Absorbent body for an absorbent article and method of producing an absorbent body

Abstract

A method of producing an absorbent body includes the steps of passing a first cut-out from a first web material through a nip and passing a second web material through the nip whereby the cut-out from the first web material overlays the second web material as the cut-out and the second web material pass through the nip. One of the following is performed as the cut-out from the first web material and the second material together pass through the nip: forming a fold line in the second web material at the peripheral edge of the cut-out of the first web material and forming a second cut-out from the second web material having substantially the same shape as the first cut-out from the first web material.

What is claimed is: 
     
         1 . A method of producing an absorbent body for an absorbent article of the type worn by a wearer and having an absorbent body disposed generally centrally of said article and adapted for absorbing liquid body waste released by the wearer, the method comprising the steps of:
 passing a first cut-out from a first web material through a nip;   passing a second web material through the nip whereby the cut-out from the first web material overlays the second web material as the cut-out and the second web material pass through the nip; and   performing one of the following as the cut-out from the first web material and the second material together pass through the nip: forming a fold line in the second web material at the peripheral edge of the cut-out of the first web material and forming a second cut-out from the second web material having substantially the same shape as the first cut-out from the first web material.   
     
     
         2 . A method as set forth in  claim 1  wherein the nip is defined by a pair of conveyor elements, the step of passing the second web material through the nip comprising conveying the second web material over one of said conveyor elements to pass therebetween, at least one of said conveyor elements having one of a fold-line forming device and a cutting device mounted thereon for contacting the second web element at the peripheral edge of the cut-out from the first web-material generally within the nip. 
     
     
         3 . A method as set forth in  claim 2  wherein the pair of conveyor elements are second and third conveyor elements defining the nip therebetween, the second conveyor element having said one of a fold-line forming device and a cutting device mounted thereon, the method further comprising the steps of conveying a first web material over a first conveyor element to a nip defined by the first conveyor element and the second conveyor element, and contacting the first web of material with said one of a fold-line forming device and a cutting device mounted on the second conveyor element with sufficient pressure to form the first cut-out from the first web material as the first web material passes through the nip formed by the first and second conveyor elements, the step of passing the first cut-out from the first web of material through the nip comprising supporting the first cut-out on the second conveyor element upon rotation of the second conveyor element to convey the first-cut out to the nip formed by the second and third conveyor elements. 
     
     
         4 . A method as set forth in  claim 3  wherein the first and second conveyor elements are rotating elements from the group consisting of rollers and wheels, the first web of material being conveyed through the nip defined by the first and second conveyor elements at a speed equal to the rotational speed of the second conveyor element. 
     
     
         5 . A method as set forth in  claim 3  wherein the first and second conveyor elements are rotating elements from the group consisting of rollers and wheels, the first web of material being conveyed through the nip defined by the first and second conveyor elements intermittently while the second rotating conveyor element rotates continuously. 
     
     
         6 . A method as set forth in  claim 1  further comprising the step of applying adhesive to at least one of the first cut-out from the first web material and the second web material prior to passing the first cut-out and the second web material through the nip such that the first cut-out is secured to the second web material upon passing through said nip. 
     
     
         7 . A method as set forth in  claim 3  wherein the step of supporting the first-cut on the second conveyor element as the first cut-out is conveyed to the nip formed by the second and third conveyor elements comprises applying a vacuum pressure to the first cut-out to hold the first cut-out on the second conveyor element during rotation of the second conveyor element. 
     
     
         8 . A method as set forth in  claim 7  wherein the first cut-out is released from the second conveyor element onto the second web material by subjecting the first cut-out to a positive pressure.