Chris Nelson, Plymouth, WI; and Collin Heinz, Sheboygan Falls, WI.
Assigned to Curt G. Joa, Inc., Sheboygan Falls, WI.

Filed: 9/7/12
Issued: 11/10/20

A method of forming an absorbent core comprising: at a first core-forming drum, forming a first core having a first fluff layer and a first super absorbent polymer (SAP) and fluff mixture layer by: introducing a nonwoven web to the first core-forming drum; applying the first fluff layer atop the nonwoven web; and applying the first SAP and fluff mixture layer atop the first fluff layer; at a first debulking unit, debulking said first core; at a second core-forming drum, forming a second core having a second SAP and fluff mixture layer; at a second debulking unit, debulking said second core; after debulking said first core, conveying at a first speed said first core towards said second core-forming drum; after debulking said second core, receiving said second core at a second speed at a core acceleration unit, said second speed being less than said first speed; wrapping at least one of said first core and said second core with a permeable web; with said acceleration unit, accelerating the second core from the second speed to substantially match the first speed; and depositing said second core from said core acceleration unit onto said first core.