable door.

In a preferred embodiment, the SAP 326 and other particulate additive material exit the feed tray 334 at its outlet takeoff edge 406 in a curtain-like stream having a consistent flow velocity across its full width. With reference to FIG. 7, the active width WA of the feed tray 334 is the width of the portion of the feed tray 334 from which the SAP 326 flows (which may be affected by the use of SAP 410 guides, as described somewhere in this document), and generally corresponds to the SAP flow width. The active width WA may vary from one application to the next, and may be varied during operation using, for example, powered-up SAP guides 410 that move together and apart under the control of a control system 320. Generally, the active width WA is preferably about the same width as the open cable fiber 312. In one embodiment the active width WA is from about 5.08 centimeters (2 inches) to about 30.48 centimeters (12 inches), and is more preferably about 7.62 centimeters (3 inches) to about 25.4 centimeters (10 inches), and, in a particularly preferred embodiment, the active width WA is approximately 9.52 centimeters (3.75 inches) to approximately 10.16 centimeters (4 inches). In another embodiment it may be desirable to vary the flow rate of SAP 326 in particular areas to provide absorbency in zones. With reference now to FIG. The plate 404 may be contoured or molded to provide concentrated flows of SAP during operation or to control the flow of the SAP in another manner. For example, in one embodiment the plate 404 may have one or more depressions 1502 along the outlet takeoff edge 406 which effectively increases the downward angle in the depressions 1502. In such an embodiment, the SAP 326 may tend to be routed within the depressions 1502, and those portions of the open cable fiber 312 passing below the depressions 1502 should receive a relatively high concentration of SAP 326. In another embodiment, the tray 404 may have depressions 1504 extending below the adjustable door 408, effectively increasing the height h of the adjustable gate 408 at those points to increase the flow velocity of the SAP through the depressions 1504. Such depressions 1504 may extend toward the outlet outlet edge 406 to further act as depressions 1502, as described above. Other variants in the geometry of the outlet takeoff 406 and plate 404 will be apparent to those skilled in the art based on the teachings provided herein. In one embodiment, the feed tray 434 may have more than one input access conduit 402 such that several SAP supplies may be fed therein. SAP supplies can comprise different types of SAP that are mixed or isolated from each other using internal circulation reducers and guides. In such an embodiment, for example, one type of SAP can be distributed to the lateral sides of the open cable fiber 312, and another type of SAP can be distributed to the central region of the open cable fiber 312. Other variants and uses of a feed tray 334 having multiple inlet access passages 402 will be apparent to those skilled in the art based on the teachings provided herein. The SAP 410 guides, comprising angled or vertical material strips, can optionally be integrated into the feed tray 344 on either side of the adjustable door 408 to serve various purposes. The SAP guides are preferably fixed to the plate 404, but can also be attached anywhere to the feed tray 334 or other objects. In a preferred embodiment, the guides contain lateral movement of the SAP 326 such that it falls only in a central region of the open cable fiber 312. In another preferred embodiment, the SAP 410 guides isolate the flow of SAP 326 from turbulent air flow. around the feeder tray 334 to provide more uniform SAP distribution. The SAP guides 410 may be close to the outlet takeoff edge 406, as shown in FIG. 4, or they can be located anywhere on the plate 404. The SAP 410 guides can also be used to isolate or mix supplies other than SAP. In one embodiment, the SAP 410 guides may also comprise additional vertically stacked layers, in addition to the plate 404, which may contain separate SAP flows. In a preferred embodiment, the SAP 410 guides are spaced apart approximately 9.52 centimeters (3.75 inches) to approximately 10.16 centimeters (4 inches) of broad SAP flow. With reference now to FIGS. 5A and 5B, the feeder tray 334 operates on the principle that the solid particles within it, such as SAP 326, will rest at their resting angle until they are disturbed by vibrations induced by the motor 340. This operating principle is described more fully in US Pat. No. 3,973,703 to Peschl, which is incorporated herein in its entirety for reference and in a manner consistent with the present invention (hereinafter referred to as "Peschl"). It should be understood that, although the inventors provide various theories on the modes of operation of the vibratory feeder 332, the invention is not intended to be limited to these or other modes or theories of operation. It has been found that the flow of the SAP 326 can generally be influenced by the properties of the SAP, the descending angle of the plate 404, the vibration speed of the motor 340, the drag distance d of the plate 404, and the height of the adjustable door 408. In the embodiment shown in FIG. 5A the downward angle a is greater than the rest angle of the SAP 326, and thus any remaining SAP along the drag distance d of the drag distance d of the plate 404 slides out of the plate 404 after which the motor 340 stops vibrating. The remaining SAP 326 is captured behind an SAP bridge 502 that is formed by friction between the SAP particles, cohesion between the SAP particles, or both. The height of the adjustable door h can be adjusted to provide ideal SAP containment and control. Raising the adjustable gate 408 generally provides a higher SAP flow rate for a given motor vibration frequency, while lowering the adjustable gate 408 generally provides the opposite result. The height of the adjustable door h is preferably adjusted to ensure that a bridge 502 is formed soon after the motor 340 stops vibrating the feed tray 344 to stop the flow of SAP 326 as quickly as possible. The flow rate of the SAP generally follows the vibration speed of the motor 340, and stops flowing almost immediately when the motor 340 is turned off. Generally, faster motor vibration rates provide higher SAP flow rates and motor vibration speeds. slower speeds provide a slower SAP flow rate. There is little or no noticeable delay between changes in the motor frequency and the flow rate of the SAP 326, such that the vibratory feeder 332 provides relatively accurate control of the SAP flow, especially when compared to known methods of distributing SAP on fiber in 312 open wire or spongy pulp. It should be noted that the remaining SAP over the drag distance d of the plate 404 may continue to flow at an uncontrolled speed after the motor frequency changes, but it has not been found that such a lag time causes appreciable detriment to the capacity of the device to accurately deposit the SAP 326 on the open cable fiber 312. If a detriment is found, however, the drag distance d can be reduced to cause the SAP flow rate to follow the motor frequency variations more closely. Reducing the drag distance can also increase the flow velocity of the SAP for a given motor frequency and adjustable gate height h, as explained in more detail in Peschl. In one embodiment, the trailing distance can be reduced to zero, and the trailing outlet edge 406 can still be within the upstream portion of the feeder tray 334 (i.e., the adjustable gate 408 can be located beyond from the starting tap edge 406). In a more preferred embodiment, shown in FIG. 5B, the downward angle a may be less than the angle of the SAP of rest and slip angle (i.e., the angle at which the SAP 326 will slide down from the surface of the plate 404), such that when the tray of power 334 is at rest the remaining SAP along the driving distance d remains on the plate 404. In such mode, the aforementioned lag between the SAP flow and the frequency changes of the motor associated with the SAP located at the drag distance d can be reduced. With reference again to FIG. 4, it has been found that the outlet outlet edge 406 of the feed tray should be located as close as possible to the vacuum drawing cylinder 322.

Reducing the offset distance c between the outlet takeoff edge 406 and the vacuum draw cylinder 322 provides several benefits. In particular, minimizing the offset distance c allows the SAP to fall on the open cable fiber 312 as quickly as possible, minimizing any redistribution or diffusion of the SAP 326 that may be caused during a larger drop by turbulent airflow around the feed tray 344 and by interaction between the SAP particles 326. Reducing the offset distance c also decreases the lag time between changes in the motor speed 340 and changes in the amount of SAP 326 being distributed to the fiber in open cable 312. In a preferred embodiment, the offset distance is from about 0.64 centimeters (0.25 inches) to about 10.16 centimeters (4 inches), and more preferably from about 0.95 centimeters (0.375 inches) to about 2.54 centimeters (1.00 inches), and more preferably approximately 1.27 centimeters (0.50 inches). The minimum value for the offset distance c may be affected by machine operating tolerances, such as to avoid contact between the open cable fiber 312 or the vacuum drawing cylinder 322 and the vibrating feed tray 334, or by other factors, such as the tolerances of the wrap sheet supplies 316, 318 and the open wire fiber 312. For example, in a preferred embodiment, the offset distance c is at least about 1.27 centimeters (0.50 inches) to allow the passage of the agglomerated accumulations of the fiber in open cable 312, which may be present during startup and during other operating conditions. In a preferred embodiment that can be used with a variety of SAPs, the descending alpha angle, as measured relative to the horizontal, is from about 10 degrees to about 45 degrees, and more preferably about 12 degrees to about 30 degrees, and more preferably about 15 degrees. Also, in a preferred embodiment, the adjustable door height h is from about 0.25 centimeters (OJ inches) to about 2.54 centimeters (1.00 inches), and more preferably from about 0.32 centimeters (0J25 inches) to about 1.91 centimeters (0.75 inches). , and more preferably from about 0.64 centimeters (0.25 inches) to about 1.25 centimeters (0.5 inches). Also in a preferred embodiment, the pulling distance d is about 0.64 centimeters (0.25 inches) to about 20.32 centimeters (8 inches), and more preferably about 5.08 centimeters (2 inches) to about 15.24 centimeters (6 inches), and more preferably approximately 10.16 centimeters (4 inches). Also in a preferred embodiment, the inlet access passage 402 has a diameter of about 10.16 centimeters (4 inches) to about 30.48 centimeters (12 inches), and more preferably about 12.7 centimeters (5 inches) to about 22.86 centimeters (9 inches) ), and more preferably about 17.78 centimeters (7 inches). In a preferred embodiment, the feed tray 334 can be derived from a SOLIDSFLOW MODEL 5000 DRY MATERIAL FEEDER, available from SolidsFlow Corporation of Port Mili, S.C. With reference now to FIGS. 6 and 7, the feeder tray 334 is preferably equipped with side plates 602 that help isolate the SAP 326 and open cable fiber 312 from the side airflow and can help contain the lateral movement of the SAP 326 after it exits. of the feed tray 334. Such lateral air flow and other air flow can alter the desired distribution of the SAP over the open cable fiber 312. The side plates 602 are preferably oriented approximately parallel to the direction of the fiber machine in open cable 312 (ie, within approximately 20 degrees of parallelism) and dimensioned to substantially reduce or block air flowing laterally within the area below the feed tray 334. Smallerly, a first edge 604 of each side plate 602 is placed proximate to the vacuum drawing cylinder 322 (or other similar drafting device); and a second edge 606 of each side plate 602 is placed proximate to the molding jet assembly 304. The side plates 602 are preferably molded and dimensioned such that they do not hit other parts of the machine when they are vibrated back and forth. . A third edge 608 of each side plate 602 is preferably adapted to conform to the second wrapping sheet supply 318 to prevent side airflow from above the feed tray from invading the SAP 326 supply. In such mode, it may also be It is desirable that the upper edge 610 of the adjustable door 408 be proximal to the second supply of the wrapping sheet 318 to further reduce the amount of air flowing inward to potentially alter the SAP 326. The SAP 410 guides may also have an edge 612 contoured to be adjacent to the second wrapping sheet supply 318 to further inhibit the development of undesirable air flow near the SAP 326. The side plates 602 may preferably be adjusted in at least the vertical direction, as indicated by the arrow with double head in FIG. 6. In other embodiments, the side plate 602 may be attached to something else instead of the feed tray 334, but in such embodiments, care must be taken to prevent the mobile feed tray 334 from hitting the side plates 602 during operation . With reference again to FIG. 4, the motor 340 is used to start and modulate the SAP 326 flow out of the feed tray 334. The motor 340 vibrates the feed tray 334 by moving it back and forth in the vibration direction V, as shown in FIG. indicated by the double-headed arrow in FIG. 4. In a preferred embodiment, both the slope p and the frequency of the motor 340 can be adjusted to modulate the flow of SAP 326. It has been found that increasing the slope of the motor (i.e. the distance crossed by the motor during each cycle) it generally increases the flow speed of the SAP, and vice versa. Also, as noted above, it has been found that increasing the motor frequency generally also increases the flow rate of the SAP, and vice versa. The efficiency of the motor 340 and the amount of control provided by the motor 340 are affected by the weight and rigidity of the feed tray 334. If the feed tray 334 is too heavy, its inertia will resist the forces imparted on it by the motor. 340, and the motor may not be able to accelerate decelerating it back and forth to create the distance p of desired slope or frequency vibrations. If the feed tray 334 is not rigid enough, it will flex when the motor 340 imparts forces on it. When the feed tray 334 is flexed, it absorbs the energy that was intended to move the feed tray 334 and does not accurately follow the intended path of the motor 340. The energy absorbed by a flexible feed tray 334 can be released at the form of undesirable variations in the desired slope p and frequency of vibration. It has been found that it is generally desirable to manufacture the feed tray 334 as light and as rigid as possible to provide the greatest amount of SAP flow control. In a preferred embodiment, the motor 340 is coupled to the feed tray 334 through a coupling 412. To provide accurate transmission of the vibrations of the motor to the feed tray 334, the coupling 412 should be rigid in the direction of vibration V, and the coupling 412 preferably has a box-like or C-shaped shape. Also in a preferred embodiment, the inlet access conduit 402, which may comprise a relatively large open space that may be susceptible to unwanted bending., is reinforced with a structural member, such as a tubular clamp 414 aligned in the direction of vibration V. In a mode in which the inlet access conduit has a diameter of approximately 17.78 centimeters (7 inches) it has been found that a tubular clamp 414 of approximately 2.54 centimeters (1 inch) in diameter is suitable for reducing undesirable flexures in the inlet access conduit 402 without adversely affecting the flow of SAP through the inlet access conduit 402. In other embodiments, in the which the inlet access conduit 402 contains flow reducers or other structures for flow direction or flow control, these structures can also serve to increase the stiffness of the feed tray, making it unnecessary to reinforce the inlet access conduit 402. As noted above, the motor 340 and the feed tray 334 are suspended below the hopper 3 36 by flexible mounts 344 which allow both the motor 340 and the feed tray 334 to move independently of the hopper 336. As such, when the motor 340 vibrates the feed tray 334 back and forth, the same motor 340 You can also move forward and backward. In a preferred embodiment, the mass of the motor 340 is significantly greater than the combined mass of the feed tray 334 and the SAP 326 contained therein, and thus the movement of the motor 340 will be negligible relative to the movement of the feed tray 334. In such an embodiment, the slope p of the motor will be almost completely converted into movement of the feed tray 334 (as shown in FIG 4). If, however, the motor 340 does not experience a significant amount of movement, more than the slope p will be converted to the movement of the motor, and less of the slope will result in movement of the feed tray 334. This reduction in the movement of the 334 tray can result in less efficient distribution and control of SAP. If it is found that motor movement adversely affects the distribution and control of the SAP, the movement of the motor may be restricted, or the slope p may be increased to increase the effective movement of the feed tray 334. Other measures may also be taken to counteract such negative effects. Those skilled in the art will be able to measure or calculate the movement of the motor 340 and feed tray 334 and make modifications in the design of the apparatus for such movements using the teachings provided herein. In a preferred embodiment, the motor 340 comprises an electromagnetic vibrator, such as those provided by Eriez, Corportation of Erie, Pa. As Model Number 30A, part number 3N-56743. Such an engine can be selected to be powered by any available power source, such as a 115 volt, 60 Hz power source. The engine may also require specific support or drive hardware and software, such as an Eriez VTF signal following the board of the controller that is supported and AB SLC analogue 0-20 mA card, available from Allen-Bradley Company of Milwaukee, Wis. Other motors 340 may also be used, such as a rotary motor that is configured to provide cyclic lateral movement or vibrations to the feed tray 334. Other useful motors 340 include pneumatic, magnetic, electric and hydraulic actuators, and the like, as long as they can be used. providing the forces necessary to vibrate the feed tray 334 on the slope p and frequency desired. Electromagnetic vibrators are preferred, since these typically provide relatively controllable movement and consume less energy than other devices. In a modality that should be appropriate for distributing a variety of SAP materials, the motor 340 can be operated from a neutral (zero Hz) to approximately 430 Hz, and more preferably up to approximately 520 Hz, and more preferably up to approximately 600 Hz. In a preferred embodiment it should be appropriate to distribute a variety of materials SAP, the frequency is approximately constant, and the flow velocity of particulate matter is controlled by modulating the slope of the motor. In such a preferred embodiment, the frequency of the motor is about 60 Hz, and the slope p of the motor varies between about 0.025 centimeters (0.01 inches) to about 0.32 centimeters (0J25 inches), and more preferably about 0.051 inches (0.02 inches) to about 0.25 centimeters (EIGHT inches), and more preferably from about EIGHT centimeters (0.04 inches) to about 0.20 centimeters (0.08 inches). Such adjustments can be obtained, for example, by varying the motor voltage between about 0 and about 90 volts. Such vibrating feeder 332 can be adapted to provide a high volume of SAP flow, and can be used at relatively high manufacturing line speeds. It is anticipated that a vibratory feeder 332 produced in accordance with a preferred embodiment of the present invention may be used with an assembly line producing diapers at a rate in excess of 600 products per minute. The vibratory feeder 332 may preferably feed superabsorbent polymer or other additives at a rate of about 10,000 grams per minute (g / min) to about 20,000 g / min, and more preferably at a rate of about 12,500 g / min to about 17,500 g / min. min, and more preferably at a rate of approximately 15,000 g / min. In a preferred embodiment, the hopper 336 is powered by a screw conveyor and another conveyor having the capacity to maintain a useful level of SAP 326 in the vibratory feeder 332. The conveyor may have a feed rate that is less than the feed speed. maximum feeding of the vibratory feeder 332, as long as the average feed rate of the vibratory feeder 332 does not exceed the average feed speed of the conveyor. The superabsorbent polymers and other particulate additives can be relatively expensive, and it is often desirable to minimize the amount of SAP that is placed in the core and "zoning" such additives only where they are most beneficial to the final product. Such zoning is particularly beneficial in fiber-based absorbent cores in cable because the lack of spongy pulp in such cores can reduce the overall absorptive capacity of the core, making it more important to place the SAP closest to the location where the fluid is most likely. that affects the garment. In a preferred embodiment, the motor 340 is controlled by a control system 320 to provide a desirable distribution of SAP 326 within the open cable fiber 312. In a preferred embodiment, such a control system 320 can be used to operate the motor 320 to deposit a stable stream of SAP 326 on the open cable fiber 312 to provide an open wire / SAP uniform fiber blend in the absorbent cores that are ultimately formed by the process. In another preferred embodiment, the control system can cyclically increase and decrease the slope p and / or frequency of the motor 340 to deposit a pulsed supply of SAP 326 to the open cable fiber 312, thus providing the absorbent cores with targeted concentrations of SAP that provide the garment 10 with divided absorbency. Preferably, the control system 320 uses a closed loop feedback method that considers several factors in determining how much SAP to distribute at any given time. In a preferred embodiment, the control system 320 is provided with information about how fast the assembly line is running using, for example, a tachometer 346 on the vacuum drawing cylinder 322 or by any other appropriate line speed measuring device ( See Fig. 3). By integrating such a line speed measuring device into the control system 320, the control system 320 can be programmed to increase or decrease the frequency slope of the motor 340 to vary the flow rate of SAP when the manufacturing speed of the machine changes. product, thus providing all products with the appropriate amount of SAP, regardless of the speed of the assembly line. Such a capacity provides a lower rate of product rejection during transition phases, thus improving the overall efficiency of the manufacturing process. In another preferred embodiment, the output of the scale 342 is integrated into the control system 320. Considering the weight of the SAP being distributed, as measured by the scale 342, the control system 320 can be programmed to modulate the motor 340 to distribute accurately the SAP at the desired flow rate. In such an embodiment, the control system 320 may also be matched by deviations in the flow characteristics of the SAP particles to continue to provide a uniform flow, such as by increasing the rate of vibration if it is found that the SAP is not flowing as fast as it is. expected, and vice versa. Such deviations may be caused by typical variations in the shape, size, humidity, density, or other characteristics of the SAP, or may be caused when a different SAP product is used in a machine that was originally established for another type of SAP or established for SAP provided by different provider. A closed cycle feedback control system 320 can also be programmed to stop the distribution of SAP in the event that a failure in the processing line is detected. For example, if a unified linked fault detection circuit in the control system 320 determines that one or more products will be defective under termination, the SAP flow can be stopped such that the defective products will not receive SAP. In such an embodiment, it may be desirable to produce the absorbent cores of the garments as late as possible in the manufacturing process to detect as many defects as possible before preparing the absorbent core 6 for each product. In one embodiment, an SAP 350 concentration detection device (FIG 3) can be integrated into the control system 320 to provide additional detection and control capabilities to the control system 320. The concentration detection device 350 can be located to measure the amount and / or placement of the SAP in the assembled absorbent core composite 348. If the amount of SAP placement is not present as desired, the concentration detection device 350 may signal this to the control system 320 such that appropriate corrections can be made in the SAP feed speed. Those skilled in the art are able to design or use an appropriate SAP 350 concentration detection device using the guide lines provided herein. The SAP flow rate can also be controlled by a control device 320 by actively adjusting the height h of the adjustable door 408 during operation. As noted above, the adjustable gate 408 can be raised and lowered during operation to increase and decrease, respectively, the flow rate of SAP 326. Such adjustments can also be made to provide a cyclically fluctuating amount of SAP to the fiber at open cable 312 to create focused regions of relatively high SAP concentration for zoned absorbency. In such modality, the control device 320 can operate the adjustable gate 408 in combination with the scale 342, tachometer 346, concentration detection device 350, or other detectors to provide closed-loop feedback control of the SAP flow. A suitable driving device for cyclically raising and lowering the adjustable door 408 preferably does not cause excessive vibrations or other movements that can cause the scale 342 to read without precision. With reference now to FIG. 8, it has been found that a "combination drum" -type vacuum drawing cylinder 800 can be advantageously used in combination with vibratory feeders 332, such as those described herein, or, alternatively with other devices and feeding methods of SAP, such as those known in the art. The combination drum 800 is characterized in that several or all of the parts that eventually form the absorbent core 6 of the garment 10 are assembled in a continuous movement around all or part of the circumference of the combination drum. In a preferred embodiment, the combination drum 800 combines the first wrap sheet feed 316, open-wire fiber 312, SAP 326 and second wrap sheet supply 318 (i.e., various constituent parts of the core composite 348, which can, of course, include other parts) in a substantially continuous operation when these are transported by the combination drum 800. Each of the parts can be transported to the combination drum 800 separately and then joined together in an integrated structure, or alternatively, some of the parts may be joined with each other prior to contacting the combination drum 800. For example, an additional layer 20 may be attached to either side of one or both of the first and second wrapper sheet supplies. , 318 before the supply is provided to the 800 combination drum. As noted above, a preferred combination process is generally described elsewhere herein with reference to Locations A, B, C, and D of FIG. 3. The operation of the combination drum 800 described herein is relatively simple compared to many known core forming apparatuses, and can be adapted to operate at high line speeds. For example, it is anticipated that the combination drum 800 may be adapted to operate with an assembly line producing a surplus of 600 diapers per minute. In a preferred embodiment the combination drum 800 has a cylindrical surface 802 generally with a vacuum surface 804 forming a circumferential belt on the cylindrical surface 802. The vacuum surface 804 comprises one or more holes 806 through which vacuum is applied to various parts of the core compound 348. The holes 806 in the vacuum surface 804 can be formed by any means known in the art, such as drilling, machining, melting, etc. In a preferred embodiment, the holes 806 have a diameter of about 0J6 centimeters (0.0625 inches) to about 1.90 centimeters (0.75 inches), and more preferably from about 0.32 centimeters (0J25 inches) to about 1.59 centimeters (0.625 inches), and more preferably from about 0.64 centimeters (0.25 inches) to about 1.27 centimeters (0.50 inches). Also in a preferred embodiment, the holes may be spaced from each other by a center-to-center distance of approximately 0.25 centimeters (EIGHT inches) to approximately 2.54 centimeters (1.00 inches). The holes may be spaced in a rectilinear arrangement, such as stepped rows, or in any other pattern that conveys the desired amount of vacuum. The vacuum surface 804 may also comprise another structure with relatively rigid holes, such as one or more mesh screens or removable perforated plates which are fixed to the openings in the cylindrical surface 802. In a preferred embodiment, the combination drum 800 may also comprise platform areas 808 on either side of the vacuum surface 804 which can be treated to improve its ability to hold the first and second wrapping sheet supplies 316, 318. Vacuum is applied to the combination drum 800 through a vacuum port 810. Referring now to FIG. 9, a cross-sectional view of the vacuum surface region 804 of a combination drum 800 is shown as it appears just after combining the first wrap sheet supply 316, open cable fiber 312, SAP 326 and second supply of wrapping sheet 318 in an integrated core composite 348. The width Wi of the vacuum surface 804 (as measured in a direction parallel to the rotational axis of the combination drum 800) preferably corresponds approximately to the width of the fiber in open cable 312 and the width of the portion of the feed tray 334 from which the SAP 326 is provided. The first and second wrapping sheet supplies 316, 318 are preferably wider than the open rope fiber 312, and their excess width is located in side areas 902 that lie above the 808 platform areas. The first and second supplies of wrapping sheet 316, 318 preferably are joined with each other in their side areas 902 by adhesive bonding, and other methods described herein or by other methods known in the art. As noted above, a configuration on the roller 330 can be used to help unite the first and second wrapping sheet supplies 316, 318 by use of pressure, crimped nodules, and the like. In a preferred embodiment, the vacuum surface 804 is recessed in the cylindrical surface by a depth of less than about 1.27 centimeters (0.50 inches) and more preferably less than about 0.25 centimeters (EIGHT inches), and more preferably by about 0.08 centimeters. (0.03 inches). It has been found that having a slight increase in the diameter of the combination drum 800 on either side of the vacuum surface 804 (i.e., a vacuum surface with recess 804) helps to maintain the first supply of wrapping sheet 316 fluted to through the combination drum 800 during operation. The width of the vacuum surface Wi can be selected to provide certain benefits to the garment in which the core composite 348 is being integrated. In one embodiment, the core compound can be integrated into the garment in a flat condition, in which case it may be desirable to make the width of the vacuum surface W.subJ and the width of the fiber in open cable 312 equal to the desired width of the absorbent core 6 of the garment. However, the core compound 348 can be stretched, folded, or otherwise resized during manufacture, in which case the width of the vacuum surface V \ l- \ should be adjusted accordingly. In a preferred embodiment, the core composite 348 is folded at least once before being integrated into the garment. Folded absorbent cores have been discussed in more detail in this document. In a preferred embodiment, the width of the vacuum surface Wi is from about 4.45 centimeters (1.75 inches) to about 30.48 centimeters (12 inches), and more preferably from about 6.99 centimeters (2.75 inches) to about 25.4 centimeters (10 inches) , and more preferably about 9.53 centimeters (3.75 inches). To reduce the loss of the SAP during core formation, the width of the vacuum surface is preferably slightly narrower (approximately 0.25 centimeters (EIGHT inches on each side) than the width of the open cable fiber supply 312 to promote a migration towards the light interior of SAP away from the side areas 902. As noted above, there have been continuing efforts to provide the desired SAP distribution within the absorbent cores 6 of absorbent garments 10. It has been found that a combination drum 800 as described herein can be used beneficially to help provide such SAP distributions desired. Open cell fiber 312 cellulose acetate and other types of fiber structures in open density wire with low fibrous density allow a relatively large amount of air to pass through them compared to conventional fluff pulp materials, and the placement of the SAP 326 can be effectively controlled by modulating the amount and position of the vacuum applied to the SAP / fiber blend in open cable. It has been found that the distribution of the SAP can be controlled more easily with fiber cores in cable / SAP than with spongy cores / SAP. When the air passes through the open cable fiber 312 in vacuum it transports the SAP 326 through the fibrous structure, and the SAP 326 particles generally tend to concentrate more densely in areas that have a high vacuum. Also, when the vacuum is increased, the SAP particles 326 generally move closer to the surface of the open cable fiber 312 that is adjacent to the combination drum 800. The degree to which the SAP migrates toward the areas with high vacuum also can be affected by the length of time the vacuum is applied to SAP 326. Vacuum also helps to prevent SAP 326 from escaping from open cable fiber 312 during manufacturing. It has been found that a desirable blend of SAP 326 within the open cable fiber 312 and reduced SAP loss can be produced using a vacuum of approximately 6.35 centimeters (2.5 inches) of water to approximately 50.8 centimeters (20 inches) of water, and more preferably from about 9.53 centimeters (3.75 inches) of water to about 31.75 centimeters (12.5 inches) of water, and more preferably of about 12.7 centimeters (5.0 inches) of water. The vacuum may be pre-set or may be controlled manually or actively by a control system 320 using an open or closed cycle feedback system. In addition to being useful for providing a homogeneous dispersion of SAP 326 in open cable fiber 312, a combination drum 800 as described herein can also be used to achieve various other desirable SAP distribution patterns. In one embodiment, the vacuum level can be modulated to provide a desirable depth of SAP penetration through the open cable fiber 312 or only in discrete areas of the open cable fiber 312. In other embodiments, the combination drum 800 can be adapted to provide machine direction (MD) and zoning (CD) of the cross machine direction of the SAP 326 particles that provide the garment with zoned absorbency. The machine direction is the direction in which a part or assembly moves during processing, and the direction of the cross machine is perpendicular to the MD. The machine direction generally corresponds to the longitudinal dimension 100 of the garment 10 completely assembled (see Fig. 1), and the direction of the transverse machine corresponds to the lateral dimension 102 of the garment, however other Relationships can also be used and are within the scope of the present invention. With reference now to FIG. 10, regions of high SAP concentration, and thus greater absorbency, can be provided in the MD and CD by manufacturing the vacuum surface 804 with specially designed target regions 1002 that transmit a greater amount of vacuum to the portions of the fiber in open cable 312. Such target regions 1002 may have larger orifices and / or a greater concentration of holes in those areas where a higher concentration of SAP 326 is desired. The greater amount of open space provided in such regions will allow a greater amount of airflow into the vacuum, and thus causes a greater amount of SAP to migrate to those areas. For example, in the embodiment of FIG. 10, region 1004 has a higher concentration of larger orifices, which should provide an SAP concentration in the portion of core compound 384 adjacent to region 1004. The particular pattern of SAP concentration can be adjusted by fabricating each of the target regions 1002 from a peel plate 1006 having the desired hole pattern. Replacement plates 1006 can be easily machined to provide different hole patterns and absorbency patterns divided into zones. In another embodiment, shown in FIG. 11, the vacuum surface 804 may be separated into discrete target regions 1102, which may have varying widths, to provide zones of high and low SAP MD and CD concentrations. In a mode in which the combination drum 800 has target regions 1002, 1102 to provide divided absorbency, the diameter Di of the combination drum 800 should be selected such that the corresponding parts of each of the target regions 1002, 1102 are spaced from each other around the circumference of the combination drum 800 by a distance corresponding to the length of the absorbent core X- |. Using such spacing, each target region 1002, 1102 will create a focused area of SAP that will appropriately place on each absorbent core 6 that is cut from core compound 348. It should be understood that by providing a distance between corresponding parts of each target region 1002, 1102 which is approximately equal to a core length Xi, the circumference of the combination drum 800 will be sized to equal an integer multiple of the length of the core Xi. At a minimum, the circumference may equal a core length Xi, but in such an embodiment, the various parts of the core composite 348 will be in contact with the vacuum for a relatively short time, which may lead to inadequate SAP distribution or other problems. of molding. Drums with smaller diameter may also be subject to greater vibration. These problems can become aggravated when the combination drum 800 is used with assembly lines with higher speed. There may also be problems with larger drum diameters. For example, manufacturing tolerances for a drum with a larger diameter may be less precise. In addition, when the size of the drum increases the amount of start-up wear can increase, particularly if a larger amount of vacuum is required for the larger drum, leading to prolonged vacuum stabilization times. Larger drums that require larger amounts of vacuum may also require more energy to produce the necessary vacuum. It will be understood that these considerations also apply to embodiments of the invention in which the combination drum 800 does not have target regions 1002, 1102, such as in the embodiment illustrated in FIG. 8. It is preferred, therefore, that the diameter of the drum DT be selected such that the circumference of the drum is large enough so that the parts of the core compound 348 are in contact with vacuum for a long enough period to properly distribute the SAP without excessive vibrations, but for a short enough period to provide the required precision and a minimum amount of start-up wear. It has been found that in a preferred embodiment, the diameter Di is selected such that the circumference is equal to between three and seven lengths of the X-core. In a preferred embodiment, the combination drum 800 (whether it has target regions 1002, 1102 or not) has a diameter Di from about 15.24 centimeters (6 inches) to about 71.12 centimeters (28 inches) and more preferably about 22.86. centimeters (9 inches) to approximately 50.8 centimeters (20 inches), and more preferably about 30.48 centimeters (12 inches). In this mode, the number of waste cores caused by vacuum hysteresis or other issues related to starting has been found to be about 5 products per start, compared to up to about 50 products per start in a conventional core formation process. It has been found that providing the necessary vacuum to such a combination drum 800 requires from about 10 horsepower to 20 horsepower, while conventional core formation systems require up to about 400 horsepower, and thus energy savings are provided significant With reference now to FIGS. 12 to 14, there is shown a preferred embodiment of the combination drum in which the combination drum 800 can be configured to apply vacuum to the parts of the core compound 348 only through a portion of the rotation of the drum. The combination drum 800 of a preferred embodiment comprises an outer drum 1202 which is arranged to rotate about a fixed internal drum 1204, for example, being fixed to a shaft 1208 that passes through the rotary supports 1210 on the inner drum 1204 Such supports 1210 may be equipped to reduce or prevent leakage of vacuum therethrough. Vacuum is applied to the space 1206 inside the inner drum by a vacuum port 810. The vacuum is transmitted to the vacuum surface 804 of the outer drum by means of one or more passages 1212 through the inner drum 1204 which are preferably located sub-adjacent to the path of the vacuum surface 804 of the outer drum 1202 to maximize the force of the vacuum applied through the vacuum surface 804.

It will be understood by those skilled in the art that inner drum 1204 may be replaced by some vacuum chamber having one or more passages 1212 that transmit vacuum to a subadjacent location to all or part of vacuum surface 804. Only those portions of the vacuum surface 804 which is immediately adjacent to the passages 1212 receives vacuum, such that the duration and placement of the vacuum application can be modified by changing the size, number, or location of the passages 1212. With specific reference to FIG. 13, the passages 1212 can be placed through an arc of the inner drum 1204 which defines a vacuum zone? V. The leading edge of the vacuum zone 1302 is preferably located proximal to the point at which the first wrap sheet supply 316 makes contact with the combination drum, which is designated as the Location A in FIG. 13. The trailing edge of the vacuum zone 1302 is preferably located proximal to the point at which the first wrapping sheet supply 316 makes contact with the combination drum, which is designated as the Location A in FIG. 3. The trailing edge of the vacuum zone 1304 is preferably located further (when the drum rotates) of the point at which the second wrap sheet supply 318 makes contact with the combination drum 800, which is designated as the Location D in FIG. 3. With reference now to FIG. 14, it can be seen that those portions of the vacuum surface 804 that are not adjacent to the passages 1212 are effectively cut from the vacuum suction. After the core compound 348 passes the trailing edge of the vacuum zone 1304 and reaches this blocked area it is released from the vacuum hold and transmitted to other parts of the assembly line. The size of the vacuum zone? V may vary depending on where the various parts are desired to be assembled to form the composite core 348. In a preferred embodiment, the vacuum zone? V is from about 45 degrees to about 180 degrees, and more preferably it is from about 90 degrees to about 160 degrees, and more preferably is about 140 degrees. Various devices may be employed with the combination drum 800 to modulate the location and amount of vacuum applied to the core composite 348. In one embodiment, shown in FIG. 13, the inner sleeves 1306 and other valve mechanisms can be used to adjust the points at which the vacuum zone? V starts and ends. In another embodiment, shown in FIG. 12, other inner sleeves 1214 and other valve mechanisms can be used to narrow or broaden the width of the vacuum zone? V, thus effectively narrowing or widening the width Wi of the vacuum surface 804. In yet another embodiment, An inner sleeve or other valve mechanism can be used to reduce the level of vacuum within all or part of the internal combination drum 1204. Any such sleeve and valve mechanisms can be actuated by control system 320 under the guidance of a system of closed or open cycle feedback. Larger or smaller amounts of vacuum can also be applied in discrete portions of the vacuum zone? Other designs will be obvious to a person skilled in the art based on the teachings provided herein. A combination drum 800, as described herein, can be used with some SAP feeding device that deposits SAP on the fiber in open wire and other fibrous materials. The embodiments of the combination drum 800 described herein have been found to be particularly useful when used in combination with the vibratory feeder 332 as described herein. The present invention offers several advantages over previous SAP depositing systems. In particular, the vibratory feeder 332 provides improved control over the volume and displacement of the SAP 326 in the fiber, preferably fiber in open cable 312, allowing greater control over the SAP distribution (and zoned absorbency) during transition phases, such as during the start of the machine, stoppage and other speed changes, leading to fewer rejected products during such times. In addition, the vibratory feeder 332 and the combination drum 800 provide improved SAP penetration into the fiber, preferably the open cable fiber 312 or other core material, and an improved ability to selectively place the SAP to provide the absorbed zoned desirable. The vibratory feeder 332 and the combination drum 800 also provide easier operation, since various features of each device can be integrated into a control system 320. Still further, the vibratory feeder 332 and combination drum 800 are relatively simple devices and reliable that require little maintenance or cleaning, thus reducing the cost of operating the machine. Another advantage of the vibratory feeder 332 and combination drum 800 is that they can be operated at high line speed without detriment to the quality of the product. Other benefits will be apparent to those skilled in the art based on the teachings provided herein. In yet another embodiment, the present invention provides an apparatus and method for forming absorbent structures having a single wrapping sheet. The single sheet absorbent cores are fabricated with a single wrap sheet (instead of multiple wrap sheets, as described hereinabove) which is wrapped around all or part of the absorbent core material. It has been found that the use of a single wrapping sheet provides manufacturing and economic advantages over the use of multiple wrapping sheets because the single sheet does not require cutting and redirecting, and can be attached to itself in an individual seam, instead of multiple seams as in the case of multiple wrapping sheets. As with multiple sheet cores, such single sheet absorbent structures can be used in some absorbent product, including garments, such as diapers and briefs to put on quickly, catamenial devices, absorbent handkerchiefs or sheets, etc. Although it is known to manufacture conventional sponge pulp / SAP absorbent cores having a single wrapping sheet, it has been found that known methods and apparatus for forming individual sheet core structures are not particularly useful for forming sheet core structures. individual made using absorbent cores based on fiber in cable. With reference now to FIGS. 16A and 16B, embodiments of single sheet absorbent structures that can be manufactured using the present invention are shown in cross section. In FIG. 16A, the absorbent structure is shown as it may appear when installed in an exemplary absorbent product, in FIG. 16B the structure is shown with the rest of the absorbent product omitted for clarity. The single sheet absorbent structure comprises an absorbent core based on cable fiber 1606 wrapped in a single wrapping sheet 1618. As can be seen in FIGS. 16A and 16B, the wrapping sheet 1618 may be individually wider than the absorbent core 1606 and then folded over the core 1606 to enclose it completely. The embodiment of FIG. 16A demonstrates a three-fold design, in which the wrapping sheet 1618 is folded into two locations to form three sheet portions. FIG. 16B demonstrates a two-fold design, in which the wrapping sheet 1618 is folded into one location to form two sheet portions. The two ends 1618a1618b of the wrapping sheet 1618 can overlap with each other such that the inside of one end 1618b projects to the outer side of the other end 1618a, as shown in FIG. 16A, or can be fired with pressure such that the ends 1618a, 1618b project onto each other on their inner sides, as shown in FIG. 16B. The ends 1618a, 1618b of the wrapping sheet 1618 can also be projected with each other without some substantial overlap, or they can be fixed and some or all of the overlap portions removed before final assembly in a product. Also, in some cases, the seam may be located on the top, bottom or sides of the absorbent core 1606, and may be detached or joined (as shown by the joint 1622) using some recently developed or known bonding technique. Various useful compositions of the fiber-based absorbent core 1606 and wrap sheet 1618 have been described in more detail hereinbefore. In a preferred embodiment, the wrapping sheet 1618 comprises a sheet of fabric. Other features of the exemplary garment 1600 of FIG. 16A include a fluid permeable topsheet 1602 and a fluid impermeable backsheet 1604. The garment 1600 may also have liquid-permeable or fluid-proof waste containment flaps 1612, which may contain elastic members 1614, and leg elastics. 1608 adjacent the leg openings 1628a, 1628b to assist leakage control. An additional layer 1620, comprising an absorbent layer or the like, may also be provided on the garment 1600, and may be located within the wrapping sheet 1618, outside the wrapping sheet 1618, or between the overlapping ends 1618a, 1618b of the wrapping sheet 1618. Useful materials and constructions for these and other components of the exemplary garment 1600 have been described in more detail herein. It has been found that the present invention can be adapted to provide a continuous supply of single sheet, fiber based absorbent core structures in cable in an economical and efficient manner. In the present invention, a vacuum drawing cylinder, such as those described herein, is used in combination with angled surfaces and other folding devices to combine the cable fiber, SAP and wrapping sheet in a continuous supply Completely folded from absorbent core composite material. From this continuous supply, a series of single sheet absorbent structures can be cut to form individual absorbent cores, which can be integrated into any type of absorbent article or device or used on their own. Various embodiments of the present invention are now described with reference to FIGS. 17-29. In one embodiment of the present invention, shown in FIG. 17, a vacuum drawing cylinder 1708, is operated in combination with a tapered cutting drum 1714 and folders 1716 to form and fold a supply of single sheet core compound. In this embodiment, the materials required to form the absorbent structure are provided to the apparatus by a cable fiber delivery mechanism 1702, a particulate matter supply mechanism 1704, and an envelope sheet supply mechanism 1706. cable fiber delivery mechanism 1702 may comprise some cable fiber transport device that provides a supply of fiber in cable, such as rolls or the like, and preferably comprises a cable fiber molding jet, as described above in This document. The cable fiber 1703 may be any suitable cable fiber, as described above, to form an absorbent structure, and preferably it is a fiber in cellulose acetate cable that is opened prior to or while being supplied to the apparatus of the present invention. The particulate matter delivery mechanism 1704 provides SAP and / or other particulate additives (which may include powders, grains, flakes, microfibers and the like) to the apparatus, and may comprise any conventional feeding device, or more preferably , a vibratory feeder, such as those described herein. The wrap sheet supply mechanism 1706 is shown as a single roll, but may comprise any sheet transport device or devices, such as rolls, feed rolls, festoons, and the like, as are well known in the art, which they are capable of providing a supply of wrap sheet 1707 (preferably a sheet of fabric) in a controlled manner to the apparatus.

With respect to the vacuum drawing cylinder 1708, the envelope sheet supply mechanism 1706, the particulate matter supply mechanism 1704 and the cable fiber delivery mechanism 1702, the embodiment of FIG. 17 may operate in the same manner as the embodiments of these components described herein, such as with reference to FIG. 3. More specifically, the vacuum drawing cylinder 1708 rotates about a first axis 1710 and pulls the open cable fiber 1703 out of the cable fiber delivery mechanism 1702 and joins it with the envelope sheet supply 1707. The particulate matter supply mechanism 1704 is positioned to deposit SAP 1705 or other particulate additives to the open cable fiber before it is combined with the envelope sheet supply 1707. In addition, a first adhesive applicator 1712 can be positioned to spray adhesive onto the envelope sheet supply portion 1707 which contacts the cable fiber 1703 to provide adhesion between the cable fiber 1703 and the envelope sheet supply 1707, and to adhere the SAP 1705 to its place. Of course, these various components can be repositioned in various ways, and this is anticipated; for example, the invention can be configured such that the particulate matter delivery mechanism 1704 deposits the SAP 1705 directly onto wrap sheet supply 1707 or such that the first adhesive applicator 1712 sprays adhesive directly onto the cable fiber 1703.

Similar to other vacuum drawing cylinders and combination drums described herein, the vacuum drum has a center surface with holes (see FIGS 8 and 24) which applies vacuum to cable fiber 1703 and supply of wrapping sheet 1707. It has been found that relatively little vacuum is necessary, and a vacuum of approximately 2.54 centimeters to 5.08 centimeters (1 to 2 inches) of water, and preferably 3.81 centimeters (1.5 inches) of water are suitable for training operations of high speed core. The central surface with holes can be molded to accommodate and transport the cable fiber 1703, and can be flat, round, angled, with recess, etc. In a preferred embodiment the center surface with holes has a recessed portion, as shown in FIGS. 9 and 27. Other features and embodiments of the vacuum drawing cylinder 1703 are described in more detail herein. In the embodiment of FIG. 17, the supply of wrapping sheet 1707, cable fiber 1703 and SAP 1705 (or other particulate additives) are combined on the vacuum drawing cylinder 1708 within a supply of unfolded open core compound 1718 that is open on the side facing the cylinder Vacuum Drawing 1708. For the purposes of this description, the term "open core compound supply" means some composite structure having a fiber material in cable on one side and a shell sheet material on the other side, wherein the wrapping sheet material does not completely enclose the fiber material in cable (thus leaving the composite structure "open"). It should be noted that in this embodiment the cable fiber 1703 is the only material between the SAP 1705 and the surface with holes and vacuum of the vacuum drawing cylinder 1708. It has been found that the cable fiber 1703 has the unexpected ability to act as a filter that provides sufficient strength to impede the flow of SAP 1705 and avoid loss of some substantial amount of SAP 1705 in a vacuum. After being formed, the supply of open core compound 1718 is preferably transferred to a vacuum conveyor 1726 for further processing. It has been found that a significant amount of static electricity can accumulate on the cable fiber 1703 during the opening process when a fiber molding jet on cable is used. The static electricity can generate sufficient attraction between the vacuum drawing cylinder 1714 and the supply of open core compound 1718 to cause undesirable adhesion which can create irregularities in the open core composite supply operation path 1718 and inhibit the speed at which the device can operate. To reduce or eliminate this static charge buildup, water can be introduced into the cable fiber molding jet and / or over the vacuum drawing cylinder 1714 to help reduce static buildup and facilitate release of the open core compound supply. from the vacuum drawing cylinder 1714. In other embodiments, an additional layer of material (not shown), such as an absorbent layer or acquisition layer may be placed on the vacuum drawing cylinder 1708 before or after the cable fiber 1703 and / or the wrapping sheet supply 1717 is applied to the vacuum drawing cylinder 1708. In these embodiments, the supply of the absorbent core compound can be formed with an integral layer 1620 being incorporated directly into the structure . The supply of wrap sheet 1707, SAP 1705 and wire fiber 1703 are formed within a pleated and substantially flat supply of the core composite material in a process shown representatively by FIGS. 18A-18C. FIGS. 18A-18C are cross-sectional drawings of the core composite materials shown in reference lines 4-4, 5-5 and 6-6 in FIG. 17, respectively, with the machinery omitted for clarity. In the first step, several materials are combined together to form a supply of open core compound 1718. In the embodiment of FIG. 17, the supply of open core compound 1718 is provided in a substantially planar configuration, as shown in FIG. 18. Then, as shown in FIG. 18B, the supply of open core compound 1718 is folded such that it has one or more obtuse angles To. Finally, the partially folded open core composite supply 1718 is completely folded such that it is substantially flat, as shown in FIG. 18C. Although the embodiment shown in FIGS. 18A-18C illustrates a three-fold design will be used that using an individual obtuse angle To, a two-fold design can be made. In other embodiments such as those subsequently described herein with reference to FIGS. 21 a 27, the various steps described above, particularly the first and second steps, can be combined to improve efficiency, reduce the size of the apparatus or obtain other benefits. In the modality of FIGS. 18A-18B, the envelope sheet supply 1707 is preferably wider than the cable fiber supply 1703 such that the ends of the envelope sheet supply can be folded over and joined with each other. In this embodiment, the wrapping sheet comprises three regions: a central region Ri and first and second lateral regions R2, R3. The central region Ri is located approximately along the center line of the wrapping sheet supply 1707, while the first and second side regions R2, R3 are located on either side of the central region R-i. The edges of the central region R-i are defined by the locations in which the obtuse angles To are made. It is also anticipated that the central region Ri may be offset to one side, and one or both of the side regions R2, R3 may be folded to cover the cable fiber to form the composite core as a two-fold design (in which only one side region is folded) or a three-fold design having an offset seam. The first adhesive applicator 1712, if used, applies adhesive 1802 continuously or intermittently to the central region to adhere the cable fiber to the envelope sheet supply 1707 and hold the SAP in place. The adhesive 1802 can be applied in lines, spirals, bands or in any other useful pattern. The adhesive is preferably not applied in the side regions R2, R3 during the initial assembly steps because such an adhesive may adhere to the vacuum drawing cylinder 1708 or other machinery and interferes with manufacture. As noted above, the type and amount of adhesive should be selected to minimize any detriment to the absorbent capacity of the core compound, and standard construction adhesive can be applied to the 1707 wrap sheet supply by a standard melt blown adhesive applicator. . The selection of adhesives, either hydrophilic or hydrophobic, and different types of applicators will be understood by those of ordinary skill in the art. An appropriate selection of adhesives and applicators will be readily apparent without undue experimentation. In a preferred embodiment, the obtuse angles To are formed in the envelope sheet supply 1707 outboard of the cable fiber 1703, as shown in the Figures. It is also anticipated, however, that it may be useful to form the obtuse angles To at locations slightly inward of the edges of the cable fiber 1703 such that the cable fiber 1703 has thicker edges. In a two-fold design, the cable fiber 1703 can also be folded along its center line to form a double-thick structure. The obtuse angles To can be formed in the supply of open core compound 1718 by cutting the supply of open core compound 1718 using one or more angled surfaces. In the embodiment of FIG. 17, the supply of open core compound 1718 is conveyed on a tapered cutting drum 1714 having an integral pair of angled surfaces 1720. The tapered cutting drum is shown in more detail in FIG. 19. As shown in FIG. 19, the tapered cutting drum 1714 comprises a central surface 1902 (which may be cylindrical, round, recessed or otherwise or textured) and two angled surfaces 1720. The two angled surfaces 1720 extend from a respective edge. 1904 of the center surface 1902 and tapered (preferably in a conical shape) to have a smaller diameter when advancing away from the central surface 1902. The taper angle is selected to impart the desired obtuse angles To in the supply of core compound open 1718. To minimize friction on the supply of open core compound 1718, the tapered cutting drum 1714 preferably rotates about the axis 1906, such that the surface velocity of the tapered cutting drum 1714 approximately equal that of the supply of core compound open 1718, and is designed to have a low rotational inertia to allow the drum to respond quickly to changes in the speed of operation. The tapered cutting drum 1714 is placed in the assembly line such that it tends to create tension in the central region Ri of the open core compound supply 1718, as shown, for example, in FIG. 17. When the tapered cutting drum 1714 is thus placed, the side regions R-i, R2, which are not under as much tension as the central region R1? they tend to follow the path of least resistance following the contours of the angled surfaces 1720, thus forming the obtuse angles To. In another embodiment shown in FIG. 20, the angled surfaces may instead comprise rollers 2004 or fixed guides which are placed at angles adjacent to a non-tapered cutting drum 2002. In this embodiment, the cutting drum 2002 applies tension to the central region Ri of the compound supply open core 1718, and the rollers 2004 impart the desired obtuse angles To in the side regions Ri, R2 of the open core compound supply 1718. The size of the obtuse angles To is preferably selected to increase the speed at which the supply of core compound open 1718 can be folded by folders 1716. This angle may depend on the type of folders 1716 that are employed. It is also anticipated that in a three-fold design the obtuse angles To may be different for each side of the open-core composite supply 1718. In a preferred embodiment, the obtuse angles To are between about 130 degrees and about 175 degrees. In a preferred embodiment, the obtuse angles To are between about 140 degrees and about 165 degrees. In still a more preferred embodiment, the obtuse angles To are approximately 154 degrees. After the obtuse angle To or angles are made in the open core compound supply 1718, it is conveyed to one or more beams 1716 that fold the compound into a supply of substantially flat folded core compound 1724. The beams 1716 can be comprising any known folding equipment, but preferably comprising a set of folding boards which maintain substantially equal web tension through the transverse direction of the fabric sheet (ie, in the direction perpendicular to the machine direction. , the folding boards prevent deformation or collapse in the fabric sheet A second adhesive applicator 1722 can, in some embodiments, be provided to apply adhesive to the center or side regions Ri, R2, R3 during the folding process to maintain the supply 1707 wrapping sheet in place once the supply of folded core compound 1724 Such an adhesive can be applied on either side of the wrapping sheet supply 1707, and can also be applied on the cable fiber 1703. It will be appreciated that the design and location of the second adhesive applicator 1722 should be selected such that it is operatively associated with the folder 1716 such that it applies adhesive to the appropriate surfaces before, during or after the folding operation performed by the folder 1716. The relative positioning of these devices, and other ways in which the second adhesive applicator 1722 can being operatively associated with the folder 1716 can be readily understood by those of ordinary skill in the art. In a preferred embodiment, the second adhesive applicator 1722 comprises a slot coater that applies construction adhesive to seal the wrap sheet supply 1707 after it has been folded. The slot coater preferably comprises a knife-like device that slides between the overlapping portions of the wrap sheet supply 1707 and applies adhesive to one or both of the oriented portions of the fold, but not yet joined, the sheet supply wrapping 1707. Of course, the second adhesive applicator 1722 may also comprise any conventional adhesive applicator, such as a conventional spray adhesive applicator or slot adhesive applicator placed prior to or on the folder 1716 which applies adhesive prior to the application of the adhesive. 1707 wrapping sheet supply is completely folded. After adhesive is applied by the second adhesive applicator 1722, the supply of folded core compound 1724 can be pressed into a compression roller or a volume reducer (not shown) to help seal the adhesive. Alternatively, or in addition to the second adhesive applicator 1722, other joining devices, other joining devices or methods may be used. For example, in a two-fold design, an edge sealer may be employed after the second adhesive applicator to secure the edges of the wrap sheet supply, as shown in FIG. 16B. In still other embodiments, the wrapping sheet supply 1707 may not be sealed at this point, and may instead be held in its closed position by contact with other parts of a garment or other article within which the supply of compound The folded core 1724 is integrated. With reference now to FIG. 21, in another embodiment of the invention, angled surfaces can be integrated into the vacuum drawing cylinder, thereby making the apparatus more compact and eliminating the need to provide a separate cutting roller and other devices between the drawing cylinder vacuum and beams 1716. In this embodiment the vacuum drawing cylinder is a tapered vacuum drawing cylinder 2102 comprising one or more angled surfaces 2104. The tapered vacuum drawing cylinder 2102 simultaneously forms the core compound supply. open 1718 and creates the obtuse angles To in the open core composite supply 1718. A vacuum transmitter 2108 then conveys the supply of open core compound 1718 to one or more folding devices 1716 where it is folded into a supply of compound of folded core 1724. In a variant of the embodiment of FIG. 21, shown in FIG. 22, the vacuum transmitter 2108 may comprise an arcuate portion 2110 that is partially wrapped around the tapered vacuum drawing cylinder 2102. It is believed that in this embodiment the presence of the arched portion of the transmitter may help to retain the SAP 1705 or other particulate matter or additives in position during the forming operation. A taper or configuration on step roller 2106 may also be used in combination with the embodiment of FIG. 21 to assist in shaping the wrapping sheet supply 1707 toward the angled surfaces 2104 of the tapered vacuum drawing cylinder 2102. An example of a configuration on the tapered roller 2106 is shown in more detail in FIG. 23. In the example of FIG. 23, the configuration on the tapered roller 330 has two tapered surfaces 2302 that engage the angled surfaces 2104 of the vacuum drawing cylinder during use, and may optionally have a central surface 3204 having an appropriate shape (preferably cylindrical) to generally splice to the central surface of the tapered vacuum drawing cylinder 2102. In other embodiments, the tapered surfaces may be replaced by one or more cylindrical or disk-like surfaces. One embodiment of a tapered vacuum draw cylinder of the present invention is now described in detail with reference to FIGS. 24-27. FIG. 24 is an isometric view of a tapered vacuum drawing cylinder 2402 showing the angled surfaces 2404 (one of which is visible) and center surface with holes 2406. The angled surfaces 2404 and center surface with holes 2405 are deposited on a rotating drum 2412 which is positioned outside an interior structure 2408. Interior structure 2408 contains one or more vacuum passages for transmitting vacuum to the central surface with holes 2406. Angled surfaces 2404 preferably comprise tapered surfaces, preferably molded as conical sections , such as those described with reference to the tapered cutting drum 1714 of FIGS. 17 and 19. It is also shown in FIG. 24 a vacuum port 2410 that can be connected to a vacuum source. Of course, it will be appreciated that in embodiments of the present invention in which a two-fold core design is produced, there may be only one angled surface 2404, and the center surface with holes 2406 may not be located in the center of the drum. rotatable Also in a two-fold design, the center surface may be peaked at the center to cut the supply of open core compound 1718 along or near its center line. With reference to FIGS. 25 and 26, the internal structure of the tapered vacuum drawing cylinder 2402 is described. As noted above, the tapered vacuum drawing cylinder 2402 comprises a rotatable outer drum 2412 disposed about an internal structure 2408. For clarity, in FIG. The outer drum 2412 is shown in section approximately in the center of the center surface with holes 2406 and the passages through the center surface with holes 2406 are omitted in both FIGS. 25 and 26. In this embodiment, the inner surface 2408 comprises a vacuum chamber 2414 toward which vacuum is provided. The inner upper 2408 also has one more vacuum passages 2418 which place the vacuum chamber 2414 in fluid communication with the lower side of the center surface with holes. As can best be seen in FIG. 26, there may be a space 2420 between the center surface with holes 2406 and the outer surface of the interior structure 2408. To prevent the vacuum from being applied to the full circumference of the center surface with holes 2406, a pair of vacuum blocks 2422 is placed in the 2420 space to inhibit the fluid communication of the vacuum. As shown in FIG. 25, the placement of the vacuum blocks 2422 dictates the size of the vacuum zone Tv in which the vacuum is applied to the center surface with holes 2406. In a preferred embodiment, the tapered vacuum drawing cylinder 2402 (or other Draft cylinder) can be additionally equipped with an air blow port to avoid removing the 1718 open core compound supply for further processing. In such an embodiment, the inner structure 2408 may further comprise a pressurized chamber 2416 to which the pressurized air is provided. The pressurized air in the pressurized chamber 2416 is placed in fluid communication with the center surface with holes 2406 to expel the supply of open core compound 1718 after it reaches the trailing edge of the vacuum zone, (iv.) Preferably, this is achieved by providing the vacuum block located at the trailing edge of the vacuum zone Tv with an air blow passage 2424 that is in fluid communication with the pressurized chamber 2416. When the outer drum 2412 rotates, the central surface with holes 2406 passes over the blow passage 2424, and the pressurized air is forced out of the center surface with holes 2406, creating a force to release the supply of open core compound 1718. The center surface with holes 2406 can be any surface that has holes or slots to pass vacuum through these, and preferably is similar to the vacuum surface 804 described previously In this document with reference to FIG. 8. Referring now to FIG. 27, in a preferred embodiment, the central surface with holes comprises three vacuum regions: a central vacuum region Zi and the first and second lateral vacuum regions Z2, Z3. The central void region Z-i is preferably approximately the same width as the supply of cable fiber material 1703, and is recessed to accommodate the cable fiber 1707 to some degree when it is being transported. The lateral vacuum regions Z2, Z3 are arranged on either side of the central vacuum region Z ^ and in contact with the wrap sheet supply 1707 during operation. The purpose of the lateral vacuum regions Z2, Z3 is to firmly support the wrapping sheet supply 1707 to form a seal that inhibits the lateral leakage of the SAP 1705 or other additives during operation, and improve the grip of the fiber on cable 1703 and 1707 wrapping sheet supply which is created in the central vacuum Zi region. In many of the embodiments described previously herein (such as the embodiments described with reference to FIGS 17, 21 and 22), the wrapping sheet supply 1707 is transported along a portion of its trajectory by the vacuum drawing cylinder 1708, 2102 in such a manner that the wrapping sheet supply 1707 is wrapped around a substantial portion of the undercutting cylinder. vacuum draw 1708, 2102. However, in other embodiments, the various devices described herein may be arranged in configurations in which a vacuum drawing cylinder deposits fiber in a cable on a supply of wrapping sheet that is transported without being wrapped around a portion of the vacuum drawing cylinder 2808. Various embodiments having this configuration are now described with reference to FIGS. 28 and 29. With reference to FIG. 28, in one embodiment of the invention a wrap sheet supply can be provided by a substantially linear conveyor 2826 (preferably a vacuum conveyor), while the cable fiber 2803 is provided by a cable fiber delivery mechanism 2802 and particulate material such as SAP 2805 is provided by a particulate matter delivery mechanism 2804. When the wrap sheet supply 2807 is transported along the conveyor 2826, a first adhesive applicator 2812 applies adhesive to all or part of a side of wrapping sheet supply 2807. After SAP 2805 is applied, and then cable fiber 2803 is deposited onto wrapping sheet supply 2807 by a vacuum drawing cylinder 2808 to form a supply of open core compound 2818. The supply of open-core compound 2818 is then transported to a folder 2816 which folds it into a supply of folded core compound 2824, substantially planar. The first adhesive applicator 2812 applies adhesive to support the SAP in place and adhere the cable fiber 2803 to the wrapping sheet supply 2807. A second adhesive applicator 2822 can also be used with the embodiment of FIG. 28 for applying adhesive to the cable fiber 2703 or wrapping sheet supply 2807 to support the folded portions of the wrapping sheet supply 2807 in place after it is formed in the supply of folded core compound 2824. In another embodiment , the second adhesive applicator 2822 can be omitted if the first adhesive applicator 2812 is adapted to apply adhesive to the wrapping sheet supply portions 2807, such as to the side regions R2, R3, which will eventually be folded to support the supply of adhesive. composed of folded core 2824 together. In an embodiment in which the first adhesive applicator 2812 is used to apply adhesive to the side regions R1 (R2 of the wrapping sheet supply, the vacuum drawing cylinder 2808 should be placed such that this does not contact the portions of the wrapping sheet. 2807 wrapping sheet supply having adhesive applied thereto to avoid adhesive buildup on the machinery, Of course other sealing devices, such as ultrasonic sealants, can also be used to form a joint to maintain supply of folded core compound 2824 The modes in which the wrapping sheet supply 2807 is not transported around the vacuum drawing cylinder 2808 provide the advantage that the apparatus can be relatively easily reconfigured to modify or complement the assembly process. shown in FIG 29, a third adhesive applicator 2813 can be included among the canister 2804 and vacuum drawing cylinder 2808 to provide another adhesive layer to hold the SAP 2805 in place and / or adhere the cable fiber 2803 to the wrap sheet 2807 supply. , the first adhesive applicator 2812 may optionally be omitted. FIG. 29 also demonstrates other features that may be used with some embodiment of the invention. For example, a second cable fiber delivery mechanism 2802 'may be used in combination with the original cable fiber delivery mechanism 2802 to provide a second cable fiber supply 2803' and thus create a multiple component or cable fiber in multiple layers. In such an embodiment, the second cable fiber supply 2803 'may be placed down, over, or adjacent to the original cable fiber supply 2803. It is also shown in FIG. 29 a second vacuum drawing cylinder 2828 and a fourth adhesive applicator 2834 that can be used to secure an additional supply of fiber to cable 2832 to the supply of folded core compound 2824. Additional supply of fiber to cable 2832 can be used , for example, as an acquisition layer or as a transfer layer, or may be infused with an additional supply of SAP (not shown) to act as an additional absorbent layer. FIG. 29 also demonstrates a embossing roller 2836 which can be used in combination with the invention for embossing the wrapping sheet supply 2807. The pattern of the embossing roller 2836 can be selected to form cavities, micro cavities or grooves on the surface of the wrapping sheet supply 2807. The SAP 2805 deposited in the wrapping sheet supply 2807 can be concentrated in these cavities or grooves, thus creating zones of greater or lesser absolubancy in the supply of completed core composite 2824. These zones can be subsequently placed on the absorbent garments to provide focused regions of high absorbency. The embossing provided by the embossing roll 2836 can also add more desirable lift or texture to the structure of the finished absorbent garment or provide other benefits. Although FIGS. 28 and 29 and the discussion thereof describe the wrapping sheet supply 2807 as being transported in a substantially linear manner by the conveyor 2826, it is also conceptualized that the conveyor 2826 may have a non-linear path, such as the conveyor 1726 in FIG. 17, with the vacuum drawing cylinder 2808 being located at the point at which the conveyor 2826 is inverted or at another location. Such variants are within the scope of the present invention. Although the cable fiber delivery mechanisms described so far (ie, points 1702, 2802, 2802 'and 2830) have generally illustrated fiber-casting jets in cable, it will be understood by those of ordinary skill in the art that mechanisms of Cable fiber supply may also comprise another type of cable fiber molding or cable fiber supply device. In fact, there is no requirement that the cable fiber be opened or otherwise conditioned "on the flight during the manufacturing process, whereas in other embodiments of the invention the cable fiber can be substantially completely prepared in one operation. of separate manufacture, and provided to the present invention as a suitable roll As used herein, "suitable roll" refers to any supply of pre-prepared material that requires little or no additional substantial processing when it is supplied to the present invention A suitable roll is preferably provided in the form of a roll, but may also be provided as sheets, as a folded supply, as a continuous or batch supply, or in some other appropriate manner, as will be apparent to those of ordinary experience In the art it is contemplated that the suitable roll or pre-made material supply may include other synthetic fiber materials alternative to fiber-based materials in cable, such as, for example, adhesively bonded, carded, materials bonded through air, non-woven wefts, non-woven wefts of two components, etc. FIG. 30 illustrates an apparatus similar to that of FIG. 29, except that the cable fiber supply mechanisms comprise several types of fiber supply mechanisms in suitable roll cable. As shown in FIG. 30, a first fiber supply in suitable roll cable 3003 forming the absorbent core 2824 can be provided as a continuous supply from a wound spool 3002 of the fiber material in suitable roll cable. A conventional tissue unknot mechanism or other appropriate device can be used to control the feed rate of the first fiber supply in suitable roll cable 3003. Several rolls 3009 can be used to transport the first fiber supply in suitable roll cable 3003 and press this to the wrapping sheet supply "2807. A second fiber supply in suitable roll cable 3032 can also be provided to lie above the supply of folded core compound 2824 to act as an acquisition layer, transfer layer or similar In the embodiment of FIG 30, the second fiber supply in suitable roll cable 3032 is separated into discrete pieces 3032 'which are spaced apart and placed over the supply of folded core compound 2824 using, for example, a conventional vacuum transfer roller and cutting knife assembly 3028. Of course, the second supply of Suitable fiber roll cable 3032 can be provided by any other appropriate device, and does not need to be provided as continuous pieces. With reference to FIGS. 31 and 32, an alternative embodiment of the diaper 10, similar to that described above with respect to FIGS. 1 and 2, includes an absorbent core 3506 of fibers in polypropylene cable. The absorbent core 3506 includes a cable fiber layer 3508 and an SAP particle layer 3510. The cable fiber layer 3508 is 100% by weight fibers in polypropylene cable. It is contemplated that other ranges of fiber concentration in synthetic cable may be employed including ranges of 50-100%, and various types of synthetic cable fibers may be employed, similar to those described above. The cable fiber layer 3508 can be formed from a suitable roll product or claimed products. The fibers can also be colored. It is evident that the cable fiber layer 3508 can include a mixture of fluff pulp. The particle layer SAP 3510 is 100% by weight SAP. It is contemplated that other SAP concentration ranges may be employed and that alternative types of SAP materials may be employed, similar to those described above. The absorbent core 3506 has a central portion 3526, side portions 3528, a front end 3530 and a rear end 3532. The absorbent core 3506 has a rectangular configuration. It is contemplated that the core 3506 may have alternative geometric configurations, such as elliptical, circular, etc. A polypropylene wrap sheet 3512 encloses the absorbent core 3506 such that the SAP particle layer 3510 is disposed therebetween. The polypropylene wrap sheet 3512 surrounds the absorbent core 3506 for disposition between the top layer 2 and the bottom layer 4, similar to the absorbent core 6 described above with respect to FIGS. 1 and 2. The diaper 10 can include one or a plurality of wrapping sheets 3512. It is considered that the wrapping sheet 3512 can be manufactured from alternative nonwoven materials, similar to those described. It is further contemplated that the wrapping sheet 3512 may also be made of films such as for example, polymeric films such as polyethylene, polypropylene, polyester, pigmented polyethylene, plastic with apertures, pre-punched plastic, two-component films. The SAP 3514 particles are also distributed with the cable fiber layer 3508 and disposed between the enclosure of the wrapping sheet 3512. It is considered that the SAP batches may not be distributed with the cable fiber layer 3508. The wrapping sheet 3512 is wrapped in a G-fold configuration around the absorbent core 3506, as will be appreciated by those skilled in the art. Other fold configurations such as C-fold, Z-fold, etc. they are contemplated. For example, as shown in FIGS. 40 and 41, the diaper 10 includes the wrapping sheet 3512 wrapped in a C-fold configuration around the absorbent core 3506. The overlapping pleats of the wrapping sheet 3512 are adhered by an adhesive 3516. The SAP 3510 particle layer is disposed with the wrapping sheet 3512 by an adhesive 3518. It is contemplated that some adhesive 3516, 3518 may be employed appropriate for applications in accordance with the principles of the present disclosure, similar to those described. Alternatively, the adhesion of the SAP 3510 particle layer to the wrapping sheet 3512 is not required.

The wrap sheet 3512 and cable fiber layer 3508 are manufactured from materials, ie, polypropylene, to facilitate ultrasonic or embossing of the wrap sheet 3512 and the cable fiber layer 3508. With reference to FIGS. 33-35, the wrapping sheet 3512 is joined (FIG.35) to the cable fiber layer 3508 to form a predetermined pattern 3520 via attachment points 3522, as shown in FIG. 33. The pattern 3520 is bonded to the wrapping sheet 3512 to define cavities 3524 (FIG.34) that are configured to contain SAP particle 3514 or SAP particle layer 3510. The cavities 3524 uniformly distribute the SAP 3514 particles over the core. 3506 and prevent unwanted accumulation of SAP particles in a particular portion of the diaper 10 that can result in gel blocking. The predetermined pattern configuration 3520 advantageously facilitates the distribution of fluid through the diaper 10 to the SAP particles 3514 to improve SAP efficiency. This result exceeds the incidence of gel blocking and decreases the basis weight of the diaper 10. Other forms of attachment are also contemplated such as, for example, various types of glue and related patterns, alternative fastening schemes such as water, glycerin, mechanical or procedures related to heat. In an alternative embodiment, the central portion 3526 is hydrophilic and the side portions 3528 are treated as hydrophobic. The portions 3526, 3528 and lower layer 4 define a fluid containment zone. The fluid containment zone maintains fluid discharge of the carrier with the diaper 10 and prevents leakage of the diaper 10 from the discharge. In another alternative embodiment, the front end 3530 and rear end 3532 are sealed to prevent leakage. With reference to FIG. 36, an alternative pattern-predetermined embodiment 3520 includes a diamond-point pattern of the joining pads 3622. The diamond pattern 3520 includes diamond shapes 3624 that are approximately 0.64 centimeters (0.25 inches) in dimension with the attachment points 3622 being approximately 1 millimeter in diameter. With reference now to FIG. 37, another alternative mode of predetermined pattern 3520 includes a spike-like pattern of waves 3724 formed from junction points 3722. Each of the waves 3724 are separated by approximately 0.64 centimeters (0.25 inches). Waves 3726 3724 are separated by approximately 4.45 centimeters (1.75 inches). The attachment points 3722 are approximately 1 millimeter in diameter. With reference to FIG. 38, another alternative mode of predetermined pattern 3520 includes a spike-like pattern of waves 3824 formed from junction points 3822. Each of the waves 3824 are separated by approximately 1.27 centimeters (0.50 inches). The wave 3826 crests 3824 are separated by approximately 4.45 centimeters (1.75 inches). The junctions 3822 are approximately 1 millimeter in diameter. With reference to FIG. 39, another alternative mode of predetermined pattern 3520 includes a bar pattern of junction points 3922. The junction points 3922 are approximately 0.64 centimeters (0.25 inches) long and 0.5 millimeters wide. The spacing of the phase shift bar pattern is approximately 0.64 centimeters (0.25 inches) between junction points 3922. Other configurations of 3520 bonding pattern and dimesional relationships of the junctions are also contemplated. With reference to FIGS. 42 and 43, an alternative embodiment of diaper 10, similar to that described above with respect to FIGS. 31-41, includes a wrapping sheet 3512 wrapped in a C-shaped crease configuration around the absorbent core 3506. An acquisition layer 4002 is configured for disposition between the absorbent core 3506 and the wrapping layer 3512. The layer acquisition 4002 is configured to facilitate the transfer of fluids to the absorbent core 3506, handling the fluid peaks, avoiding soaking, containing the absorbent core, improving core stability and other purposes. The acquisition layer 4002 may be manufactured from various materials, similar to those described herein. It is contemplated that the acquisition layer 4002 may be disposed between the upper layer 2 and the wrapping layer 3512. It is further contemplated that one or a plurality of acquisition layers 4002 may be employed. With reference to FIGS. 44 and 45, an alternative modality of diaper 10, similar to that described above with respect to FIGS. 31-43, includes an absorbent core 4106 including an SAP 4110 particle layer. The SAP 4110 particle layer is 100 wt.% SAP. It is contemplated that other SAP concentration ranges may be employed and that alternative types of SAP materials may be employed, similar to those described above. The SAP 4110 particle layer has a rectangular configuration. It is contemplated that layer 4110 may have alternative geometry configurations, such as elliptical, circular, etc. A wrapping sheet 4112 encloses the SAP 4110 particle layer. The wrapping sheet 4112 surrounds the SAP 4110 particle layer for disposition between the upper layer 2 and the lower layer 4, similar to the absorbent core 6 described above with respect to FIGS. . 1 and 2. An acquisition layer 4102 is configured for disposition between the SAP 4110 particle layer and the wrapping sheet 4112. The SAP 4114 particles are also distributed around the acquisition layer 4102. The wrapping sheet 4112 is wrapped in a C-shaped configuration around the SAP 41 particle layer 10 and the acquisition layer 4102, as will be appreciated by those skilled in the art. Other fold configurations such as G-fold, Z-fold, etc. they are contemplated. For example, as shown in FIGS. 46 and 47, the diaper 10 includes the wrapping sheet 4112 wrapped in a G-shaped configuration around the SAP 4110 particle layer and acquisition layer 4102. The overlapping folds of the wrapping sheet 4112 are adhered by an adhesive 4116 The SAP 4110 particle layer is disposed with the wrapping sheet 4112 by an adhesive 4118. Alternatively, the absorbent core 4106 may include a layer of synthetic cable fibers. The layer of synthetic cable fibers is separated from the absorbent core 4106 and disposed adjacent thereto. The wrapping sheet 4112 can be bonded to the layer of synthetic cable fibers, similar to those described above. With reference to FIG. 48, an alternative embodiment of the system for molding absorbent articles based on cable fiber and envelope sheet supply, similar to those described above with respect to FIG. 28, to form an absorbent article such as, for example, the diaper 10 described with respect to FIGS. 31 and 32 are shown. The system also includes the second cable fiber delivery mechanism 2802 ', described with respect to FIG. 29, and a joining apparatus such as, for example, an ultrasonic bonding apparatus 4236. The supply of folded core compound 2824 is transported along the conveyor 2826 and ultrasonic bonding apparatus 4236 joins the wrapping sheet 3512 with the cable fiber layer 3508 to form a predetermined pattern 3520 via junction points 3522 (FIGS 33-35). The pattern 3520 is bonded to the wrapping sheet 3512 to define cavities 3524 (FIG 34) which are configured for containment of SAP particles. Various configurations of bond patterns 3520 and dimensional relationships of junctions are contemplated including those discussed above with respect to FIGS. 36-39.

Alternatively, as shown in FIG. 49, the system includes an embossing roller 4336 to form the predetermined pattern 3520. In this embodiment, the supply of folded core compound 2824 is transported along the conveyor 2826 and the embossing roll 4336 joins the sheet 3512 wrapper with the cable fiber layer 3508 to form a predetermined pattern 3520 via attachment points 3522. The claims are intended to cover all the preceding classes of absorbent articles, without limitation, whether disposable, unitary or otherwise. These classifications are used interchangeably throughout the specification, but are not intended to limit the claimed invention. The invention will be understood to encompass, without limitation, all classes of absorbent articles. The invention of the present description can be represented in other specific forms without deviating from the spirit or essential characteristics thereof. The present embodiments are therefore considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims in addition to the foregoing description, and all changes that fall within the meaning and range of equivalence of the claims are therefore intended to be encompassed here.

Claims (32)

1. NOVELTY OF THE INVENTION CLAIMS 1. - An absorbent article comprising: a liquid permeable top layer; an absorbent core of synthetic cable fibers; a wrapping layer that is arranged to surround the core so that the superabsorbent particles are disposed therebetween, the wrapping layer joins the core to form a predetermined pattern, the pattern is configured for containment of the superabsorbent particles, and a layer liquid impervious back, wherein the wrap layer is disposed between the top layer and the back layer. 2. The absorbent article according to claim 1, further characterized in that the pattern is formed by ultrasonic bonding. 3. The absorbent article according to claim 1, further characterized in that the pattern defines cavities configured for disposition of the superabsorbent particles. 4. The absorbent article according to claim 1, further characterized in that the pattern includes a plurality of joining points that define a diamond-shaped pattern. 5. The absorbent article according to claim 1, further characterized in that the pattern is embossed. 6. - The absorbent article according to claim 1, further characterized in that the wrapping layer is wrapped in a G-shape around the core. 7. The absorbent article according to claim 1, further characterized in that the wrapping layer includes a single wrapping sheet. 8. The absorbent article according to claim 1, further characterized in that the wrapping layer includes a plurality of wrapping sheets. 9. The absorbent article according to claim 1, further characterized in that the wrapping layer is formed of a non-woven material. 10. The absorbent article according to claim 1, further characterized in that the non-woven material includes polypropylene. 11. The absorbent article in accordance with the claim 1, further characterized in that the SAP is adhered to the wrapping layer. 12. The absorbent article according to claim 1, further characterized in that the synthetic cable fibers are formed from a suitable roll product. 13.- The absorbent article in accordance with the claim 1, further characterized in that it additionally comprises an acquisition layer disposed between the absorbent core and the wrapping layer. 14. - The absorbent article according to claim 1, further characterized in that the core includes a mixture of spongy pulp. 15. The absorbent article according to claim 1, further characterized in that a central portion of the absorbent article is hydrophilic and side portions of the absorbent article are hydrophobic and the portions and the lower layer defining a fluid containment zone. 16. The absorbent article according to claim 1, further characterized in that the absorbent article defines a core body between the lateral sides thereof, the wrapping layer is arranged to surround the core body. 17. The absorbent article according to claim 1, further characterized in that it additionally comprises a front end and a rear end that are sealed. 18.- The absorbent article in accordance with the claim 1, further characterized in that the synthetic cable fibers include polypropylene. 19. An absorbent article comprising: a liquid permeable top layer; an absorbent core of fibers in polypropylene cable; a polypropylene wrap sheet that encloses the core so that the superabsorbent particles are disposed therebetween, the wrap sheet is ultrasonically bonded to the core to form a predetermined pattern, the pattern defines cavities that are configured for containment of the superabsorbent particles; and a liquid impermeable backsheet, wherein the wrapping sheet is disposed between the top layer and the back layer. 20. An absorbent article comprising: a liquid permeable top layer; an absorbent core of fibers in polypropylene cable; a polypropylene wrap sheet which is arranged to surround the core so that the superabsorbent particles are disposed therebetween; and a liquid impermeable backsheet, wherein the wrap sheet is disposed between the top layer and the back layer. 21. The absorbent article in accordance with the claim 1, further characterized in that the superabsorbent particles are adhered to the wrapping sheet. 22. An absorbent article comprising: a liquid permeable layer; an absorbent core of synthetic cable fibers; a wrapping layer which is arranged to surround the core so that the superabsorbent particles are disposed therebetween, the wrapping layer joins the core to form an embossed pattern, the embossed pattern defines cavities being configured to contain the superabsorbent particles; and a liquid impermeable backsheet, wherein the wrap layer is disposed between the top layer and the back layer. 23. An absorbent article comprising: a liquid permeable top layer; an absorbent core of synthetic fibers of a suitable roll product; a wrapping layer which is arranged to surround the core so that the superabsorbent particles are disposed therebetween, the wrapping layer joins the core to form a predetermined pattern, the pattern is configured to contain the superabsorbent particles; and a liquid impermeable backsheet, wherein the wrap layer is disposed between the top layer and the back layer. 24. An absorbent article comprising: a liquid-permeable upper layer; an absorbent layer comprised of 100% by weight of superabsorbent particles; a wrapping layer that is arranged to surround the absorbent layer; and a liquid impermeable backsheet, wherein the wrap layer is disposed between the top layer and the back layer. 25.- The absorbent article in accordance with the claim 24, further characterized in that it further comprises an absorbent core of synthetic cable fibers, wherein the absorbent layer is separated from the absorbent core and disposed adjacent thereto, the envelope layer is bonded with the core. 26. The absorbent article according to claim 24, further characterized in that it additionally comprises an acquisition layer disposed between the upper layer and the wrapping layer. 27. The absorbent article according to claim 1, further characterized in that the pattern includes a plurality of attachment points that define a pattern in a spike shape. 28. - The absorbent article according to claim 1, further characterized in that the pattern includes a plurality of attachment points that define a bar-like pattern. 29. The absorbent article according to claim 1, further characterized in that the absorbent core consists of 100% by weight of synthetic cable fibers. 30. The absorbent article according to claim 1, further characterized in that the wrapping layer is manufactured from a film. 31.- An apparatus for forming absorbent structures having an individual wrapping sheet, the apparatus comprising: a fiber supply mechanism in cable to provide fiber material in cable; a mechanism for supplying particulate matter to provide particulate matter; a wrapping sheet supply mechanism for providing wrapping sheet material; a vacuum drawing cylinder being rotatable about a first axis and positioned to receive the fiber-in-cable material, the particulate matter and the jacket sheet material to form a supply of open-core compound; angled surfaces positioned to create at least one obtuse angle in the supply of open core compound; a folder for further folding the obtuse angles in the supply of open core compound to form a supply of open core compound; and a joining apparatus configured to join the wrapping sheet material with the woven fiber material to form a predetermined pattern in the supply of folded core compound that is configured for containment of particulate matter. 32.- A method for preparing absorbent structures that have a wrapping sheet, the method comprises: providing fiber material in cable; provide particulate matter; provide wrapping sheet material; forming a supply of open core compound by combining the fiber material in cable, the particulate matter, and the shell sheet material in a vacuum drawing cylinder; creating at least one obtuse angle in the supply of open core compound using at least one angled surface; forming a supply of folded core compound by folding the obtuse angles in the supply of open core compound; and joining the wrapping sheet material with the woven fiber material to form a predetermined pattern in the supply of folded core compound which is configured for containment of the particulate matter.