Process for producing absorbent core structures

1. A method for producing a sandwich structure comprising a pattern of particulate material, said method comprising the steps of:

a.) providing an air permeable carrier material and a cover material, wherein each of the carrier and cover material include at least one essentially flat web material;

b.) providing an essentially endless support means for said carrier material having a support pattern, said support pattern comprising a plurality of support pins on the outer surface of the support means, said support pins having an outwardly extending surface of at least about 0.8 mm 2 ;

c.) providing a carrier material holding means comprising vacuum air suction;

d.) positioning said carrier material over said essentially endless support means, whereby said carrier material contacts only said support pattern with its support surface and whereby the relative speed between carrier material and the contact surface of said carrier support means is essentially zero;

e.) providing a particulate material;

f.) pre-metering the amount of the particulate material;

g.) transferring the particulate material to the carrier material and providing a sandwich fixation means;

h.) combining said cover material with said carrier material and said particulate material being sandwiched there between;

i.) supporting said carrier material only in the region of the support pattern of the support means;

j.) deforming said carrier material by said carrier material holding means such that indentations are formed in the unsupported regions of said carrier material; and

k.) transferring said particulate material into said indentations of said carrier material, thereby forming a primary pattern of particulate material.

2. A method for producing a sandwich structure according to claim 1 , wherein said carrier material is a non-woven material selected from the group consisting of SMS type and SMMS type.

3. A method for producing a sandwich structure according to claim 1 , wherein said carrier material has a CD-extensibility or a MD-extensibility of more than about 20%.

4. A method for producing a sandwich structure according to claim 1 , wherein said carrier material has a ratio of MD-extensibility to CD-extensibility at a given load of not more than one to two.

5. A method for producing a sandwich structure according to claim 1 , wherein said cover material is a non-woven material.

6. A method for producing a sandwich structure according to claim 1 , wherein said particulate material is a bulk material.

7. A method for producing a sandwich structure according to claim 1 , wherein said carrier support means is a rotatable drum, preferably having an outer cylinder shell.

8. A method for producing a sandwich structure according to claim 1 , wherein said carrier support pins have a distance of more than 5 mm from each neighboring support pin.

9. A method for producing a sandwich structure according to claim 8 , wherein said carrier support pins have a distance of not more than 30 mm from each neighboring support pin.

10. A method for producing a sandwich structure according to claim 1 , wherein said carrier material has a support region and a bonding region that is at least 2% of the support region.

11. A method for producing a sandwich structure according to claim 10 , wherein said bonding region is not more than 50% of the area of the pattern area support region.

12. A method for producing a sandwich structure according to claim 1 , wherein said bonding region comprises essentially no particulate material, as assessed by the method for determining the absence of particles in the bonding area.

13. A method for producing a sandwich structure according to claim 1 , wherein said carrier fixation material holding means extends said carrier material such that said carrier material deforms out of the original flat state forming an indentation.

14. A method for producing a sandwich structure according to claim 13 , wherein said indentations have a volume of more than 30 mm 3 .

15. A method for producing a sandwich structure according to claim 13 , wherein the particulate material fills more than 5% of the volume of said indentations.

16. A method for producing a sandwich structure according to claim 15 , wherein the particulate material fills not more than 150% of the volume of said indentations.