CPC A61F 13/532 (2013.01) [A61F 13/15658 (2013.01); A61F 13/42 (2013.01); A61F 13/4756 (2013.01); A61F 13/531 (2013.01); A61F 13/533 (2013.01); A61F 13/534 (2013.01); A61F 13/539 (2013.01); B32B 37/02 (2013.01); B32B 37/1018 (2013.01); B32B 37/142 (2013.01); B32B 37/22 (2013.01); A61F 13/1565 (2013.01); A61F 2013/15926 (2013.01); A61F 2013/423 (2013.01); A61F 2013/530131 (2013.01); A61F 2013/530481 (2013.01); A61F 2013/530868 (2013.01); A61F 2013/53908 (2013.01); B29D 99/0064 (2013.01); B29K 2023/00 (2013.01); B29K 2713/00 (2013.01)] | 20 Claims |
1. A process of making an absorbent core (101) comprising the steps of:
i. providing a mold having a longitudinal axis extending along a length of the mold and crossing a front portion, a middle portion, and a back portion of the mold; a transverse axis extending along a width of the mold and crossing a first side and a second side of the mold; and comprising a 3D insert therein, said 3D insert comprising an inverse shape of one or more substantially interconnected channels, wherein the 3D insert comprises:
a first channel portion extending substantially along the longitudinal axis proximal to the first side and through the middle portion;
a second channel portion extending substantially along the longitudinal axis proximal to the second side and through the middle portion and spaced apart from the first channel portion; and
a single connecting channel portion that connects said first and second channel portions, and
wherein substantially the entire surface of the mold is in fluid communication with an under-pressure source except for the 3D insert;
ii. applying a first nonwoven web to said mold;
iii. applying a three-dimensional absorbent material over at least a portion of said nonwoven;
iv. applying a second nonwoven web directly or indirectly over the three-dimensional absorbent material;
v. applying a bonding step to form a laminate comprising said first nonwoven, said second nonwoven and said three-dimensional absorbent material therebetween;
vi. removing said laminate from the mold to form an absorbent core comprising one or more substantially interconnected channels having an inverse shape of said 3D insert; and
characterized in that at least for the duration of step iii the underpressure source is arranged to provide a vacuum force forcing said three-dimensional absorbent material around the 3D insert such to substantially evacuate the surface thereof from three-dimensional absorbent material and form one or more substantially interconnected channels substantially free of three-dimensional absorbent material.
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