Patrick Tsang, Matlock, England; Kuo-Shu Edward Chang, Charlotte, NC; and Andrew Wright, Chesterfield, England.
Assigned to DSG Technology Holdings Ltd., Kwai Chung, N.T., Hong Kong.

Filed: 3/19/12
Issued: 2/7/17

A method of manufacturing a pulp-free composite sheet capable of stabilizing a layer of absorbent particles against migration, comprising the steps of: positioning a first fabric to pass directly below a supply of absorbent particles to receive absorbent particles; depositing absorbent particles on said first fabric, whereby a population of superabsorbent particles is released from the supply of superabsorbent particles and pass from the supply directly onto the first fabric below the supply, as the first fabric is conveyed and passes horizontally below the supply of superabsorbent particles fixed above the moving first fabric; positioning said second fabric relative to said first fabric; and forming a plurality of arrangements of bond sites each of which extends between said first and second fabric, thereby sandwiching a discrete layer of pulp-free absorbent particles between said first and second fabrics; and wherein said superabsorbent particles are secured between said first fabric and said second fabric; and wherein said depositing absorbent particle comprises mixing absorbent particles with adhesive in the form of thermal plastic particles and depositing said absorbent particles mixed with adhesive on said first fabric, and wherein after forming said arrangement of bond sites, said bond sites and said adhesive stabilizes superabsorbent particles against migration.