MXPA06011183A - Two-step contact and non-contact printing - Google Patents

Abstract

A method of printing a substrate includes contact printing a first graphic in a first operation and non-contact printing a second graphic in a second operation. A method of printing an outer cover for an absorbent article includes contact printing the outercover in a first operation, non-contact printing the outer cover in a second operation, and joining the outer cover with an absorbent and a liner to produce an absorbent article. A method of minimizing substrate printing waste includes contact printing absence advertisements in a first operation and non-contact overprinting a second graphic in a second operation. A method of distributing customized products to different customers includes contact printing substantially uniform graphics on a substrate in a first operation, non-contact printing customized graphics on a substrate in a second operation, and distributing the substrate to customers.

Description

CONTACT PRINTING AND NON-CONTACT TWO STEPS BACKGROUND OF THE INVENTION Graphics are commonly printed on articles of manufacture to increase their aesthetic appeal. An example of this is graphics or images printed on absorbent garments, such as diapers for infants and children and underpants for learning. The outer covers of these items are frequently printed with brightly colored images in the form of designs and characters that are pleasing to the child and the caregiver. Images can also be printed on other absorbent articles such as women's health care products, adult incontinence garments and bandages. However, the graphics are not exclusive to personal care products and can be, for example, applied to a cleaning cloth or a sheet product.

Traditionally, the printing of the outer cover material or another part of an article with an image has been carried out by flexographic printing. Gravure printing, screen printing, offset printing, or other types of contact printing techniques prior to the assembly of the absorbent article (for example, printing is done "offline"). Typically, the image is printed on the outer cover material before being moved or sent to the place where the absorbent article is assembled. Even though the printing of an image during the manufacture of the absorbent articles (for example the "on line" printing) by the use of traditional contact printing processes is possible, this has not traditionally been practical. Online contact printing can be difficult, time consuming and costly. These problems can be exacerbated when there is a desire to change the printed image. Changing the image typically requires closing the entire assembly process and installing new rollers, screens or printing plates. Additionally, online printing can create a significant amount of waste and a delay during start-up, closure, and other transient process changes and therefore also does not lend itself to online manufacturing of mass-produced absorbent articles.

Non-contact printing systems are known to provide flexibility in image printing and typically include ink jet printing, wax jet printing, bubble jet printing, laser jet printing and the like. Changing from one image to the next can be done quickly without stopping the process. The piezoelectric ink jet printing apparatus has been used on demand to apply inks to a variety of substrates. Generally, a piezoelectric drop-on-demand ink jet printing apparatus discharges small individual drops of ink onto a substrate in a predetermined pattern. In this type of apparatus, the print head does not make contact with the cloth on which it prints.

However, when the substrate is running under the print head at a higher speed (for example 100 feet per minute or more), it is very difficult for the print head to be controlled or to supply an adequate amount of ink so that they can be applied exactly a large number of dots per inch (dpi). This is particularly true, wherein as a result of the operation of the absorbent garment assembly apparatus, the image must be formed in a single passage of the material under the print heads. Non-contact printing is also complicated when wider patterns are desired. Typically, when using a non-contact printer to create a wide pattern, additional banks of printheads are required - to achieve the desired graphics. Consequently, even though there has been progress in the area of contactless printing, printers have been limited in the sense that they are not capable of producing an image of commercially acceptable quality at the higher speeds found in the assembly of a garment. absorbent such as a diaper or training underpants.

Additionally, online contactless printing can result in significant waste. Specifically, when a substrate, intended to be used as a component of an absorbent article encounters a printing failure, the entire absorbent article is usually discarded as defective. This increases the amount of waste that results from printing failures.

In view of the aforementioned problems, the need arises for a method of printing high quality images on substrates that is cost effective and minimizes the waste associated with printing faults.

SYNTHESIS OF THE INVENTION In response to the difficulties discussed and the problems previously encountered, the present invention provides methods for printing a moving substrate, methods for printing an outer cover for an absorbent article, methods for minimizing waste of substrate printing, and methods to distribute tailored products to different clients.

An embodiment for printing a moving substrate includes the steps of: supplying a moving substrate to a first conversion operation, contact printing of at least a first graphic on the moving substrate, supplying the moving substrate with the first graphic to a second conversion operation, and printing without contacting at least a second graph on the moving substrate.

In several embodiments, a gravure printer, a flexographic printer, an offset printer or a screen printer can be used for contact printing. A wax jet printer, an ink jet print, a laser jet printer, or a bubble jet printer can be used for non-contact printing. The first graph and the second graph can together form a plot of a story. The moving substrate may be moving at least 100 feet per minute during non-contact printing.

In several embodiments, at least one third graphic can be printed without contact on the moving substrate and at least a part of the third graphic can be at least partially printed on the first graphic. The second graph can at least be printed partially on the first graph. The first graph and the second graph can together form a master graph.

The second conversion operation can produce disposable absorbent articles and the moving substrate can form an outer cover of the articles in some embodiments. The moving substrate can form a side-to-body liner of the disposable absorbent articles in some embodiments. The moving substrate can form an absorbent of the disposable absorbent articles in some embodiments.

The substrate can be a laminate made of a film layer and a nonwoven layer and the first graph can be printed on the film layer and the second graph can be printed on the non-woven layer. Alternatively, the substrate can be a laminate made of a film layer and a nonwoven layer and the first graph can be printed on the non-woven layer and the second graph can be printed on the non-woven layer. Alternatively, the substrate can be a laminate made of a film layer and a nonwoven layer and the first graph can be printed on the film layer and the second graph can be printed on the film layer.

An embodiment for printing an outer cover for an absorbent article includes the steps of supplying a first moving substrate to a first printing operation, the first moving substrate comprising a film; contact printing of at least a first graph on the first substrate in motion in the first printing operation using a gravure roller printer or a flexographic printer; laminating a second substrate in motion to the first moving substrate to form an outer cover, the second moving substrate comprises a nonwoven fabric and the outer cover defines a width; supplying the outer cover to a second printing operation; printing without contacting at least a second graph on the outer cover in the second printing operation using a wax jet printer, an ink jet printer, a bubble jet printer, or a laser jet printer, the first graph covering at least 60% of the width of the outer cover and being visible to the naked eye, the second graph being placed within the central third of the width of the outer cover and being visible to the naked eye; and attaching the outer cover to an absorbent of a liner to produce an absorbent article.

The absorbent article may have a front waist region, a back waist region, and a crotch region that connects the front waist region and the rear waist region. In such an article, the second graph can be placed within the frontal waist region. Alternatively, the second graph can be placed within the posterior waist region. Alternatively, the outer cover may have two or more second graphics arranged so that at least one second graphic is positioned within the front waist region and at least one second graphic is positioned within the back waist region of the absorbent article. .

An embodiment for minimizing the waste of substrate printing includes the steps of: supplying a moving substrate to a first conversion operation; printing by contact a plurality of absence announcements on the moving substrate; supply the moving substrate with the absence announcements to a second conversion operation; at least about partially printing the second graphics on at least some of the absence announcements using a non-contact printer, where a failure to print a second graphic on an absence announcement results in the absence announcement remaining visible on the substratum. In various aspects of this embodiment, the substrate can be attached to an absorbent and a liner to form an absorbent article in which the absence announcement forms form part of an interactive game or contest involving the user of the absorbent article. Alternatively, the absence announcement may carry a contact information to a consumer of the absorbent article.

An incorporation of the print on the outer cover for an absorbent article includes the steps of: laminating a first substrate made of a film to a second substrate made a nonwoven to form an outer cover, the outer cover defining a side of a film one side nonwoven opposite the film and a width; supplying the outer cover to a printing process and printing by contact at least a first graph on the non-woven side; supplying the outer cover to a conversion operation, the conversion operation combines the outer cover with an absorbent assembly to form an absorbent article; print without contact at least a second graph on the nonwoven side in the conversion operation, the first graph covers at least 60% of the width of the outer cover and is visible to the naked eye, the second graph being placed within the third central of the width of the outer cover, and both first and second graphs are visible to the naked eye.

An incorporation of the distribution of tailored products to different customers includes the steps of: supplying a moving substrate to a first conversion operation; print with contact at least a first graph on the moving substrate, the first graph being essentially uniform for all clients; supplying the moving substrate with the first graph to a second conversion operation; printing without contact a plurality of second graphics on the substrate in movement, the plurality of the second graphics is tailored to specific customers; and distribute the substrate to customers. In several additions, tailored graphs can be of different languages for geographically differentiated clients. In these additions, tailored charts can be different clues for business customers.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 representatively illustrates a plan view of an embodiment of an example method.

Figure 2 representatively illustrates a vertical sectional view of a gravure printing process of example.

Figure 3 representatively illustrates a vertical sectional view of a wax jet printing process of example.

Figure 4 representatively illustrates a perspective view of an example diaper.

Figure 5 representatively illustrates a plan view of an incorporation of a substrate including exemplary graphs.

Figure 6 representatively illustrates a plan view of an incorporation of a substrate including the example plots.

Figure 7 representatively illustrates a plan view of an incorporation of a substrate that includes the example plots.

Fig. 8 representatively illustrates a plan view of an incorporation of a substrate including the example plots.

DETAILED DESCRIPTION OF THE DRAWINGS One aspect of the present invention relates to a method for printing substrates. More specifically, one aspect relates to a method for printing a first graph on a moving substrate using a contact printing method such as, for example, flexographic printing, rotogravure printing, offset printing, lithographic printing. , screen printing or similar. The method also involves printing the substrate using a non-contact printing method such as, for example, a wax jet print, ink jet print, bubble jet print, laser jet print, or the like. In some embodiments, the method further includes the step of producing a disposable absorbent article with one or more of the printed substrates. The substrates can be used as an outer cover, a liner, a side panel, fins, absorbent or combinations thereof in the disposable absorbent articles. As used here, the term "printing" or "printing" means making an image of something. Frequently, printing involves the formation of an image by the transfer of pigments, dyes or brighteners in the form of ink, wax, paint or the like. The printed image is visible to the human eye and may include, for example, patterns, designs, objects, similarities of real or fictitious characters, or the like, or combinations thereof. For example, the printing may include the direct transfer of the pigment from a printing roller, a plate or a screen to the substrate. The printing may also include depositing pigment from a source of pigments onto a substrate without direct contact between the pigment source and the substrate, such as, for example, ink jet printers, wax jet printers, bubble jet printers, laser jet printers, or the like or combinations thereof. As used herein, the term "substrate" means a fabric of material capable of moving through a machine. A substrate may include a contiguous material wherein the individual units of material are connected or attached directly to the immediately preceding material and glue units. For example, a substrate may include a continuous weave of a woven material, a nonwoven material, a film or the like, or combinations thereof. A substrate may also include absorbent articles interconnected in various stages of manufacture. A substrate may also include a woven of discrete units of material separated by space or other materials. For example, a substrate may include discrete absorbent articles that are moved through a conversion operation through one or more conveyor belts or other conveying means known in the art.

An embodiment of the method is generally illustrated at point 11 in Figure 1. In Figure 1, a moving substrate 101 is supplied to a first conversion operation 37. The substrate 101 has a machine direction 17, a direction of the transverse machine 18 and a width 19. The width 19 is measured in the direction transverse to the machine 18. The first conversion operation 37 prints at least a first graph 80 on the substrate 101. The substrate 101 is then supplied to a second conversion operation 39. The second conversion operation 39 prints at least a second graph 82 on the substrate 101. In several additions, the number of conversion operations can be 3, 4, 5, 7, 8, 9, 10, or more than 10. In several embodiments, the substrate 101 can be cut and / or rolled and then transported to the second. conversion operation 39 wherein the substrate 101 is unwound or otherwise delivered to the second conversion operation 39.

In several embodiments, the first conversion operation 37 may be a traditional contact printing process. Contact printing has traditionally been an inexpensive way to print large and / or wide patterns on a substrate with reproducible results. However, contact printing can result in a very high initial expense due to the specific pattern rolls, plates or screens that must be manufactured. Due to custom manufacturing, subsequent changes to the printing pattern may require the manufacture of new equipment and may fuel the economical realization of rapid change of the printing pattern for specific needs or limited production situations. As used herein, "contact printing" refers to a form of printing in which the substrate is contacted directly by the printing apparatus. For example, the first conversion operation 37 may include a gravure process as generally illustrated at point 100 in Figure 2. Printing through a gravure process is an example of contact printing. In the gravure process 100, a substrate 101 is passed between a rubber printing roller 102 and a gravure cylinder 103. The surface of the gravure cylinder contains a large number of depressions or cells 104 which are designed to receive, retain and transferring dye to the substrate 101. The dye or rinse aid 105 is applied to the surface of the gravure cylinder 103 underneath a pressure point 108 and is removed from the plaster areas of the gravure cylinder with the doctor blade 106. When the substrate 101 enters the pressure point 108, it is pressed against the gravure cylinder 103 by the rubber printing roller 102, thereby allowing the dye or polish 105 to be transferred from the gravure cylinder cells. 104 and being deposited on the surface of the substrate 101 in small colored or polished areas 107 corresponding to the photo cylinder cells. Individual etching 104. When printing with inks, the general pattern of the small colored or polished areas remains relatively intact in the final substrate. In such cases, the percentage of the surface area of the substrate 101 covered by the colored areas will closely match the percentage of the surface area of the gravure roll covered by the gravure cells. The gravure process 100 uses an engraved print roller 103 that increases the life of the printing pattern and provides superior definition when printing on plastic substrates. Additionally, the gravure equipment can be used with water-based, solvent-based and hot-melt-based inks, or the like.

The first conversion operation 37 can alternatively comprise flexographic printing as is well known in the art. Flexographic printing provides high-quality, high-speed printing suitable for printing non-woven fibrous fabrics, while maintaining the soft feel of the fabric. Flexography is a printing technology, which uses flexible rubber or photopolymer plates to bring the image to a given substrate. The flexible plates carry a typically low viscosity ink directly on the substrate. The quality of flexographic printing in recent years has advanced rapidly so that, for many end uses, it is comparable to lithographic or gravure printing.

The types of plates that can be used with the process include, but are not limited to, the plates identified as DuPont Chirle .RTM.HL, PQS, HOS, PLS and LP, which can be obtained from E.I. DuPont de Nemours & Company, Inc., 1007 Market Street, Wilmington, Delaware 19898, E.U.A .; a plate identified as BASF Nyloflex.RTM. , which was obtained from BASF, 1255 Broad Street, Clifton, New Jersey, 07015, E.U.A.; and a plate identified as Flex-light .RTM. type FL-SKOR.RTM. , which can be obtained from W.R. Grace and Company of 5210 Philip Lee Drive, Atlanta, Georgia 30336, E.U.A. Other vulcanized rubber cylinders laser etched include such as those supplied by Luminite Products Corporation, 115 Rochester Street, Salamanca, New York, 14779, E.U.A., or by Flexo Express, 270 Rochester Street, Salamanca, New York 14779, E.U.A; or rubber printing plates, such as those provided by Fulflex, Incorporated, of P.O. Box 4549, Middleton, Rhode Island 02804, E.U.A. The rubber plates and the vulcanized cylinder can be made of natural rubber, EPDM, nitrites or urethanes.

The first conversion operation 37 can alternatively comprise lithographic printing, offset printing or screen printing as well known in the art very well. Lithographic printing is based on the immiscibility of water and oil. The ink receiving areas are generally on the surface of a hydrophilic surface. When the surface is moistened with water and the ink is then applied, the hydrophilic background areas will stop the water and repel the ink and the ink receiving areas will accept the ink and repel the water. The ink is transferred to the surface of a material on which the image will be reproduced. Typically, the ink is first transferred to an intermediate blanket, which in turn transfers the ink to the surface of the material on which the image is to be reproduced. The screen printing process typically forces the ink through the unblocked areas of a metal screen, silk or synthetic fiber by spreading the ink on the screen and passing a rubber roller over the screen by forcing both the ink inside the substrate. Offset printing typically involves a transfer roller that is capable of being rotated. An ink fountain is located near the transfer roller and supplies the ink on the transfer roller. A fabric is present and makes contact with the transfer roller. The substance is dispensed on the transfer roller and is transferred to the tissue through the contact of the transfer roller and the tissue.

In various embodiments, the second conversion operation 39 may include a manufacturing line for absorbent articles such as, for example, a diaper conversion operation. As such, the second conversion operation 39 can use a non-contact inkjet printing process to print at least a second graph 82 on the previously printed substrate 101. The use of ink jet printing is well suited for produce fine patterns with a high detail. Inkjet printing also allows quick changes to the pattern with just one change in programming against the manufacture of new printing rollers, screens or plates. However, non-contact printing may not be optimal for producing wide patterns or patterns that require a large amount of ink waste. As used herein, "non-contact printing" refers to a form of printing in which an image is formed on a substrate without directing contact between the substrate and the apparatus that produces the image.

As an example of a non-contact printing, the second conversion operation 39 may include an ink jet printing process as generally illustrated at point 46 in Figure 3. The ink jet process 46 includes an apparatus 40 which it can be used to print at least a second graph 82 on a substrate 101. The substrate 101 can be used on an outer casing, a liner, a side panel, a fin, an absorbent or combinations thereof. Additionally, the substrate 101 may be a complete or partially complete diaper or other absorbent article. The second graph 82 can be printed on several places on the article such as, for example, the outer cover, the side panel, the liner, the fin or combinations thereof. For the purposes of this description, the substrate 101 will be illustrated as an outer cover for an absorbent article such as a diaper. Therefore, the second graph 82 can be formed in the same process as the set of the various components of the diaper. However, in particular embodiments, the first and second conversion operation may include printing or not the assembly of an absorbent article. The composition and configuration of the diapers and diaper conversion operations are well understood by those of ordinary skill in the art and are representatively described by way of illustration in United States of America patents No. 5,743,994 issued on April 28, 1998 to Roessler and others; 5,827,387 issued October 27, 1998 to Reynolds and others; 5,827,259 granted on October 27, 1998 to Laux and others; and 5,853,402 granted on December 29, 1998 to Faulks and others, all of which are incorporated herein by reference where this is not contradictory. Referring to Figure 3, the outer cover material can be fed from a roll (not shown) as a substrate 101 to a guide 44, then to an ink jet printing station 46 and then to the assembly line (not shown). A controller 48 can be used to control the operation of the apparatus 40, and in particular the operation of the ink jet printing station 46. In a particular aspect, a tissue guide 44 can be used to monitor the position in the direction transverse to the substrate machine 101 to maintain the latter in a controlled position just prior to entering the printing station 46. An example of a suitable fabric guide is the Symat 50 offset pivot guide from Fife Corporation of Oklahoma City, Oklahoma, USA The illustrated ink jet printing station 46 includes a frame 49 which supports the bearings 50 (only one is shown) supported by a printing drum 52 for rotation about a generally horizontal axis. A suitable bearing will be a model number F4BDL200 manufactured by Dodge Bearings Incorporated of Greenville, South Carolina, E.U.A. These bearings 50 provide resistance to vibration of the drum 52, which is particularly likely to occur during the start and closure of the diaper assembly apparatus. Vibrations can make the image appear blurred to the point that diapers may have to be discarded as commercially unacceptable in the absence of vibration control. The bearings 50 holding the printing drum 52 by the rotation can be mounted for a slidably adjustable vertical movement in the frame 49. Two electrically driven linear motion actuators 54 (only one is shown), on the opposite sides of the frame 49, they can be connected to the printing drum bearings 50 to move the bearings and the printing drum 52 in relation to the frame. A suitable linear actuator is a GSX30 model manufactured by Exlar Corporation of Chanhassen, Minnesota, E.U.A.

A piezoelectric ink jet printing unit on demand may include a box 58 mounted on the frame 49. The illustrated case 58 supports the first to fourth print heads (designated 60, 62, 64 and 66 respectively) arranged along the length of the printhead. a top portion of the circumference of the printing drum 52 even when any number of print heads can be used. The print heads 60-66 are located in a series along the circumference portion. The lower ends of the print heads 60-66 (from which the ink drops are discharged) can be closely spaced with the drum 52. As an example, the print heads 60-66 can be spaced apart from the drum 52 in a manner that the spacing between the upper surface of the substrate 101 and the print heads is between about 1 millimeter and about 3 millimeters. In one embodiment, the cylinders 54 move the printing drum 52 so that in operation, the spacing of each print head 60-66 from the fabric is about 1 millimeter to 3 millimeters in operation, and is larger when not in use to facilitate threading the substrate material 101 through the inkjet printing apparatus 46. Movement is achieved by the actuators 54.

Although other inks can be used to print the second graph 82, it has been found that phase change or thermochromic inks, such as wax-based inks, have certain advantages in that these inks have reduced tendencies to scatter and smear and they do not require time or equipment for drying, which is highly desirable in the context of manufacturing. These types of inks do not require the use of solvents either. The wax-based inks are received in solid blocks which are melted in an ink supply system 70, schematically illustrated as being mounted on the frame 49. The melted ink of a particular color is fed through one of 4 lines ( designated 70A, 70B, 70C and 70D, respectively) to one of the print heads 60, 62, 64 and 66, as claimed by the printhead. A suitable system for melting and supplying the ink is the S DYNAMELT® hot melt supply system available from ITW Dynatec of Hendersonville, Tennessee, E.U.A. This system, marketed to supply adhesives, can be modified to supply melted ink. In one embodiment, the system includes a metering gear pump (not shown) for accurate ink delivery, which gear pump includes stainless steel components in contact with the ink. further, the commercially available system can also be modified by adding a filter of 10 microns. Other filter sizes can be used as specified by the printhead vendor or the ink seller. The ink supply system controls the ink temperature. In one embodiment, the melted ink is maintained at about 51.7 ° C. The temperature can be controlled to any level specified by ink sellers or printhead sellers.

The suitable print heads 60, 62, 64 and 66 which can be used in an embodiment to produce an image are the Galaxy PH 256/80 HM 256 channel ink jet printheads (serial numbers 5601320, 5601325, 5601326, 561327) available from Spectra, Inc. of Lebanon , New Hampshire, USA These print heads 60-66 each have two piezoelectric crystals with each crystal having two independent electrical circuits. Each circuit is associated with 64 buildings for a total of 256 holes per printhead. Each of the orifices can be examined individually so that the controller 48 can select which of the 256 orifices will be fired in each cycle. The holes are spaced and separated by about 0.0254 centimeters ± 0.0245 centimeters. It will be understood that other printheads having a different number of holes and / or holes with different spacings can be used without departing from the scope of the present invention. A longer print head can allow a wider image (in the transverse direction of the outer cover material) to be printed. In addition, the print heads may be inclined (placed side-by-side in the transverse direction) to print a wider image. The print heads 60-66 can each have an ink reservoir on the print head having an ink level sensor that can be used to signal the ink supply system 70 to deliver additional ink to the print head .

The application of the ink by the ink jet printheads to the substrates at high speed was also discussed in Sharma et al., United States of America patent application number 10 / 330,515, entitled PRINTING WITH INTA A HIGH CHOKE SPEED FOR VIBRANT GRAPHICS AND COLOR FIRMNESS ON TISSUE MATERIALS OR FINAL PRODUCTS, filed on December 27, 2002, the totality of which is incorporated herein by reference where it is not contradictory. Other suitable apparatuses, ink types, color measurements and design techniques are also discussed in Anderson et al., United States Patent Application No. 10 / 623,030, entitled ABSORBENT ARTICLE WITH HIGH-QUALITY INK JET IMAGE PRODUCED A LINE SPEED, presented on July 18, 2003, the entirety of which is incorporated herein by reference where it is not contradictory.

In several embodiments, the substrate 101 may be moving at least 100 feet per minute (fpm) during the non-contact printing operation 46 in the second conversion operation 39. Alternatively, the substrate 101 may be moving at least 200. feet per minute, 300 feet per minute, 400 feet per minute, 500 feet per minute, 600 feet per minute, 700 feet per minute, 800 feet per minute, 900 feet per minute, or 1,000 feet per minute during non-contact printing operation 46 in the second conversion operation 39. In several other embodiments, the substrate 101 may be moving faster than 1,000 feet per minute during the non-contact printing 46 in the second conversion operation 39.

In several embodiments, the first conversion operation 37 may include multiple contact printing steps wherein one or more colors or patterns are applied. The first conversion operation 37 may also include contact or contactless printing or may be a combination of contact and contactless printing. Additionally, the second conversion operation 39 may include multiple contact printing steps, contactless printing steps or combinations thereof.

It will be readily appreciated that the methods of the present invention can be used with various substrates such as, for example, absorbent garments, personal care products, textiles, clothing, paper, fabrics, nonwovens, films and the like. Referring now to Figure 4, an absorbent garment in the shape of a diaper (indicated generally with the number 10, having at least a first image 80 and at least a second image 82 can be formed by the method of the present invention The diaper 10 comprises a front waist region 12, a rear waist region 14, and an intermediate crotch region 16 interconnecting the front and rear waist regions.The waist regions 12 and 14 comprise those portions of the diaper 10 which when used, cover or completely or partially surround the waist or lower middle torso of the user.The intermediate crotch region 16 lies between and interconnects the waist regions 12 and 14, and comprises that part of the article 10 which, when is used, it is placed between the legs of the user (not shown) and covers the lower torso of the user.The outside of the diaper 10 is essentially formed by an outer cover 20 with Structured to form a barrier to liquid.

The diaper 10 has a generally three-dimensional configuration, as illustrated in Figure 4 when fastened on a wearer. In this configuration, the diaper has an interior space 22 for receiving the lower torso of a person using the diaper, a waist opening 24 for receiving the user in the interior space of the diaper, and a pair of leg openings 28 (only one is shown). In the illustrated embodiments, the fastener appendages 28 are permanently fastened to a rear waist region 14 of the diaper. These appendages 28 can be releasably attached to the front waist region 12 of the diaper 10 to secure the diaper around the wearer's lower torso. Other fastening systems (not shown) may be used without departing from the scope of the present invention.

The diaper 10 generally includes a side-to-body liner 32 on its innermost surface that contacts the skin of the person using the diaper 10. The liner 32 is desirably a soft and compliant material which is highly permeable to liquid and hydrophobic to allow the passage of liquid through the liner and to maintain a relatively dry surface in contact with the skin. These types of materials are well known to those with ordinary skill in the art and do not require to be more fully described here. Between the body side liner 32 and the outer cover 20, there is typically some form of liquid retention structure (not shown), such as an absorbent pad made of a fibrous absorbent material and a sorptor absorbing material (SAM). One example of such an absorbent pad is shown in United States Patent No. 6,383,960 assigned jointly. There is also typically an emergence layer (not shown) of the material that rapidly absorbs the liquid that passes through the liner from side to body. The emergence layer can distribute the liquid over a larger surface area before releasing it to the absorbent pad. Suitable surfacing layers are described in co-assigned U.S. Patent Nos. 4,798,603, 5,364,382, 5,429,629, 5,490,846, 5,522,810 and 5,562,650.

To further improve the containment and / or absorption of the body exudates, the article 10 may include a front waist elastic member, a rear waist elastic member and the leg elastic members, as known to those skilled in the art. . The elastic waist members can be operatively attached to the outer cover 20 and / or to the side liner to the body 32 along the opposite waist edges, and can extend over some or all of the waist edges. The elastic leg members are desirably operably linked to the outer cover 20 and / or the side-to-body liner 32 along the opposite lateral edges and are placed in the crotch region 16 of the diaper.

The waist elastic members and the leg elastic members can be formed of any suitable elastic material. As is well known to those skilled in the art, suitable elastic materials include sheets, threads or ribbons of natural rubber, synthetic rubber, or thermoplastic elastomeric polymers. The elastic materials can be stretched and attached to a substrate, fastened to a folded substrate, or fastened to a substrate and then elastized or shrunk, for example with the application of heat; so that the forces of elastic constriction are imparted to the substrate. In a particular embodiment, for example, the leg elastic members include a plurality of dry spun co-extruded multiple filament elastomeric yarns sold under the trade name LYCRA® available from E.I. DuPont de Nemours and Company, of Wimington, Delaware, E.U.A.

To further improve still the containment and / or absorption of any of the body exudates discharged from the user, the diaper 10 can include a pair of containment hems 34 (only one is shown) which are configured to provide a barrier to the transverse flow of body exudates. An elastic fin member (not shown) can be operatively linked to each containment fin 34 in any suitable manner as is known in the art. The elasticized containment fins 34 define the elasticized containment fins 34 define an unbonded edge that assumes a generally perpendicular and upright configuration in at least the crotch region 16 of the diaper 10 to form a seal against the wearer's body. The containment fins 34 may be located along the transversely opposite side edges of the diaper 10 and may extend longitudinally along essentially the entire length of the diaper or may only extend partially only along the length of the diaper. Suitable constructions and arrangements for containment fins 34 are generally well known to those skilled in the art.

The outer cover 20 desirably comprises a material which is essentially impermeable to liquid, and may be elastic, extensible or non-stretchable. The outer cover 20 can be a single layer of a liquid impervious material, but desirably comprises a multilayer laminated structure in which at least one of the layers is impermeable to the liquid. For example, the outer cover 20 may include an outer layer permeable to the lye and an inner layer impermeable to the liquid that are suitably joined together by a laminated adhesive, ultrasonic bonds, thermal bonds or the like. Suitable laminated adhesives, which may be applied continuously or intermittently as beads, a spray, parallel swirls or the like, may be obtained from Findley Adhesives, Inc., of Wauwatosa, Wisconsin, E.U.A. or from National Starch and Chemical Company, of Bridgewater, New Jersey, E.U.A. The liquid-permeable outer layer can be any suitable material and desirably one that provides a generally cloth-like texture. An example of such material is a non-woven polypropylene fabric bonded with yarn of 20 grams per square. The outer layer can also be made of the same materials as the liquid-permeable body side liner 32. While it is not necessary for the outer layer of the outer cover 20 to be permeable to liquid, it is generally desired that it provide a relatively stable texture. type of cloth to the user. The outer layer can generally be any suitable nonwoven material as is known in the art.

The inner layer (not shown) of the outer cover 20 may be both impermeable to liquid and vapor or may be unstable to the liquid and permeable to vapor. The inner layer can be made of a thin plastic film, although other flexible liquid impervious materials, the inner layer or the outer waterproof cover when it is a single layer can also be used, prevents the waste material from wetting the articles, such as bed sheets and clothes, as well as the user and the caregiver, a liquid impermeable film suitable for use as an inner layer impervious to liquid or an outer shell impermeable to the single layer liquid 20 is a film of 0.02 mm polyethylene commercially available from Pliant Corporation of Schaumburg, Illinois, USA Alternatively, a suitable liquid impervious film is a high breathability film made primarily of polyethylene and calcium carbonate having a basis weight of 19 grams per square meter and a thickness of 0.02 millimeters. Such a film is commercially available from Pliant Corporation of Schaumburg, Illinois, E.U.A. and is designated type XP-8635Y.

If the outer shell is a single layer of material, it can be etched and / or matte finished to provide a more cloth-like appearance. As mentioned above, the liquid impervious material can allow the vapors to escape from the interior of the disposable absorbent article, while still preventing liquids from passing through the outer cover. A suitable "breathable" material is composed of a microporous polymer film or a nonwoven fabric that has been coated or otherwise treated to impart a desired level of liquid impermeability. As used herein, the term "non-woven fabric" refers to a fabric having a structure of individual fibers or filaments which are interleaved, but not in an identifiable repetitive manner. The nonwoven layers have been formed, in the past, through a variety of processes known to those skilled in the art such as, for example, spunbonding, meltblowing, wet forming and various weaving processes. carded and united. A suitable microporous film is a PMP-1 film material commercially available from Mitsui Toatsu Chemicals, Inc. of Tokyo, Japan, or a polyolefin film XKO-8044 commercially available from 3M Company of Minneapolis, Minnesota, E.U.A. A description of the alternate outer cover materials made of extensible materials (so that the outer covers are expandable) can be found in United States Patent No. 6,265,641 assigned jointly and entitled EXPANDABLE COVERAGE GARMENT, issued on July 24. of 2001.

In several embodiments, the substrate 101 can be an outer cover 20 of a diaper 10. In the illustrated embodiment of Figure 4, the diaper 10 has a first graph 80, a second graph 82, and a third graph 84 applied in a region of front waist 12 of the outer layer of the outer cover 20 of the diaper 10. In several embodiments, the outer cover 20 can provide a white background on which the graphics 80, 82 or 84 are applied or the background may be another one of non-colored white, selected to highlight the colors in the graph. In several embodiments, wherein the outer cover 20 has more than one layer, the graphics 80, 82 and 84 can be applied on an inner layer of the outer cover 20, an outer layer of the outer cover 20 or both. The graphics 80, 82 and 84 can be applied on either side of the layers of the outer cover 20. For example, some, all or none of the graphics 80, 82 or 84 can be "between" the inner and outer layers of the outer cover 20 after lamination. In a suitable embodiment, the first graph 80 is applied to an inner layer of an outer casing 20 and the second graph 82 is applied to an outer layer of the outer casing 20.

In several embodiments, the inner layer and the outer layers of the outer cover 20 can be laminated together, before, after or simultaneously with the application of the first graph 80, the second graph 82, the third graph 84 or combinations of same. In several embodiments, the first graph 80 may be applied on the same side of the substrate 101 as the second graph 82, the third graph 84 or both. Alternatively, the first graph 80 may be shown on the opposite side of the substrate 101 as the second graph 82, the third graph 84, or both. Alternatively, the first graph 80, the second graph 82, the third graph 84, or the combinations thereof may be on both sides of the substitute 101. As used herein, the term "applied upon" includes those situations in which the first graph 80, second graph 82, third graph 84 and / or additional graphs are applied to a first layer of an outer cover 20 and the pigment, ink, dye, wax or the like partially or completely penetrate the first layer and are partially or completely deposited on the second layer. For example, the pigment, the dye, the dye, the wax or the like can be applied on the non-woven layer of an outer cover 20. The pigment, ink, dye, wax or the like can partially or completely penetrate the layer Non-woven and make contact with the film layer. In such a case, the pigment, the dye, the dye, the wax or the like can be "applied" on the non-woven layer even when a part is finally deposited on the film layer. The pigment, ink, dye, wax or the like may not be "applied over" the film layer in this example.

In embodiments where the substrate 101 is used as a component of an absorbent article, the first graph 80 may be printed prior to the formation of the absorbent article, simultaneously with the formation of the absorbent article or after the formation of the absorbent article. Similarly, the second graph 82 and / or the third graph 84 can be printed before the formation of the absorbent article, simultaneously with the formation of the absorbent article or after the formation of the absorbent article.

Referring now to Figure 5, a part of an example substrate 101, suitable as an outer cover of a diaper, is illustrated. The substrate 101 has a first graph 80, a second graph 82, and a third graph 84. In several additions, the first graph 80 can be a background graph. As used, the term "background graphic" means an image that includes components of an image, which provides the stage or background behind one or more images, such as, for example, a characteristic graph. Background graphics can include the part of an image that represents what lies behind the image or images in the background. Additionally, the background graphics can provide a less conspicuous image in comparison with the ostentated graphic. As used here, the term "characteristic graphs" refers to graphs by which the product can be easily recognized. Typically, such graphics will constitute the "focus" of the visual markings and will generally constitute more detail, definition and / or color than those used for the background graphics. However, in several additions, background graphics and characteristic graphics can be equally intense and attractive to a consumer. For example, a first graph 80, as illustrated in Figure 5 is as vibrant and attractive as a second graph 82 and a third graph 84, but the first graph 80 can be considered a background graph, while the second graph 82 and / or the third graph 84 can be considered characteristic graphs. In some embodiments, the graphic or characteristic graphics may include, for example, personal cartoons, animals, cartoon animals, vehicles, toys, flowers, numbers, letters or the like or combinations thereof.

In several embodiments, the first graph 80 may encompass 100% of the width 19 of the substrate 101, as illustrated in Figures 5, 6 and 7. As used herein, the term "encompass" means to extend from one bank to another bank. . As seen in Figures 5, 6 and 7, the first graph 80 extends from one edge of the substrate 101 to the other edge of the substrate 101 thereby covering 100% of the width 19 of the substrate 101. The unprinted spaces within the first Graph 80 does not change what is covered in the graph. In alternate embodiments, the first graph 80 may extend to at least 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20% or 10% of the width 19 of the substrate 101. In the Illustrated embodiment of Figure 5, first graph 80 comprises subcomponents 88, 80 and 90. Subcomponent 88 includes the letters "A, B, C". Subcomponent 89 includes four arched lines. Subcomponent 90 includes two diamond-shaped objects. In one embodiment, the first graph 80 is applied during a first conversion operation 37. In several additions, the second graph 82, the third graph 84, or the additional graphs may be centered generally along the width 19 of the substrate 101 as shown in FIG. illustrated in figures 5, 6 and 7. In several additions, the second graph 82, the third graph 84 or the additional graphs can be printed within 1 /, 1/3, 1/4, or 1/5, of the width 19 of the substrate 101.

The substrate 101 of Figure 5 is suitable for use as an outer cover on an absorbent article, such as the outer cover 20 of the diaper 10, as illustrated in Figure 4. Referring specifically to the embodiments illustrated in Figures 5 and 6 , the second graph 82 includes a dog fishing. The third graph 84 includes the same dog fishing but with the orientation inverted. This orientation of the second graph 82 and the third graph 84 is advantageous when manufacturing an absorbent article. For example, the second graph 82 can be matched so that the second graph 82 is placed in the front waist region 12 of an absorbent article 10 as illustrated in Fig. 4. Additionally, the third graph 84 can be recorded from so that the third graph 84 is positioned in the rear waist region 14 of an absorbent article 10. As such, both the second graph 82 and the third graph 84 are placed in a top-up configuration in the fully assembled diaper. In this embodiment, the second graph 82 and the third graph 84 are examples of characteristic graphs. Similarly, the first graph 80 may be matched so that the subcomponent 80 is generally centered in the crotch region 16 of an absorbent article 10. As such, the subcomponent 89 of the first graph 80 may be matched in relation to the leg openings 26.

Referring now to Figure 6, a portion of a second example substrate 101 is illustrated, suitable for use as an outer cover for an absorbent article. The substrate 101 has a first graph 80, a second graph 82 and a third graph 84 similar to the embodiment illustrated in figure 5. However, in figure 6, the first graph 80 comprises subcomponents 88, 90 and 91. In subcomponent 89, the arched lines have been replaced by subcomponent 91, which includes an arched shadow. In a suitable embodiment, the first graph 80 can be matched so that the subcomponent 91 is generally centered in the crotch region 16 and an absorbent article 10. As such, the subcomponent 91 of the first graph 80 can be matched in relation to the leg openings 26.

In several additions, the graphs can be composed of different colors. For example, in some embodiments, the first graph 80 may be composed of 1 color, 2 colors, 3 colors, 4 colors, 5 colors, 6 colors, 7 colors, 8 colors, 9 colors, 10 colors, 11 colors or 12 colors. In other embodiments, the first graph 80 may be composed of more than 12 colors. In several additions, the second graphic 82 can be composed of 1 color, 2 colors, 3 colors, 4 colors, 5 colors, 6 colors, 7 colors, 8 colors, 9 colors, 10 colors , of 11 colors or 12 colors. In other embodiments, the second graphic 82 may be composed of more than 12 colors. In several additions, the third graph 84 can be composed of 1 color, 2 colors, 3 colors, 4 colors, 5 colors, 6 colors, 7 colors, 8 colors, 9 colors, 10 colors , of 11 colors or 12 colors. In other embodiments, the third graphic 84 may be composed of more than 12 colors. In several other additions, more than 3 graphics can be applied.

The present methods may further include non-contact printing means with the ability to change the second graphic 82 and / or the third graphic 84 without buying or manufacturing new equipment, such as a printing roller, plate or screen. For example, the controllers associated with the ink jet printer, the bubble jet printer, the wax jet printer, the laser jet printer, and the like and combinations thereof can be programmed to change the second graph 82, the third graph 84 and / or the additional graphs as desired. For example, graphs can be part of a story line, can be selected at random, or can be according to the season, can be made to measure or similar or combinations of them.

As used here, the term "story line" refers to multiple graphs that when taken as a whole provide a consistent and consistent story or theme. An example of a coherent history may comprise a nursery rhyme rhyme wherein the nursery rhyme parts are illustrated and in graphic sequences applied on sequential absorbent products made by particular methods of the present invention. Alternatively, a story line may include a common background graphic with different characteristic graphics all related to the same subject. In an embodiment, the background graphic includes a pond, a shore and the sky. The characteristic graphics associated with the background graphic may include a boat, people and / or cartoon people in the boat, a fish, people and / or characters of cartoons fishing, people and / or cartoon characters swimming or playing on the shore , and the like, and combinations thereof. In this incorporation, the theme is "things associated with a pond". In another example embodiment, the background graphic may include a meadow of flowers and sky. The characteristic graphics associated with the background graphic may include people and / or cartoon characters who are planting seeds and watering them. Feature graphs in this story line can also include flowers in various stages of development, or they can show people and / or cartoon characters playing between flowers, picking flowers or the like, and combinations of them. In this incorporation, the theme is "things associated with a flower meadow".

As used herein, the term "randomly selected" refers to a process for using a controller and means for generating a random number of selected graphs from a list of preselected graphs. For example, a background graphic, suitable for use with randomly selected graphs, can include a prairie and sky field. The characteristic graphs associated with the background can be selected at random from the graphs of birds, bees, insects, clouds, sunrays, rain, animals, trees, trees with various fruits, flowers, flowers at various stages of development, roads, babies playing and exploring and similar and combinations thereof.

As used herein, the term "station" refers to the graphs that are changed as to coordinate with the station and / or a particular region. For example, during the winter, the graphics can for example, show snow, snowmen, sleds, people and / or cartoon characters skiing or ice skating, or the like, or combinations thereof. During the fall, the graphics can show, for example, the leaves changing colors, the falling leaves, piles of leaves, pumpkins, bunches of ears of corn and the like and combinations of them. The spring graphics may include, for example, flowering plants, flowers, trees, kites and the like, and combinations thereof. Summer graphics can include, for example, people and / or characters from cartoons swimming, sailing in a boat, fishing, playing or similar or combinations of them. Additionally, summer graphics may include baseball bats, baseballs, soccer balls, bicycles and the like and combinations thereof. One skilled in the art will appreciate that other graphs are possible and the examples illustrated herein are illustrative and are not intended to limit the scope of the present invention.

As used here, the term "tailored" refers to the graphics that are changed to suit a small demographic, customer or similar region. For example, a common background graphic can be used to print exterior covers for absorbent articles. The characteristic graphics can be changed to provide a corporate logo for a limited production run of products for a particular retailer and then changed again to provide a different logo or reason for a second retailer. Additionally, the characteristic graphs can include several languages that can allow an accurate tailoring of products in markets and / or small regions. In such situations, economy of scale is realized when a consistent background graphic is produced through contact printing and is complemented by the making of characteristic graphics through contactless printing to satisfy smaller demographic regions.

Certain aspects of the present invention utilize contactless printing capability to quickly change graphic features while still maintaining the cost-effective use of contact printing for background graphics. For example, the first graph 80 may show a "standard" background that may accentuate or complement several second and third graphs 80 and 84. In the currently illustrated embodiments, subcomponents 88, 89, 90 and 91 of the first graph 80 may provide a consistent background for the second and third charts 82 and 84. These aspects therefore use the consistency of a common fund pattern produced at lower costs through traditional contact printing methods while also maximizing the capacity to make the substrate 101 through non-contact printing.

In several embodiments, at least a portion of the second graph 82 and / or of the third graph 84 prints over at least a portion of the first graph 80. As used herein, the term "overprinting" means printing a second image in the same general location as the first image. Printing on a second image may obscure the first image or may complement the first image. As used here, the term "complement" means filling, completing or making a whole. For example, the first image can be part of a master graphic and the second image can add, and potentially complete the master graphic. A master chart can comprise two or more images that combine to make a single image. As used herein, the term "master graphic" refers to a visual composite, which is constructed by individual images. For example, a first image can include a flower pot and a second image can overprint flowers on the flower pot. The master graphic can include the visual "all" of the flower pot containing flowers. A second example of a master graphic includes a first image of a pond with at least a second image of a fish printed on it. The master graphic will include the visual "whole" of the fish swimming in a pond.

Another example of overprinting involves creating a first image that announces the absence of a second image. If the second image is printed on the first image, the announcement of the absence is obscured and only the second image is seen. However, if the second image fails to print on the first image, then the first image will remain visible.

Referring now to Figure 7, a part of an example substrate 101, suitable for use as an outer cover of an absorbent article, is illustrated. The substrate 101 includes a first graph 80. The first graph 80 includes four subcomponents: 88, 90, 91 and 92. Subcomponents 88, 90, and 91 are similar to those described in Figure 6 given above. Nevertheless, subcomponent 92 is an absence announcement. As used here, an "absence announcement" is a graph that carries the message that an additional graph is missing. The announcement of absence may take the form of paintings, words, outlines, shadows or other forms of communication or combinations thereof. The failure to overprint the absence announcement 92 does not result in a defective substrate or a defective product because the absence announcement 92 creates a "backup" system for printing. For example, if the second graph 82 and / or the third graph 84 prints on the absence announcement 92, the absence advertisement 92 is obscured and the overprinting graph is visible on the finished product or substrate. However, if the overprint fails, the absence announcement 92 is still visible on the substrate or finished product. As a consequence, the finished product or substrate is not wasted because the absence of the advertisement 92 is chosen so that the appearance of the absence announcement 92 on the substrate or finished product will carry a desirable message such as, for example, a comment of humor, a contact information, a coupon, or similar, or combinations thereof.

In various configurations, the absence of advertisement can be used as a marking device. For example, in Figure 7, subcomponent 92 is an absence announcement.

As illustrated, subcomponent 92 includes the dotted contour of a dog, sitting on a boat, with a fishing pole. Included within the dotted outline are the words "I went fishing!". The combination of the contour figure of the dog and the words within the outline carries the message that the dog that is fishing is missing, for example, an absence of advertisement. Alternatively, only the dotted outer line can be used or only the words can be used. In several additions, a second graph 82 can be printed on a subcomponent 92. If the overprint was successful, only the second graph 82 can be visible (see for example element 82 of figure 6) since the absence of announcement is by at least partially obscured by the overprinted graphic. However, if the overprint fails, the subcomponent 92 may be visible on the substrate or finished product, as illustrated in Figure 7. Despite the printing failure, the resulting substrate and / or product will not be wasted because the absence announcement 92 can be marketed as, for example, a game or contest. In the illustrated embodiments, a consumer will normally see the second graph 82 as illustrated in Figure 6, but on occasion he will see subcomponent 92 of the first graph 80 as illustrated in Figure 7. The absence of advertisement 92 will include the consumer in such a "game" of the missing graph provided by both a backup system to print and therefore reduce the waste associated with printing failures. In figure 7, the consumer will be included in the search for the missing graph when they see the absence of graph 92. As such, instead of a defective product, the consumer will be notified that the second graph 82 has a phrase " I went fishing! " thus doing what was typically considered a product failure in a product attribute.

In an alternate embodiment, the absence of advertisement 92 may include a contact message with the consumer. For example, referring now to Figure 8, there is illustrated a portion of an example substrate 101, suitable for use as an outer cover of an absorbent article. The substrate 101 includes a first graph 80. The first graph 80 includes four subcomponents 88, 90, 91 and 92. Subcomponents 88, 90 and 91 are similar to those described in Figure 6 given above. However, subcomponents 92a and 92b are examples of the absence of advertisements. The absence of advertisement 92a carries a telephone number graphically displayed as "1-XXX-contact". Alternatively or additionally, the absence of advertisement 92b provides a network site graphically displayed as a "network site". The absence of advertisements 92a and 92b provides means of accessing the customer service department, where the consumer can register a complaint regarding a missing graphic and / or receiving information regarding reimbursements or coupons. Alternatively, the absence of advertisement 92a, 92b may include an information coupon associated with a telephone number or a network site. In such additions, the consumer may call or go online to receive a coupon or the like. Those skilled in the art will appreciate that many absences and adequate advertisements are possible. Those included herein are illustrative and are not intended to limit the scope of the present invention.

Another aspect of the present invention relates to a method for distributing tailored products to different customers. The method includes the steps of supplying a moving substrate to a first conversion operation; the contact print of at least a first graph on the moving substrate, the first graph being essentially uniform for all clients; supplying the moving substrate with the first graph to a second conversion operation; printing without contact a plurality of second graphs on the substrate in movement, the plurality of second graphs being tailored to specific clients; and distribute the substrate to customers. As used herein, the term "substantially uniform" refers to a graphic or image that generally has the same appearance as another graphic or image and the differences (if any) between the graphics or images are not noticeable to consumers without being directed to the differences.

In several embodiments of this aspect, the moving substrate with the first graph can be divided into a plurality of rolls made from moving parts of the substrate before supplying the wound substrate to at least one second conversion operation. The moving substrate can be divided by cutting, slits or any other suitable cutting process as is well known in the art or combinations thereof. Some rolls of substrate can be printed with one or more graphics while others can be printed with a second graphic. Some rolls can be printed with additional graphics in addition to the second graphics. In other embodiments, the plurality of substrate rolls with only the first chart may be sent to more than one second conversion operation or may be printed with more than one second chart. The second graphics may be different from one another conversion operations, within a particular conversion operation, or both.

An addition to distribute tailored products to different customers includes the distribution of absorbent articles. In several embodiments, the moving substrate can be an outer cover and the first conversion operation can be a contact printing operation such as a rotogravure printing, a flexographic printing, an offset printing, a lithographic printing, a screen printing or similar, or combinations thereof. The first graphic can be printed on the outer cover using one or more of the contact printing operations. The first graph can be essentially uniform for all clients in a given group. A group can be formed based on ethnicities, nationalities, locations, interests, language or any other suitable delineation or classification. For example, in Figure 5, the first graph 80 can be printed on all the outer casings for all customers in the "North America" group. The outer cover can then be supplied with an essentially uniform graph 80 to one or more of the second conversion operations in one or more places. In the present example, such conversion operations can be one or more diaper conversion operations wherein the outer cover is combined with a liner and an absorbent to form a disposable diaper. During the diaper conversion operation, one or more second graphics can be printed without contact on the outer cover. The second graphics can be customized to specific customers. For example, customers within the "North America" group may include Canadian customers, United States of America and Mexican customers. The second graphs can be made to measure by several non-contact printing methods as previously discussed. The conformation can take the form of several languages. For example, second tailored charts for Canadian customers may include French and English text, second tailored charts for American clients may include English text and second tailored charts for Mexican clients may include the text in Spanish. The disposable diaper with essentially uniform graphics and custom graphics can then be distributed to customers. Alternatively, the outer cover alone can be distributed to customers for the use of the customers.

In other examples, the group may be the "world" and the clients may be several continents, countries, regions or other desirable delineations. Alternatively, customers can be specific businesses for which the graph or tailored charts include several clues. As used herein, the term "indicia" refers for example to a company logo, a company brand, a company phrase, a licensed character, proprietary characters, or other desirable brands or combinations of the same that are specific or desirable for a particular client. In such additions, contact printing can produce essentially uniform graphics and contactless printing can result in custom graphics before distribution to customers.

As previously discussed, the method of distributing tailor-made products to different customers can include several substrates, including various combinations of laminates. Additionally, the graphics can include background graphics, characteristic graphics, complementary graphics, master graphics, and the absence of advertisements. Graphics can also be part of a story line. They can be selected at random, they can be stationary or they can be made to measure.

In various embodiments, it may be desirable to align the various graphs by coincidence as is commonly known in the art. For example, the first graph, the second graph, the third graph or combinations thereof may be matched in relation to the substrate, a match mark or any other graph by means known in the art. For example, the coincidence by the use of a reference marker is taught in U.S. Patent No. 5,286,543 issued February 15, 1994 to Ungpiyakul et al., The entirety of which is incorporated herein by reference where it is not contradictory. . Additionally, a process for matching two layers continuously in motion by the use of match marks is taught in U.S. Patent No. 5,766,389 issued June 16, 1998 to Brandon et al., The entirety of which is incorporated herein by reference. reference where it is not contradictory.

Although the invention has been described in detail with respect to the specific embodiments thereof, it will be appreciated by those skilled in the art to achieve an understanding of the foregoing that alterations, variations and equivalents of these embodiments will readily be conceived. Therefore, the scope of the present invention should be evaluated as that of the appended claims and any equivalent thereof.

Claims (20)

R E I V I ND I C A C I O N S

1. A method for printing a substrate in motion comprising: supplying a moving substrate to a first conversion operation; print by contact at least a first graph on the moving substrate; supplying the moving substrate with the first graph to a second conversion operation; Y print without contact at least a second graph on the moving substrate.

2. The method as claimed in clause 1, characterized in that the contact printing uses a gravure printer, a flexographic printer, an offset printer, a screen printer, the contactless printer uses a wax jet printer, a an inkjet printer, a laser jet printer or a bubble jet printer.

3. The method as claimed in clause 1, characterized in that the first graph and the second graph together form a story.

4. The method as claimed in clause 1, characterized in that the moving substrate is moving at least 100 feet per minute during non-contact printing.

5. The method as claimed in clause 1, characterized in that it further comprises: contactless printing in at least one third graphic on the moving substrate, wherein at least a part of the third graphic is overprinted at least partially on the first graph.

6. The method as claimed in clause 1, characterized in that the second conversion operation produces disposable absorbent articles and the moving substrate forms an outer cover of the articles.

7. The method as claimed in clause 1, characterized in that the second conversion operation produces disposable absorbent articles and the moving substrate forms a side-to-body liner or an absorbent of the articles.

8. The method as claimed in clause 1, characterized in that the second graph at least partially prints on the first graph.

9. The method as claimed in clause 1, characterized in that the first graph and the second graph together form a master graph.

10. The method as claimed in clause 1, characterized in that the substrate is a laminate comprising a film layer and a non-woven layer and the first graph is printed on the film layer and the second graph on the non-woven layer .

11. The method as claimed in clause 1, characterized in that the substrate is a laminate comprising a film layer and a nonwoven layer and the first graph is printed on the non-woven layer and the second graph is printed on the non-woven layer.

12. The method as claimed in clause 1, characterized in that the substrate is a laminate comprising a film layer and a nonwoven layer and the first graph is printed on the film layer and the second graph is printed on the film layer.

13. A method for printing an outer cover for an absorbent article comprising: supplying a first moving substrate to a first printing operation, the first moving substrate comprises a film; printing by contact at least a first graph on the first substrate in motion and the first printing operation using an engraving roller printer or a flexographic printer; laminating a second substrate in motion to the first moving substrate to form an outer cover, the second moving substrate comprises a nonwoven fabric and the outer cover defines a width; supplying the outer cover to a second printing operation; printing without contacting at least a second graph on the outer cover in the second printing operation using a wax jet printer, an ink jet printer, a bubble jet printer, a laser jet printer, the first graphic covering at least 60% of the width of the outer covering and being visible to the naked eye, to the second graphic being placed within the central third of the width of the outer covering and being visible to the naked eye; Y attaching the outer cover with an absorbent and a liner to produce an absorbent article.

14. The method as claimed in clause 13, characterized in that the absorbent article has a front waist region, a back waist region, and a crotch region that connects the front waist region and the rear waist region, and the second graph is placed within the frontal waist region.

15. The method as claimed in clause 13, characterized in that the absorbent article has a front waist region, a back waist region, a crotch region connecting the front waist region and the rear waist region, and the Second graph is placed within the posterior waist region.

16. The method as claimed in clause 13, characterized in that the absorbent article has a front waist region, a back waist region, and a crotch region that connects the front waist region and the rear waist region, in addition comprising two or more second graphs, at least one second graph is positioned within the front waist region and at least one second graph positioned within the rear waist region.

17. A method for minimizing waste of substrate printing comprising: supplying a moving substrate to a first conversion operation; printing a plurality of ad absences on the moving substrate using a contact printer; supply the moving substrate with the absence announcements to a second conversion operation; at least partially print on the second graphics on at least some of the absence announcements using a contactless printer, where a failure to print a second graphic on an absence announcement 62 results in the absence announcement remaining visible on the substrate.

18. The method as claimed in clause 17, characterized in that it comprises joining the substrate to an absorbent and a liner to form an absorbent article, the absence of advertisement forming a part of an interactive game or contest involving the user of the absorbent article .

19. The method as claimed in clause 17, characterized in that it further comprises joining the substrate with an absorbent and a liner to form an absorbent article, the absence of advertisement carries contact information to a consumer of the absorbent article.

20. A method for printing an outer cover for an absorbent article comprising: laminating a first substrate comprising film to a second substrate comprising a nonwoven to form an outer cover, the outer cover defining a film side, a nonwoven side set to the film side, and a width; supplying the outer cover to a printing process and printing with contact at least a first graph on the nonwoven side; supplying the outer cover to a conversion operation, the conversion operation combines the outer cover with an absorbent assembly to form an absorbent article; print without contact at least a second graph on the nonwoven side in the conversion operation, the first graph covers at least 60% of the width of the outer cover and is visible to the naked eye, the second graph being placed within the third central of the width of the outer cover and both first and second graphs being visible to the naked eye. SUMMARY A method for printing a substrate includes contact printing a first graphic in a first operation and a non-contact printing a second graphic in a second operation. A method for printing an outer cover for an absorbent article includes contact printing the outer cover in a first operation, the non-contact printing of the outer cover in a second operation, and joining the outer cover with an absorbent and a liner to produce an absorbent article. One method to minimize waste of substrate printing includes contact printing with no ads in a first operation and non-contact overprinting of a second graphic in a second operation. - A method for distributing tailored products to different customers. which includes printing with contact essentially uniform graphics on a substrate in a first operation, contactless printing of tailored graphics on a substrate in a second operation, and distributing a substrate to the clients.