Method and apparatus to mechanically shape a composite structure

1. A method for forming a shaped fibrous nonwoven structure, comprising:

delivering a high speed composite stream comprising thermoplastic polymer fibers and a secondary material;

mechanically redirecting at least a portion of the composite stream with a deflector;

collecting the composite stream on a collection surface of a movable collection device;

wherein the deflector moves in synchronization with the movable collection device, such that the composite stream is collected on the collection surface forming a fibrous nonwoven structure having at least one non-linear edge.

2. The method of claim 1 wherein the high speed composite stream is delivered at a velocity of at least 50 feet/second (15 m/sec).

3. The method of claim 1 wherein the high speed composite stream comprises from about 1-50% by weight absorbent fibers, from about 30-99% superabsorbent particles and about 5-90% polymer fibers.

4. The method of claim 3 wherein the absorbent fibers are cellulose fibers and the thermoplastic polymer fibers are elastic fibers.

5. The method of claim 1 wherein the movable collection device is an endless belt.

6. The method of claim 1 wherein the movable collection device is a porous rotating drum.

7. The method of claim 1 wherein the high speed composite stream contains absorbent fibers.

8. The method of claim 1 wherein the high speed composite stream contains superabsorbent particles.

9. The method of claim 1 comprising a first deflector and a second deflector, wherein the first deflector mechanically redirect at least a first portion of the composite stream, the second deflector mechanically redirect at least a second portion of the composite stream.

10. The method of claim 9 , wherein the first deflector and the second deflector are slidably attached to the movable collection device.

11. The method of claim 1 wherein the deflector rotates about an axis.

12. The method of claim 11 wherein the axis is substantially parallel to the composite stream.

13. The method of claim 11 wherein the axis is substantially perpendicular to the composite stream.

14. The method of claim 1 wherein the deflector intersects the high speed composite stream at an angle of not greater than 40 degrees.

15. A method for forming a shaped fibrous nonwoven structure, comprising:

delivering a high speed composite stream comprising thermoplastic polymer fibers and a secondary material at a velocity of at least 50 feet/second (15 m/sec);

mechanically redirecting at least a portion of the composite stream with a deflector;

collecting the composite stream on a collection surface of a movable collection device;

wherein the deflector is fixedly attached to the movable collection device, such that the composite stream is collected on the collection surface forming a fibrous nonwoven structure having at least one non-linear edge, and the high speed composite stream comprises from about 5-25% by weight cellulose fibers, from about 40-90% superabsorbent particles and about 5-55% thermoplastic polymer fibers.

16. The method of claim 15 wherein the movable collection device is an endless belt.

17. The method of claim 15 wherein the movable collection device is a porous rotating drum.

18. The method of claim 15 wherein the high speed composite stream contains absorbent fibers.

19. The method of claim 15 wherein the high speed composite stream contains superabsorbent particles.

20. The method of claim 15 wherein the at least one deflector intersects the high speed composite stream at an angle of not greater than 40 degrees.