Forming media with enhanced air flow properties

Abstract

A forming receptacle and method for receiving particulate material thereon, and thereby fabricating particulate congregates for use as absorbent cores in personal care absorbent articles is disclosed. The forming receptacle can comprise sheet material defining bottom and side walls of the receptacle. The bottom and side wall have first and second major surfaces and a thickness. The forming receptacle also comprises an array of apertures connecting first and second major surfaces, and further comprises a matrix of sheet material between apertures defining outer perimeters of respective apertures. Respective aperture walls taper from the first major surface toward the second major surface. Aperture walls of adjacent apertures intersect the second major surface without intersecting each other. The array of apertures can be arranged in a series of parallel rows wherein spacing between apertures is substantially constant from row to row. The rows can be displaced laterally such that adjacent apertures in adjacent rows define angles with respect to an imaginary line parallel to the rows. The apertures, measured at a smallest cross-section of opening, can define a composite open area representing at least about 35 percent of the combined areas of the bottom and side walls. Some embodiments introduce a forming drum comprising a plurality of forming receptacles designed and configured to form particulate congregates. The forming drum can comprise mounting structure for mounting the forming drum about an axis of rotation, and a forming receptacle repository extending about a circumference of the forming drum and supported from the mounting structure.