MXPA99005656A - Method and system for making an absorbent pad for use in absorbent articles - Google Patents

Abstract

Methods and systems for making an absorbent pad for use in an absorbent article utilize a forming device for forming material into an absorbent core, a supply device for supplying a containment layer against the first surface of the absorbent core and spray apparatus for spraying fibers of molten resin onto the second surface of the absorbent core. The fibers form a stabilization layer on the absorbent core that increases the integrity of the absorbent core. The spray apparatus includes a nozzle having a resin aperture for exhausting resin therefrom and multiple gas apertures for exhausting gas therefrom to provide a random pattern to the fibers of molten resin as the fibers are sprayed onto the second surface. Resin can also be sprayed onto first and second portions of the containment layer extending outwardly from edges of the absorbent core so the containment layer and the stabilization layer encompass the absorbent core. In another embodiment, a second containment layer can be placed on the second surface of the absorbent core and first and second stabilization layers can be spaced outwardly therefrom and deposited on the absorbent core.

Description

METHOD AND SYSTEM FOR. MANUFACTURE AN ABSORBENT PAD FOR USE IN ABSORBING ITEMS FIELD OF THE I3S-VENTION Absorbent articles such as infant diapers, training underpants, adult incontinence products, and the like are well known.

Such articles have achieved great acceptance due to their ability to receive and absorb body acclimates.

BACKGROUND OF THE INVENTION In general, absorbent articles are formed by means of multiple fabrics of material. Such fabrics generally include a body side edge and an outer cover over the outer surfaces found of the absorbent article. An absorbent core is generally located between the side-to-body edge and the outer shell. The absorbent core generally has a preformed barrier tissue located on the first surface and a preformed forming tissue located on a second opposing surface. The barrier tissue and the forming tissue, in combination, completely surround and support the absorbent core.

European patent application 0 685 213 A 2 published on December 6, 1995 describes the deposition fibers on a surface of the absorbent core material to provide a cover. Once the fiber cover has been deposited and adhered to the absorbent core material, the absorbent core is wound spirally and compressed radially to form a "plug." The fibers at least partially adhere to the surface of the absorbent core. Absorbent core material on which these have been deposited The fibers form an outer covering on the absorbent material.

US Patents 5,227,107 and 5,409,768 issued to Dickenson et al. Describe forming devices including forming chambers for forming absorbent structures. The teachings of Dickenson and others include a melt spray polymer in the forming chamber, along with other fibers to form an absorbent core. The sprayed and melted polymer is blended with the fibers and thus forms an absolving structure including melted and sprayed polymers dispersed through the absorbent core.

SYNTHESIS OF THE DESCRIPTION The present invention relates to methods and systems for manufacturing absorbent pads for use in the absorbent articles. The opposing surfaces of an absorbent core are supported by a first preformed containment layer and a second resin fiber containment layer. More particularly, the methods include forming an absorbent core of material in a forming device, applying a first preformed containment layer against a first surface of the absorbent core, and depositing a second containment layer comprising resin fiber over a second. Absorbent core surface. The resin fiber between acts with the absorbent core on the second surface to increase the integrity of the absorbent core. Generally the first containment layer is applied to the first surface of the absorbent core before depositing the second containment layer on the absorbent core.

The method is devoid of the step of attaching a preformed containment layer with a material on the second surface of the absorbent core.

In the preferred embodiments, the resin fibers are deposited on the second surface of the absorbent core in a random vortex pattern while the fibers are in such condition that the properties of the fibers contribute to the securing of the fibers to the absorbent core in the second surface. The resin fibers may comprise polyolefins, such as polypropylene.

In some embodiments, the resin fiber is deposited on the second surface of the absorbent core using a spray nozzle assembly comprising a plurality of nozzles.

The nozzles in the nozzle spray assembly can be arranged in an array that extends through the width of the absorbent core formed. The plurality of the nozzles apply the resin fiber through an absorbent core width, from about 4 inches to about 10 inches. Each nozzle preferably includes a single resin perforation expelling the resin fiber therefrom, and multiple gas openings directing the resin fiber expelled therefrom to the absorbent core, and imparting a vortex pattern to each such fibers.

In some embodiments, the resin fibers can be deposited on the second surface in a condition such that some of the fibers are attached to the absorbent core on the second surface, one another at the resin fiber crossing points. The resin fiber directed towards the absorbent core may comprise a spray of melted fibers.

Some modalities of the method include pulling a vacuum on a rotating forming drum of the device former and thus assist in pulling the absorbent material towards the drum in the absorbent core forming step.

In most embodiments, the absorbent sausage, including the first and second containment layers, is cut at separate locations along the length thereof, to form the individual absorbent pads. The absorbent pad is mounted on a side-to-body liner, so that the first containment layer is located between the side-to-body liner and the absorbent core, an outer cover is mounted on the second surface of the absorbent core, so that the second containment layer is located between the absorbent core and the outer cover.

In some embodiments, the first containment layer has the first and second edge portions extending outwardly from the first and second opposite edges of the absorbent core. The fibers of the second containment layer are deposited on at least part of the first and second edge portions of the first containment layer while the fibers are in condition to assist in securing the fibers to the first containment layer. The fibers are secured to the first containment layer, and the subsequent cooling of the fibers causes the fibers to lose their characteristic assurance, while retaining the securing to the first containment layer. The layers of First and second containment can fully encompass the absorbent core.

Another embodiment includes a system for manufacturing an absorbent core comprising a forming device for forming a material in an absorbent core, a delivery device for supplying a preformed first containment layer against the first surface of the absorbent core and an apparatus of spraying to spray the melted resin fibers onto the second surface of the absorbent core, thereby depositing a second containment layer on the second surface so that the resin fibers interact with the absorbent core to increase the integrity of the absorbent core. The absorbent core may comprise a continuous absorbent sausage, the absorbent sausage being a fiber layer formed of continuous air.

In some embodiments, the forming device includes a forming chamber and the rotary forming drum, preferably a vacuum forming drum, to form the absorbent core. The forming device may also include a shaving roller for shaving material to reduce the thickness of the absorbent core.

In some embodiments, the spray apparatus includes at least one nozzle that has an opening for resin to expel the resin therefrom, and multiple gas openings to expel gas therefrom. The spraying apparatus may comprise a nozzle assembly having the plurality of nozzles that deposit the melted resin on the second surface of the absorbent core. The plurality of nozzles can define an array of nozzles that extend through the width of the absorbent core formed, and can deposit the melted resin through an absorbent core width of from about 4 inches to about 10 inches.

In some embodiments, the spray apparatus comprises a melt spray assembly for directing the melted resin to the second surface of the absorbent core as a spray of melted fibers.

In some embodiments, the system includes a vacuum transfer device for receiving the absorbent core from the forming device prior to applying the resin to the second surface of the absorbent core. The first surface of the absorbent core and the first "containment" layer are positioned towards the transfer device under vacuum.

In some embodiments, the system includes a trimming device for trimming the first containment layer around the absorbent core.

In some embodiments, an absorbent sausage that cuts the device periodically cuts the absorbent sausage, including the first and second containment layers, to form the respective absorbent pads.

In the preferred embodiments, a binder secures each respective absorbent pad between a side liner to the respective body and a respective outer cover, the second containment layer being on one side of the outer cover.

In typical embodiments, a cutting device periodically cuts the liner from the side to the body and the outer cover to thereby form the respective absorbent articles.

In some embodiments, the first and second portions of the first containment layer extend outwardly from the first and second opposite edges of the absorbent core. The spray apparatus deposits the resin fiber on at least part of the first and second parts of the first containment layer so that the resin fiber it interacts with the first containment layer, thus contributing to the assurance of the resin fiber to the first containment layer.

In another embodiment, the system makes an absorbent article comprising a frame. The frame is formed of an outer cover, and of a side-to-body liner mounted on the outer cover and makes contact with a user's body. An absorbent core is placed between the side-to-body liner and the outer shell. The first preformed containment layer is positioned between the side-to-body liner on the first surface of the absorbent core. A second resin fiber containment layer is placed between the absorbent core and the outer cover. The second containment layer interacts with the absorbent core on the second surface to increase the integrity of the absorbent core.

In most embodiments, the second containment layer comprises the fibers deposited on the second surface in a swirl pattern, the properties of the fibers contribute to the securing of the second surface. The fibers are typically secured to one another at the crossing points between one of the fibers. The fibers may comprise the polymeric material.

In some embodiments, the first containment layer has the first and second parts that extend outwardly from the opposite edges of the absorbent core, the second containment layer is secured to the first containment layer in at least part of the first portions. and second, the first and second containment layers, in combination, encompassing the absorbent core.

In most embodiments, the first containment layer comprises a barrier tissue and the second containment layer comprises a material that is not generally considered to be an adhesive.

In another embodiment a second containment layer was placed along the length of the second surface of the absorbent core. The first and second stabilization layers are then spaced on each side of the second containment layer. The stabilization layers can be secured to only the absorbent core, or more nozzles can be selected so that the melted fibers of the first and second stabilization layers can make contact with the second containment layer and the first containment layer thereby ensuring the layers of containment to the absorbent core.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 shows diagramatically a system for making an absorbent pad of the invention for use in an absorbent article.

Figure 2 shows a top view of a length of an absorbent sausage, and a spray nozzle assembly, taken at point 2-2 of Figure 1.

Figure 3 shows a top view as in Figure 2 where the resin is applied over a larger width of the combination of the absorbent sausage and the first containment layer.

Figure 4 shows a top view of a section of a second real representative containment layer of Figure 3.

Figure 5 representatively shows the arrangement of the nozzles in the spray nozzle assembly, as seen from the vacuum transfer device.

Figure 6 shows the spray fiber output end of a single nozzle useful in the invention.

Figure 7 shows a second embodiment of the systems of the invention for making an absorbent pad.

Figure 8 shows a top view of a section of an absorbent sausage, taken at point 8-8 of Figure 7.

Figure 9 shows a top view as in Figure 8 where the resin has been applied over a larger width of the combination of the absorbent sausage and the containment layer.

Figure 10 shows another embodiment of the present invention wherein a second containment layer is applied to the second surface of the absorbent sausage.

Figure 11 shows a top view of a length of the absorbent sausage, and a spray nozzle assembly taken at point 11-11 of Figure 10.

Figure HA shows a top view of a section of the absorbent sausage and a spray nozzle assembly taken at point 11-11 of Figure 10, the spray nozzle assembly sprays the stabilization layers over the first and second containment layers, and portions of the absorbent sausage.

Figure 12 shows a block diagram of the additional processing apparatus which acts on the absorbent sausage of the invention to form an absorbent article.

Figure 13 shows a top view of a length of the absorbent sausage of the invention after parts of the containment layer have been trimmed.

Figure 14 shows a top view of a completed absorbent article made with an absorbent pad of the invention.

Figure 15 shows a cross-sectional view of a completed absorbent article taken at item 15-15 of Figure 14.

The invention is not limited in this application to the details of construction and arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other incorporations or of being practiced or carried out in various ways. Also, it is understood that the terminology and phraseology used here are for the purpose of description and illustration and should not be seen as limiting. Equal reference numbers are used to indicate equal components. The drawings are for illustration purposes, and are not necessarily drawn to scale.

DETAILED DESCRIPTION OF THE ILLUSTRATED INCORPORATIONS The present invention is directed to methods and systems for making an absorbent pad for use in an absorbent article. An example method replaces forming the tissue with melted resin sprayed to increase the integrity of the absorbent core. Such practice maintains the overall integrity of the absorbent article while reducing the cost of production.

Figure 1 shows a first system 8 for manufacturing an absorbent core. The system 8 includes a fiberizer 10, contained in a forming chamber 12 for receiving the absorbent material, and a forming drum 14 which rotates, generally continuously, in the direction of the arrow 15. The system 8 also includes a coupling roller 16 The coupling roller 16 shaves the excess absorbent material from an absorbent sausage 20 formed by the forming drum 14. A vacuum transfer device 32 delivers the absorbent sausage to the pressure point rollers 58A and 58B. A supply device 22, turning rollers 24 and 26 and transfer conveyor 28, deliver a preformed containment layer 30 to pressure point roller 58A. In the pressure point rollers 58A and 58B, the containment layer 30 is secured to a first surface 34 of the absorbent sausage 20.

A heated melting tank 42 receives a particulate resin from a storage hopper 44, and heats the resin to a melted state. A heated resin delivery pipe 46 delivers the melted thermoplastic resin to a heated spray nozzle assembly 38. A heated recirculation pipe 48 recirculates the unused resin back to the melting tank 42 for reuse.

A compressed gas line 52 supplies the compressed gas to a gas heater 50. The gas heater 50 heats the compressed gas as needed. A supply line 54 supplies the compressed and heated gas to the spray nozzle assembly 38. A spray nozzle assembly 38 sprays a resin fiber 40 onto a second surface 36 of the absorbent sausage 20 to form a stabilization layer 65.

In the context of the invention, the "absorbent sausage" refers to any absorbent material or combination of absorbent materials having a generally continuous length, and may also include superabsorbent materials.

The "absorbent pads" refer to cut sections of the absorbent sausage, including the containment layer 30 and the stabilization layer 65, which can be placed in absorbent articles.

The "absorbent core" 20C shown in the Figure 14, refers to a designated fibrous block segment formed individually on the forming drum 14. The absorbent core 20C includes an absorbent material used to form the absorbent sausage, but does not include any stabilization layer or containment layer applied thereto.

The absorbent sausage 20 is positioned from a vacuum transfer device 32 on a transfer conveyor 56, and advances on the transfer conveyor to the first and second pressure point rollers 58A and 58B comprising the uncoiler 60. In the unloader 60 the preformed containment layer is secured to the absorbent sausage 20. The absorbent sausage 20 then advances to the transfer conveyor 62. The arrow 64 indicates a path leading to the absorbent sausage 20 towards additional processing stations not shown in Figure 1.

The fiberizer 10 fiberizes the absorbent material in the forming chamber 12. Therefore, the fiberizer 10 breaks the fibrous material boards to form the individualized eraser. The absorbent sausage 20 comprises a matrix of generally hydrophilic fibers, such as a cellulose fluff fabric, preferably in combination with the particulate high-absorbency material commonly known as superabsorbent material. In a particular embodiment, the absorbent sausage 20 comprises a mixture of superabsorbent hydrogel forming particles and wood fluff fibers. Instead of the wood pulp fluff, one can use any of a variety of synthetic fibers, a combination of synthetic fibers, or a combination of synthetic fibers and natural fibers. At least part of the absorbency of the absorbent material can also be derived from the capillary action resulting from the arrangement of fibers with respect to one another. The absorbent sausage 20 preferably does not contain any polymeric material sprayed with internal melt to its structure. The absorbent sausage 20 preferably comprises a continuous layer of fiber formed by air.

The forming drum 14 forms the absorbent sausage 20 using gravity, and a vacuum chamber (not shown) contained in the forming drum. A vacuum generating apparatus (not shown) generates an air flow which, in combination with the vacuum chamber and openings (not shown) on the forming surface of the forming drum 14, helps pull the absorbent material 18 on the forming surface of the drum. The amount of vacuum supplied by the vacuum generating apparatus can be varied, turned off, or blocked to meet the specific needs of the particular absorbent sausage 20 being formed. For example, at the point where the absorbent sausage 20 must be released and transferred to the vacuum transfer device 32, the vacuum in the transfer area may be blocked on the forming drum 14. An example of the forming devices for use with the invention is set forth in Figures 17-19 of the United States of America patent 5,227,107, the disclosure of which is hereby incorporated by reference in its entirety.

In most embodiments, the forming drum 14 comprises a first sausage carrier, and the vacuum transferring device 32 comprises a second sausage carrier. In certain cases, the shaped absorbent sausage 20 may desirably be contoured in shape, or shaved to reduce its thickness. As suggested by Figure 1, the rasper roller 16 shaves the absorbent sausage 20 while the sausage is on the forming drum 14, and before the transfer of the absorbent sausage to the transfer device with vacuum 32.

Even when Figures 1-3 show the absorbent sausage 20 as a continuous fabric of material, the absorbent cores of absorbent material 18 can also be formed as separate individual cores on the forming drum 14. Such an arrangement makes it obvious to cut at spaced locations of the absorbent sausage 20 to create individual absorbent cores in the subsequent step. In any case, the absorbent cores placed by air are formed directly on the forming drum 14.

The vacuum openings (not shown) on the forming drum 14 can be arranged so that the forming chamber 12 constitutes a shaped absorbent sausage 20. The absorbent sausage 20 can, for example, be in a "T" shape as in the Figures 2, 3, 8, 9, 11, HA, 13 and 14, an hourglass shape, or any other form suitable for an absorbent article.

The preformed containment layer 30 preferably comprises a barrier tissue. A typical barrier tissue is a low porosity creped wadding of a single stratum or the like. Other tissues may also function as the containment layer provided adequate porosity and other characteristics are present. An example barrier tissue has a basis weight of 12.5 lbs / ream, a porosity of approximately 90 cubic feet per minute per square foot, and a strength of about 500 grams.

The containment layer 30 is pulled around the turning rollers 24 and 26 and onto the transfer conveyor 28 to the pressure point roller 58A. The pressure point rollers 58A, 58B place the containment layer on the first surface 34 of the absorbent sausage 20.

In another potential embodiment (not shown), the containment layer 30 advances from the conveyor 28 to an exterior surface of the vacuum transfer device 32. After the placement of the containment layer 30 on a vacuum transfer device 32, or almost simultaneously with it, the absorbent sausage 20 is transferred onto the transfer device under vacuum. A second vacuum generating apparatus (not shown) assists the vacuum transfer device 32 in maintaining the containment layer 30 and the absorbent sausage 20 thereon. The porosity of the containment layer 30 should be sufficient to allow sufficient vacuum through the containment layer to support the absorbent sausage 20 on the transfer device with vacuum 32. This is because the layer of The containment is generally placed between the first surface 34 of the absorbent sausage and the outer surface of the vacuum transfer device 32. Therefore, such incorporation is not contemplated as being particularly effective unless the porosity of the containment layer 30 is very large. .

Even when the vacuum transfer device 32 holds the absorbent sausage 20, the spray nozzle assembly 38 deposits the melted and / or semi-squeezed resin fibers 40 on the second opposing surface 36 of the absorbent sausage 20, thereby forming the layer of stabilization 65. Figure 2 shows the spray nozzle assembly 38 applying the resin fiber 40 along a continuous length of a middle section of the absorbent sausage 20 between the opposite outer edges 66 and 68 of the absorbent sausage. The arrow 70 represents the direction of movement of the absorbent sausage 20 in the process. The resin fiber 40 rapidly cools and hardens to form the stabilization layer 65.

In the embodiment of Figure 2, for example, the system of Figure 1 deposits the resin fibers 40 in the central part of the absorbent pad 20 to form the stabilization layer 65. In this embodiment, not all Individual nozzles of the spray nozzle assembly 38 need to be operated to deposit the resin fiber 40.

In the embodiment of Figure 3 more individual nozzles of the spray nozzle assembly 38 deposit the resin fibers 40 through the full width "W" of the absorbent sausage 20. Thus, some amount of melt spraying between the ears 21 of the absorbent sausage 20 is over sprayed and wasted. In subsequent incorporations, when the melt spray is applied, the containment layer 30 is in surface-to-surface contact with the opposite surface of the absorbent sausage 20 and therefore receives the overspray. In such an arrangement, the overspray secures the stabilization layer 65 to the containment layer 30.

In other embodiments, the spray nozzle assembly 38 includes at least some intermittently operated individual nozzles that form the spray pattern corresponding to the shape of the absorbent sausage 20 with a minimum spray envelope. Therefore, the amount of resin fibers used can be conserved and the cost of the process reduced.

The stabilization layer 65 shown and deposited on the second surface 36 of the absorbent sausage 20 in Figures 2 and 3 is for the purposes of illustration only. Figure 4 shows a detailed photomicrograph indicating a section of a real representative stabilization layer 65. The stabilization layer 65 preferably comprises the resin fibers 40 which are composed of multiple individual fibers that form a pattern of random cloth type. as shown in Figure 4. At crossing points where one fiber intersects another, the melted fibers directly attach to one another without adhesive. The stabilization layer 65 is permeable to liquids and gases. Where the melted resin fibers 40 contact the second surface 36 of the absorbent sausage 20, the fibers can interact with the individual absorbent fluff fibers to increase the integrity of the absorbent sausage structure. For example, the melted resin fibers 40 may have sufficient thickness and deformability to mechanically form and bond to the fibers in the absorbent sausage 20, or in the containment layer 30, if present when the melt spray occurs. Desirably, the fibers essentially have no adhesive or tack characteristics after cooling to room temperature. The direct bonding of the fibers 40 to the second surface 36 of the absorbent sausage 20 preferably occurs before the fibers are completely cooled. The fibers 40 cool very rapidly to room temperature which solidifies and hardens the fibers. The fibers 40 are first cooled on their outer surface while the interior of The fibers remain melted for a longer period of time. As a result of this, the fibers 40 tend to deform and wrap around the fluff fibers of the absorbent material. Therefore, the thicker fibers 40 tend to work better than the thinner fibers with respect to deformation and securing to the absorbent sausage 20. The ability to deform and other properties of the fibers 40 helps to stabilize the fluff fibers and as a result they help to contain the fluff fibers and the superabsorbent material within the absorbent sausage 20. Thus the fibers 40 form the stabilization layer 65 and are secured to the absorbent sausage 20 on the second surface 36.

The random cloth type pattern of the stabilization layer 65 shown in Figure 4, and the structural characteristics of the fibers 40 which constitute the layer assist in the stabilization of the absorbent material, including the fluff fibers and any superabsorbent material, of the absorbent sausage 20. Thus, the random cloth type pattern of the stabilization layer 65 improves the overall integrity of the absorbent sausage 20. The stabilization layer 65 also helps to protect the outer cover of for example the penetration by particles of superabsorbent material. Therefore, the stabilization layer 65 of the fibers 40 replaces the use of the forming tissue between an absorbent core and a cover outside in an absorbent article. Therefore the system and the method are typically devoid of attaching a previously formed containment layer with the absorbent material on a second surface 36 of the absorbent sausage 20. Furthermore, depositing the resin fibers 40 as the stabilization layer 65 is less expensive than applying a preformed tissue layer to the absorbent sausage 20. In a preferred embodiment, the stabilization layer 65, on the absorbent sausage 20 has a weight of about 2 to about 12 grams per square meter.

In the context of the invention, the term "resin" refers to any solid or liquid organic material of natural or synthetic origin having a melting point and is generally polymeric. The thermoplastic resin may comprise polymers such as polyolefins. For example, the resin may comprise polyethylene, polypropylene, or the like. In addition, the thermoplastic resin may comprise combinations of various polymers. The melting point or spots of the resin fibers 40 typically range from about 140 ° C to about 260 ° C.

European patent application 0 658 351 Al granted to Korpman, published on June 21, 1995, is incorporated herein by reference in its entirety. Korpman describes the thermoplastic polymers that can be used in the formation of effective microfibers in some embodiments of the invention. Desirably, the thermoplastic resins used to form the stabilization layer 65 of the invention do not include the pressure sensitive adhesive materials in amounts which may themselves activate the securing or other fastening of the stabilization layer 65 to the absorbent core. or a lining from the side to the body. They also do not include a similar amount of any other composition generally known as an adhesive material.

The general spray apparatus for applying the fibers 40 is preferably a melt spray apparatus. Examples of such melt spray apparatuses include melting tank 42 which receives the particulate resin material from hopper 44. A preferred melting tank comprises a grid melter, model MX40110 manufactured by Nordson Corporation of Duluth Georgia.

The melting tank 42 includes a heating apparatus (not shown) for melting the thermoplastic resin and keeping the resin in a melted state. The melting tank 42 keeps the thermoplastic resin at a desired temperature. The heated resin delivery pipe 46 delivers the melted resin to the spray nozzle assembly 38. The heated resin recirculation pipe 48 returns the excess melted resin to the melt tank 42. The circulation Continuing the resin through the pipes 46 and 48 helps to maintain the proper temperature and pressure in the spray nozzle assembly 38, and thus avoids cooling and hardening of the resin within the spray nozzle or spray nozzle assembly. the delivery pipe 46. For example, if the spray nozzle assembly 38 stops spraying the thermoplastic resin fibers 40, the recirculation pipe 48 and the delivery pipe 46, in combination, continuously provide the melted resin to the assembly. of spray nozzle. In addition, the temperature of the thermoplastic resin in the spray nozzle assembly 38 can be easily controlled, and adjusted dynamically, by adjusting the resin flow rate through the pipes 46 and 48 and / or by adjusting the temperature of the resin. the resin in a melt tank 42. The temperature of the polypropylene resin is preferably between about 204 degrees centigrade and about 232 degrees centigrade.

The supply of compressed gas 52 provides the compressed gas to the gas heater 50. The gas heater 50 heats the compressed gas to the desired temperature. The heated gas supply pipe 54 carries the compressed and heated gas from the gas heater 50 to the spray nozzle assembly 38. The compressed gas is delivered to the nozzle assembly 38 to control the pattern of the fibers 40 being applied. to the absorbent sausage 20 as will be described in more detail below. The compressed gas is preferably heated to a temperature similar to the temperature of the resins that are being applied to the absorbent sausage 20 and at a pressure of about 40 to about 70 pounds per square inch over the atmospheric pressure (PSIG).

Figure 5 shows the side of the spray nozzle assembly 38 facing the absorbent sausage 20. An array of eleven nozzles 76 is shown extending through the length of the spray nozzle assembly 38. Each nozzle 76 can be considered a separate module and supplied with the melted resin through a gear pump. As shown in Figures 2 and 3, a spray nozzle assembly 38 is positioned so that the nozzles 76 are located at the locations spaced across the width "" of the absorbent sausage 20 and of the containment layer 30. As a result of this, the selected nozzles 76 can expel resin fibers 40 through the width "W" of the absorbent sausage 20 to form the stabilization layer 65.

While eleven nozzles are shown, any number of nozzles can be used. Similarly, one or more of the nozzles in a nozzle array can be locked to limit the number of nozzles used for a particular operation. For example, fewer nozzles (such as three nozzles) can be used to form the narrow spray pattern of the stabilization layer 65 shown in Figure 2, and more nozzles (such as five nozzles) can be used to form the wider spray pattern indicated for the stabilization layer 65 shown in Figure 3. In addition, even when Figure 5 shows a row of nozzles 76, the second and additional rows can be used to increase the amount of material used to form the stabilization layer 65 on the second surface 36 of the absorbent sausage 20, or the rate at which the material is applied, or to provide a more uniform distribution of such material. For example, in a preferred arrangement, a second row of eleven nozzles (not shown) aligned in the machine direction and offset in the transverse direction to the machine from the first row of nozzles 76 can be provided in addition to the first row of nozzles. . In a typical melt spray embodiment, the individual nozzles comprise modules spaced approximately one inch apart.

The number and spacing of the nozzles 76 in a spray nozzle assembly 38 is sufficient to allow application of the stabilization layer 65 across a width of the absorbent sausage 20 preferably from about 2.5 inches (narrow spray pattern) ) to at least about 10 inches (wide spray pattern). Additional nozzle assemblies can be used to apply a wider stabilization layer 65 through a wider width of an absorbent core, a containment layer 30, or other base fabric. In addition, nozzles 76 need not be arranged in a linear array. Thus, the nozzles 76 can be arranged in virtually unlimited number of nozzle patterns as long as the nozzles provide a sufficient amount of fibers 40 distributed over the underlying substrate at a desired weight and in a desired pattern, typically a uniform distribution pattern. The individual nozzles 76 can be controlled, for example, intermittent operation, to vary the width and the area covered by the spray patterns. In addition, the amount of resin that is being deposited by the individual nozzles 76 can also be controlled.

The nozzles 76 can be controlled so that the heavier application of the fibers 40 occurs in some areas of the absorbent sausage 20, and the less heavy application of the fibers 40 occurs in other areas on the second surface 36 of the absorbent sausage 20. For example, in the embodiment of Figure 3, the increased fibers 40 can be applied to the middle of the absorbent sausage 20 and a smaller amount of fibers 40 can be applied to the ears of the absorbent sausage. Thus, the amount of the fibers 40 can be varied in the transverse direction of the absorbent sausage 20. This arrangement preserves the amount of melted fibers 40 applied to form the stabilization layer 65 and reduce the overall cost of the products thus formed.

In other embodiments, the nozzles 76 can be operated intermittently to vary the amount of fibers 40 applied in the machine direction. For example, in the embodiment of Figure 14, the fibers 40 can be applied randomly to the absorbent pad 90 at locations where the pad is present and not applied at locations where the pad is not present during the formation of the absorbent article. . This arrangement preserves the amount of fibers 40 applied to form the stabilization layer 65 and therefore reduces the cost of products made by this process.

Figure 6 shows the outlet end of a single example nozzle 76 of the spray nozzle assembly 38. The nozzle 76 includes a single resin opening 78 for expelling the resin fiber 40. The multiple gas openings 80 are generally spaced apart. evenly around the resin opening 78. The resin opening 78 is preferably centered on the outlet end of the nozzle 76. In a preferred nozzle, the resin opening 78 has a diameter of about 0.025 inches and gas openings 80. which have diameters of about 0.030 inches. In operation, the gas openings 80 continuously eject the gas which controls the application of the resin fiber 40 to the absorbent sausage 20. The design of the nozzle 76, for example, the diameter of the resin opening 78, and the diameter and angle of the gas openings 80 cause a Random movement of fiber 40. Random movement of resin fiber 40 creates a pattern of random cloth type exemplified in stabilization layer 65 and shown in Figure 4. Compressed gas opening 80 preferably has a total production of between about 0.4 and about 0.8 standard cubic feet per minute. The resin aperture 78 preferably has a total production of between about 3 pounds per inch per hour and about 5 pounds per inch per hour of resin fiber 40 for the incorporation of melt spray.

Even when the preferred gas is air, other gases and gas mixtures can be used. The compressed gas attenuates the resin exiting the resin opening 78, thus to form elongated and correspondingly thinned resin fibers 40. To the extent that the gas openings 80 are of a diameter different from that mentioned above. 0.030 inches, the velocity and flow of gas expelled from the respective openings is changed, causing the fibers to pull more or less severely. Such pulling changes the diameter of the resulting fibers 40.

The multiple gas openings 80 and the resin opening 78, in combination, spray the melted resin fibers having a random pattern. Such fibers are soft when sprayed. In the formation of the stabilization layer 65, illustrated, the multiple nozzles 76 eject a corresponding multiple number of fibers. The gas from the multiple gas openings 80 imparts random patterns to the multiple fibers which, in combination, form the fabric type pattern of the stabilization layer 65 shown in Figure 4. Even when six gas openings are shown for a nozzle given in Figure 6, more or less gas openings can be used, provided that the exhaust gas from the gas openings of a given nozzle effectively controls the resin fiber 40 being expelled from the resin opening 78. The resin fibers thus formed typically have a diameter of from about 8 microns to about 73 microns, and preferably fiber diameters sized from about 20 microns to about 40 microns. The larger fibers of 80 microns tend to be noticeable with the touch for the user of the absorbent article made thereof. Therefore, the larger fibers tend to negatively impact on the comfort and overall aesthetics of an absorbent article thus constructed. The resin fibers are generally continuous in length when sprayed with melt onto a substrate, such as a second surface 36 of absorbent sausage 20 or a containment layer 30.

The melt spray systems may include a separate gear pump stream (not shown) for each nozzle 76 or module for delivering the resin fibers 40 under pressure to the absorbent sausage 20.

The heated resin delivery pipe 46, the heated resin recirculation pipe 48 and the gas heater 50 allow the melt spray system to maintain a temperature of the thermoplastic resin even when the melt spray is intermittently applied or closed for an extended period of time. Therefore, with the restart, the melt spray system generates very little waste material compared to a corresponding melt blow system. An example of an intermittent or pulsed operation of the melt spray nozzle assembly 38 may be to not provide resin or less resin over an area of the absorbent sausage 20 that is remote from the crotch portion of the final absorbent article, and therefore it requires less integrity.

Other equipment which can be used for the spray nozzle assembly 38 can be found in columns 14-16 of the United States of America patent 5,227,107. The European patent application 0 685 213 A2 published on December 6, 1995, and therefore incorporated herein by reference in its entirety, discloses a spray equipment of specific melt and some resin materials useful in the invention.

Another adhesive spray assembly and exemplary nozzle are set forth in U.S. Patent No. 4,785,996 issued to Ziecker et al. The disclosure of which is hereby incorporated by reference in its entirety. Figures 2 and 3 especially show details of an exemplary nozzle useful for the applicant's invention.

The meltblowing apparatus, although less preferred, can also be used with the invention. Typical melt blowing devices have holes in the order of about 0.0145 inches in diameter, and have 30 or so of those holes per inch in the transverse direction of a die tip, and two opposing air slots formed on each side . As the melt spray, once the high pressure air exits the die tip, it expands rapidly, thereby attenuating the molten resin streams leaving the respective die tip. For the applicants' invention, the meltblowing apparatus must produce fibers having a diameter of at least 8 microns. The smaller diameter fibers tend to form an impermeable layer on the absorbent sausage 20. The smaller fibers also tend to to deform less, and therefore, to conform less to the surface of the absorbent sausage.

The melt blowing apparatuses useful in the present invention receive the heated resins from a melting tank and apply the resins to a material, but have no means of recirculation. Thus, "melt blowing apparatuses generally have a faster onset time and reach operating pressure faster than meltblowing systems.

The melt tank 42, the gas heater 50, and the nozzle spray assembly 38 are generally controlled by a conventional central controller (not shown), such as an ANAPHASE® controller made by? Ordson Corporation of Duluth, Georgia. Such electrical controllers include panel annunciator alarms, status indicators, control switches, and other control mechanisms. The central controller can monitor and control all temperatures including the temperatures in the melt tank 42, the resin delivery pipe 46, the resin recirculation pipe 48 and the gas heater 50.

The de-volumizer 60 generally comprises a pressure point formed by the rollers 58A, 58B. The de-volumizer 60 controls the thickness of the sausage absorbent 20 by compressing the sausage at the tip between the rollers 58A and 58B. The de-voluminizers are known conventional devices that can be used to control the thickness of the absorbent pads.

After the containment layer 30 is applied to the first surface 34, and the stabilization layer 65 is deposited on the second surface 36, the absorbent sausage 20 passes through a de-volumizer 60, and the absorbent sausage advances along of path 64 for further processing.

Figure 7 shows a second embodiment of the invention wherein the prefix "1" on the element numbers indicates the second embodiment. The second and third digits are used in common with the first incorporation to represent the corresponding structure for similar structures in the first incorporation. The system 108 includes a fiberizer 110 which breaks the fiber board in the absorbent material and ejects it into the forming chamber 112 and deposits it on the forming drum 114. The forming drum 114 generally rotates continuously in the direction of the arrow 115 The forming drum 114 has a rasper roll 116 close to shave the applied material to reduce the thickness of the absorbent sausage 120. The delivery device 122 supplies the containment layer 130 to the conveyor transfer 157. In this embodiment, the transfer conveyor 157 receives the containment layer 130 and receives the absorbent sausage 120 on one side of the containment layer. The first surface 134 of the absorbent sausage 120 makes contact with the containment layer 130. The second surface 136 of the absorbent sausage 120 adjacent to the spray nozzle assembly 138 receives the fiber from the ream 140. The heated melting tank 142 receives the particulate resin from a storage hopper 144 and heat it to the melted state. A heated resin delivery pipe 146 delivers the melted thermoplastic resin to a set of spray nozzles 138. A heated recirculation pipe 148 recirculates the unused resin back to the melting tank 142 for reuse.

The compressed gas supply 152 supplies the compressed gas to the gas heater 150. The gas heater 150 heats the compressed gas, such as air, to a desired gas temperature. The heated gas supply pipe 154 supplies the compressed and heated gas to the spray nozzle assembly 138. The spray nozzle assembly 138 deposits the resin fiber 140 on the second surface 136 of the absorbent sausage 120 to form a layer of spray. stabilization. The absorbent sausage 120 advances on the transfer conveyor 157 to the first and second pressure point rollers 158A and 158B comprising the De-volumizer 160. The de-volumizer 160 varies the thickness of the absorbent sausage 120 by controlling the compressive force at the pressure tip. From the de-volumizer 160, the absorbent sausage 120 advances to the transfer conveyor 162. The arrow 164 indicates a path that leads the absorbent sausage 120 to additional processing stations. Examples of such additional processing stations are shown in Figure 12 and will be described in greater detail below.

Figure 9 shows the first and second opposing portions 172 and 174 of the containing layer '130 extending outwardly beyond the respective edges 166 and 168 of the absorbent sausage 120. As shown in Figure 8, for example , the resin fiber 140 does not generally contact or does not reach the containment layer 130.

In the embodiment of Figure 9, the spray nozzle assembly 138 sprays the resin fiber 140 through essentially the full width "W" of the second surface 136 of the absorbent sausage 120, optionally somewhat beyond the outer edges. of the absorbent sausage, and on at least part of a first portion 172 and a second opposing portion 174 of the containment layer 130. As with the embodiment of Figure 8, the resin fiber 140 cools and hardens rapidly , forming the stabilization layer 165.

Thus, the containment layer 130 and the stabilization layer 165 can, in combination, encompass the absorbent sausage 120. the stabilization layer 165, of course, remains porous with respect to the liquids.

Figure 10 describes another embodiment of the invention. The embodiment of Figure 10 is essential to the same as the embodiment of Figure 7, except that the absorbent sausage 120 leaves the opposite side of the forming drum 114 and more importantly, a supply roll 179 containing a second containing layer. preformed 181 provides the second containment layer for the absorbent sausage. In addition, the preferred arrangement of applying the melted fibers 140 after the de-volumizer 160 is shown in Figure 10. A first containment layer 130 is placed in a surface-to-surface relationship with the first surface 134 of the absorbent sausage 120. The second containment layer 181 proceeds along a path and around a tumbling roller 191 toward absorbent sausage 120. The second containment layer 181 is then applied in a surface-to-surface ratio to the second surface 136 of the absorbent sausage 120 on the pressure point rollers 158A and 158B.

The second preformed containment layer 181 may comprise a narrow strip of a forming tissue as shown in Figure 11. The second preformed containment layer 181 can stabilize and the absorbent liner of the absorbent sausage 120. As shown in Figure 11, the second containment layer 181 comprises a narrow layer through a central portion of the absorbent sausage 120. The first and second edges 183 and 185 of the second containment layer 181 extend along the outer length thereof.

The second preformed containment layer 181 can have a width of from about 2.5 inches to about 9 inches. An example forming tissue has a porosity of approximately 400 cubic feet per minute per square foot, and a dry strength of about 730 grams.

The spray nozzle assembly 138 in the Figure 10 deposits the resin fibers 140 on the absorbent sausage 120, on the second containment layer 181 and the first and second parts 172 and 174 of the first containment layer 130. As shown in Figure 11, the nozzles in the The middle and outer section of the spray nozzle assembly 138 can be turned off, especially in the melt spray system, so that a first stabilization layer 165A of the resin fibers 140 was applied to the absorbent sausage 120 between the outer edge 166. of the absorbent sausage 120 and the outer edge 183 of the second preformed containment layer 181. Other nozzles of the assembly spray nozzle 138 can simultaneously spray the resin fiber 140 onto the absorbent sausage 120 to form a second stabilization layer 165B between the outer edge 168 of the absorbent sausage 120 and the outer edge 185 of the second containment layer 181. In this way, portions of the uncovered absorbent sausage 120 held by the second preformed containment layer 181 can be stabilized. As shown in Figure 11, the central region of the absorbent sausage 120 in the surface-to-surface ratio with the second containment layer 181 does not require having resin fibers 140 sprayed thereon. In some embodiments, the adhesive may be applied to the second containment layer 181 prior to placement on the absorbent sausage 120.

In the embodiment of Figure HA, the individual nozzles of the spray nozzle assembly 138 can be controlled so that the resin fibers are deposited on the first and second parts 172 and 174 of the first containment layer 130, as well as deposited on the absorbent sausage 120. In addition, the individual nozzles can also be controlled so that the resin fibers are deposited in contact with the second containment layer 181 near the outer edges 183 and 185 thereof. Thus, the entire absorbent sausage 120 can be surrounded by the containment layers 130, 181 and the stabilization layers 165A and 165B of the resin fiber material. Such arrangement stabilizes the waste material of the absorbent sausage 120 and improves the integrity thereof. Surprisingly, the arrangement of Figures 10, 11, and HA is very close to the functional form of the absorbent articles currently being manufactured, while the cost of the absorbent articles is significantly reduced by reducing the amount of the containment material. , such as the forming tissue, necessary to manufacture the absorbent article.

Figure 12 shows the additional exemplary processing apparatus that forms the absorbent articles which include the absorbent sausage 20 as an element thereof. A combination of the absorbent sausage 20, the containment layer 30, and the stabilization layer 65 is represented graphically by the arrow 85 in Figure 12.

A water trimming device 82 or other conventional trimming device trims the excess material from the first and second portions 172 and 174 of the containment layer 130 near the outer edges 166 and 168 of the absorbent sausage 120 of Figure 9 The water trimming device 82 follows the shape of the absorbent sausage 120 corresponding to a "T". Preferably it is retained about a half inch width for each respective first and second part 172 and 174 of the containment layer 130, extending outward from each respective outer edge 166 and 168 of the absorbent sausage 120. Figure 13 shows an absorbent sausage 120 after portions of a first part 172 and a second part 174 have been cut out. For the purposes of illustration only, the stabilization layer 165 is not shown in Figure 13. In those embodiments where the stabilization layer 165 is trimmed together with the containment layer 130, a mechanical knife cutter may be used, more well that the water trimming device 182, in order to effectively cut the resin layer 165.

After trimming the containment layer 130, the trimmed absorbent sausage 120 advances as graphically represented by the arrow 165A in Figure 12. The absorbent sausage cutting device 84 then cuts the absorbent sausage 120, including layers 130 and 165 , in individual absorbent pads. The dotted lines 86 in Figure 13 show exemplary places where the absorbent sausage cutting device 84 cuts the absorbent sausage 120 across its width to form the individual absorbent pads 90. The absorbent pads 90 are represented graphically by the arrow 90 in Figure 14. Such absorbent sausage cutting devices are well known in the art and include, for example, pressure point rollers having a cutter element mounted on one of the rollers on it, and other conventional devices.

The main welder 92 assembles and secures discrete absorbent pads 90 between an outer cover and a side-to-body liner to create an absorbent article sausage represented by "arrow 94" in Figure 12. -The main welder 92 is a conventional apparatus for forming absorbent articles on the absorbent article sausage 94. Referring now to Figure 14, preferably, the hot melt adhesive is sprayed onto the body side liner 102 and / or the outer cover 104 (both shown in FIG. Figure 15) to provide permanent securing of the outer cover 104, the side-to-body liner 102, and the absorbent pad 90, to each other in the main welder 92. The main welder 92 includes a fastening point that applies pressure to several elements to ensure the assurance of the elements to each other. The absorbent pad 90, fed to the welder 92, includes the containment layer 130 and the resinous stabilization layer 165 of the fiber 140. Even though the adhesive and the pressure at the attachment point of the main welder 92 can secure the aforementioned elements , ultrasonic bonding and other securing methods are also considered acceptable.

The cutting device of the absorbent article fabric 96 receives the absorbent article sausage 94 as shown in Figure 12, and cuts the absorbent article fabric into individual absorbent articles 100. Figure 14 shows a complete absorbent article 100. absorbent article 100 includes the T-shaped absorbent pad 90 shown in dotted lines therein. The body side liner 102 comprises the surface of the absorbent article closest to that seen in the view of Figure 14. A cross-sectional view of the absorbent article 100, shown in Figure 15, and taken across the width of the article. of Figure 14 shows the relationship between the various elements. A frame formed by the body side liner 102 and the cover 104 enclose and thus encompass the absorbent pad 90. the containment layer 130, comprising a barrier fabric, is located between the side-to-body liner 102 and the body. absorbent pad 90. The containment layer 130 resists the return of the liquid to the side-to-body liner 102 after the liquid passes through to the absorbent pad 90 and migrates from the superabsorbent material towards the wearer of the absorbent article. The stabilization layer 165 is located between * the absorbent pad 90 and the outer cover 104 and is adjacent to the outer cover. The stabilization layer 165 provides improved integrity to the absorbent pad 90 and reduces the possibility of the exudates discoloring the outer cover 104 of the absorbent article 100. The layer of Stabilization 165 also helps to protect the outer cover 104 from being damaged or penetrated by the material, especially particles of the superabsorbent material migrating from the absorbent pad 20C.

Other steps and apparatuses for applying the leg cuffs, waistbands, restraining flaps, fastening lugs, or the like are considered conventional and are within the scope of this description. For example, an emergence layer (not shown) can be located between the body-side liner 102 and the containment layer 130. The emergence layer also allows the exudates to spread over essentially the complete absorbent pad 90. Thus the emergence layer assists the absorbent pad 90 to absorb a large amount of sudden urine.

Those skilled in the art will now see that certain modifications to the invention described herein can be made with respect to the illustrated embodiments without departing from the spirit of the present invention. And even though the invention has been described above with respect to the preferred embodiments, it will be understood that such an invention is adapted for numerous rearrangements, modifications and alterations, all such arrangements, modifications and alterations being within the scope of the appended claims.

To the extent that the following clauses use a media language plus function, it is not meant to include there, or in the present description, anything that is not structurally equivalent to what is shown in the embodiments described in the specification.

Claims (52)

R E I V I N D I C A C I O N S

1. A method for making the absorbent pad for use in an absorbent article, the method includes the steps of: (a) forming an absorbent core of material in a forming device, the absorbent core formed having the first and second opposing surfaces, the first and second opposing edges, and a width between the first and second opposite edges; (b) applying a first preformed containment layer against the first surface of the absorbent core; Y (c) depositing a permeable stabilization layer on the second surface of the absorbent core, the stabilization layer comprises a resin in the form of fibers, the fibers interact with the absorbent core on the second surface to increase the integrity of the absorbent core.

2. A method as claimed in clause 1, characterized in that it includes applying the layer of containment to the first surface of the absorbent core before depositing the stabilization layer.

3. A method as claimed in clause 1, characterized in that it includes depositing the stabilization layer on the second surface of the absorbent core before applying the containment layer-to-the first surface.

4. A method as claimed in clause 1, characterized in that the containment layer comprises the barrier tissue.

5. A method as claimed in clause 1, characterized in that the method is devoid of the step of attaching a previously formed containment layer to the second absorbent core surface.

6. A method as claimed in clause 1, characterized in that the fibrous resin reservoir includes applying resin fibers to the second surface of the absorbent core in a random pattern.

7. A method as claimed in clause 6, characterized in that the resin fibers comprise polypropylene.

8. A method as claimed in clause 6, characterized in that the resin fibers comprise polyolefin.

9. A method as claimed in clause 1, characterized in that it includes depositing the resin on the second surface of the absorbent core formed using a spray nozzle assembly comprising a plurality of nozzles.

10. A method as claimed in clause 9, characterized in that the plurality of nozzles defined an arrangement extending across the width of the absorbent core formed, of the plurality of nozzles that apply the resin fibers across a width, of the absorbent core, from about 2.5 inches around 10 inches.

11. A method as claimed in clause 9, characterized in that each nozzle has a single resin opening expelling the resin fiber therefrom, and multiple gas openings directing the resin fibers towards the absorbent core, the fibers respective describe random patterns as well to be directed towards the absorbent core.

12. A method as claimed in clause 10, characterized in that it includes depositing the resin fibers on the second surface in such condition that the properties of the fibers contribute to the securing of the fibers to the absorbent core in the second surface.

13. "Un-method as-claimed" in clause 11, characterized in that it includes depositing the resin fibers on the second surface in such a condition that the properties of the fibers contribute to securing the fibers to the absorbent core on the second surface .

14. A method as claimed in clause 1, characterized in that it includes directing the resin fibers towards the absorbent core as a spray of melted fibers.

15. A method as claimed in clause 1, characterized in that it includes heating the resin to a temperature between about 204 degrees and about 232 degrees celsius before applying the resin fibers to the absorbent core as a spray of melted fibers.

16. A method as claimed in clause 1, characterized in that the forming device includes a rotating forming drum which receives the core material absorbent thereon, the method includes pulling a vacuum on the forming drum and thereby assisting in pulling the material towards the drum and forming the absorbent core.

17. A method as claimed in clause 1, characterized in that the absorbent core comprises an absorbent sausage having a length, the forming device comprising a first sausage carrier, the method includes, before depositing the stabilization layer on the second surface of the absorbent sausage, transferring to the absorbent sausage of the forming device to a second sausage carrier so that the first surface of the sausage formed and correspondingly the containment layer, are adjacent to the second sausage carrier.

18. A method as claimed in clause 17, characterized in that it includes cutting the absorbent sausage at spaced locations along the length thereof, to form the individual absorbent pads.

19. A method that includes mounting an absorbent pad as indicated in clause 18, to a side-to-body liner, so that the containment layer is located between the body-side liner and the absorbent pad.

20. A method as claimed in clause 19, characterized in that it includes mounting an outer cover to the second surface of the absorbent pad, so that the stabilization layer is located between the absorbent pad and the outer cover.

21. - A method-as claimed in clause 1, characterized in that the containment layer having the first and second edge portions extend outwardly from the first and second opposite edges of the absorbent core, the method includes depositing the fibers of the stabilization layer on at least part of the first and second edge portions of the containment layer, the fibers being in such condition that the same properties secure the fibers to the containment layer, the fibers subsequently they cool so that the fibers lose the securing properties while retaining the securing to the containment layer, the containment layer and the stabilization layer in combination, encompassing the material defining the absorbent core.

22. A method as claimed in clause 1, characterized in that it comprises the step of depositing the permeable stabilization layer on the second surface of the absorbent core comprising intermittently depositing the stabilization layer so that the Areas of the absorbent core that require less integrity do not receive resin.

23. A method as claimed in clause 1, characterized in that the step of depositing a permeable stabilization layer on the second surface of the absorbent core comprises controlling the deposition of the stabilization layer so that the areas of the absorbent core that require Less integrity receive less resin than areas that require greater integrity.

24. An absorbent article having a length and a width, said absorbent article comprises: (a) a framework comprising: (i) an outer cover, and (ii) a body side liner secured to said outer cover and making contact with a user's body; (b) an absorbent core, between said side-to-body liner and said outer cover, said absorbent core having the first and second opposing surfaces; (c) a preformed containment layer between said side-to-body liner and said first surface of said absorbent core; Y (d) a permeable stabilization layer, comprising resin fiber between said absorbent core and said outer cover, said stabilization layer interacts with said absorbent core on said second surface to increase the integrity of the absorbent core.

25. An absorbent article as claimed in clause 24, characterized in that said absorbent article is devoid of a containment layer previously formed between the outer cover and the absorbent core.

26. An absorbent article as claimed in clause 24, characterized in that said stabilization layer comprises multiple resin fibers deposited on the second surface in a random pattern, the properties of said fibers contribute to securing the fibers to the second surface .

27. An absorbent article as claimed in clause 26, characterized in that said multiple fibers are secured to each other at the crossing points between one of said fibers.

28. An absorbent article as claimed in clause 26, characterized in that said multiple fibers comprise polymeric material.

29. An absorbent article as claimed in clause 24, characterized in that said containment layer has the first and second parts extending outwardly from the first and second opposite edges of the absorbent core, said stabilization layer being secured to said containment layer in at least part of said first and second parts, said containment layer and said stabilization layer, in combination, encompass said absorbent core.

30. An absorbent article as claimed in clause 24, characterized in that said containment layer comprises the barrier tissue.

31. An absorbent article as claimed in clause 24, characterized in that said stabilization layer comprises a non-adhesive material.

32. An absorbent article as claimed in clause 24, characterized in that said absorbent article includes a second containment layer previously formed between said outer cover and said absorbent core, said second containment layer previously formed having a narrower width than that of the absorbent core, said second preformed containment layer having the first and second edges along the length thereof, said stabilization layer comprises a first stabilization layer placed near and away from the first edge of the second preformed containment layer.

33. An absorbent article as claimed in clause 32, characterized in that said absorbent article includes a second stabilization layer comprising resin fiber between the absorbent core and said outer cover, said second stabilization layer interacts with said absorbent core in the absorbent core. second surface positioned near and away from the second edge of the second preformed containment layer to increase the integrity of the absorbent core.

34. An absorbent article as claimed in clause 33, characterized in that said first and second stabilization layers extend inwardly over at least a portion of the respective first and second edges of said second preformed containment layer.

35. An absorbent article as claimed in clause 24, characterized in that said fibers of resin comprise said stabilization layer having diameters of at least about 8 microns.

36. An absorbent article as claimed in clause 24, characterized in that said resin fibers comprise said stabilization layer having diameters of from about 8 microns to about 73 microns.

37. An absorbent article as claimed in clause 24, characterized in that said resin fibers comprise said stabilization layer having diameters of from about 20 microns to about 40 microns.

38. A system for manufacturing an absorbent pad, said system comprises: (a) a forming device for forming the material in an absorbent core having the first and second opposing surfaces and the first and second opposed edges; (b) a supply device for supplying a preformed containment layer against the first surface of the absorbent core; Y (c) a spraying apparatus for spraying melted resin fibers onto the second surface of the absorbent core, thereby depositing a permeable stabilization layer on the second surface so that the resin fibers interact with the absorbent core to increase the integrity of the absorbent core.

39. A system as claimed in clause 38, characterized in that said forming device has the ability to form the absorbent core as a continuous absorbent sausage having a length, the sausage comprises a layer formed by continuous air of fibers extending to along the length of it.

40. A system as claimed in clause 38, characterized in that said forming device includes a fiberizer, a forming chamber and a rotating forming drum for forming said absorbent core thereon.

41. A system as claimed in clause 40, characterized in that the forming device includes a reaming roller for shaving the material of said absorbent core to reduce the thickness of said absorbent core.

42. A system as claimed in clause 38, characterized in that said spraying apparatus it comprises at least one nozzle having a resin opening for expelling the resin therefrom, and multiple gas openings for expelling the gas therefrom.

43. A system as claimed in clause 42, characterized in that said spraying apparatus comprises a nozzle assembly having a plurality of nozzles that deposit the melted resin on the second surface of the absorbent core.

44. A system as claimed in clause 43, characterized in that said plurality of nozzles define an array extending across the width of said formed absorbent core, and deposit the melted resin through a width of from about 2.5 inches. to around 10 inches.

45. A system as claimed in clause 38, characterized in that the spraying apparatus comprises a melt spraying assembly for directing the resin towards the second surface of the absorbent core as a spray of melted fibers.

46. A system as claimed in clause 45, characterized in that said melt spray assembly includes a recirculation pipe for recirculating the resin from a melting tank so that the resin remains melted whether or not the spray apparatus is applying the resin as a spray of melted fibers.

47. A system as claimed in clause 38, characterized in that it includes a transfer device with vacuum, said transfer-convaction device receives the absorbent core of the forming device before the application of the melted resin to the second surface.

48. A system as claimed in clause 38, characterized in that it includes a trimming device for trimming the containment layer around the absorbent core.

49. A system as claimed in clause 48, characterized in that said forming device forming the absorbent core as an absorbent sausage of continuous length, said system includes a cutting device for periodically severing said absorbent sausage in the respective absorbent pads.

50. A system as claimed in clause 49, characterized in that it includes a main welder to secure each respective absorbent pad between a side facing to the respective body and an outer cover respective, in forming an absorbent article, the stabilization layer being adjacent to the outer cover.

51. A system as claimed in clause 50, characterized in that it includes a cutting device for periodically cutting the liner from side to body and the outer cover to form the absorbent articles.

52. A system as claimed in clause 38, characterized in that the first and second parts of the containment layer extend outward from the first and second opposite edges of the absorbent core, said spraying apparatus deposits the melted resin over less part of the first and second parts of the first containment layer so that the melted resin cools and becomes hard, and interacts with the absorbent core on the second surface to increase the integrity of the absorbent core. SUMMARY Methods and systems for making an absorbent pad for use in an absorbent article use a forming device to form the material in an absorbent core, a delivery device for supplying a containment layer against the first surface of the absorbent core and the apparatus of spraying to spray the melted resin fibers onto the second surface of the absorbent core. The fibers form a stabilization layer on the absorbent core which increases the integrity of the absorbent core. The spraying apparatus includes a nozzle having a resin opening for expelling the resin therefrom and multiple gas openings for ejecting the gas therefrom to provide a random pattern to the melted resin fibers when the fibers are sprayed on. the second surface. The resin can also be sprayed onto the first and second parts of the containment layer extending outwardly from the edges of the absorbent number so that the containment layer and the stabilization layer encompass the absorbent core. In another embodiment, a second containment layer may be applied on the second surface of the absorbent core and the first and second stabilization layers may be spaced outwardly therefrom and deposited on the absorbent core.