ZERO SCRAP ABSORBENT CORE FORMATION PROCESS AND PRODUCTS DERIVED FROM WEB-BASED ABSORBENT MATERIALS

摘要

Described herein is a multiple layer absorbent core having a front ear section, a crotch section and a back ear section, wherein the machine direction length of the crotch section equals the combined machine direction length of the front ear section and the back ear section, the angle and radii forming the transition from the crotch width to the ear width being equal, the core being suitable for use in an absorbent article, and a method for manufacturing such multiple layer absorbent core. The method comprises providing a single web (10) of absorbent core material from a roll, in which the web having parallel straight longitudinal side edges; continuously transporting the web of absorbent core material in the machine direction; continuously cutting (12) the web of absorbent core material longitudinally into web sections having at least one full-pattern strip (14) having a repeating hourglass-shape and first (16) and second (18) side trim pieces each of the side trim pieces having a straight edge defined by one of the parallel straight longitudinal side edges of the web and an opposite non-linear longitudinal edge having a pattern corresponding to one of the longitudinal edges of the full-pattern strip (14); continuously orienting the side trim pieces relative to the full-pattern strip (14) such that the ear sections and said crotch section of the side trim pieces are superimposed in registration with said full-pattern strip (14) to form a continuous multiple layer composite strip (24); and successively cutting the composite strip (24) in the transverse direction at predetermined intervals to form discrete multiple layer absorbent cores (26).