Patent ID: 7524449

Claim:
A method of forming an absorbent core assembly containing a discrete batt of particulate material comprising the steps of: providing a laydown drum, said laydown drum comprising a plurality of vacuum zones, said vacuum zones being substantially permeable to permit air to pass through and into said laydown drum, a plurality of fence zones, said fence zones being substantially impermeable to inhibit air from passing through, said fence zones being positioned laterally adjacent to said vacuum zones, and a plurality of blow-off zones, said blow-off zones being substantially permeable to permit air to pass out of and through said laydown drum, said blow-off zones being positioned between said vacuum zones; providing a continuous first web of material; positioning said continuous first web of material substantially adjacent to said laydown drum; generating a vacuum through said laydown drum and said continuous first web of material such that air is passed through said vacuum zones; depositing a dispersion of air and particulate material onto said continuous first web of material such that the air being pulled through the vacuum zones directs said dispersion to said vacuum zones whereupon the particulate material is positioned to form said batt; blowing air through said blow-off zones so as to substantially displace said particulate material from a position located above said blow-off zones; providing a continuous second web of material; positioning said continuous second web of material adjacent to said particulate material; combining a portion of said continuous second web of material to said continuous first web of material; and severing said continuous webs to separate said absorbent core assembly.