CA2323851A1 - A block of material from a folded web of material and a process for producing this block of material - Google Patents

Abstract

A block of material from a folded web of material and a process for producing this block of material The block of material (MB) comprises a folded web of material (1), which is divided into a plurality of adjacent and coherent layers of strips (3) by means of perforation lines (2) imparted along the longitudinal direction of the web of material.

The perforated block (MB), which is precompressed in its height (H) to create standing stability, is spliced, with the same strip sides, at its trailing strip end (4a) and the leading strip end (4b) of its adjacent strip layers (3), to form. a strip (4) with identical strip sides (S) that is continuous through the entire block (MB), after which it is completely compressed in its height (HI) and packaged into a heat-sealed plastic wrap (5) that maintains the block compression, so that it forms a free-standing material block (MB).

Description

1bi10 '00 DO 09:52 FAX +49 521 68043 i~~ KIR8Y CD I~ 002 Oct-16-2000 10:46am From-BROHDY AND NEWARK T-012 P.002 F-663 My-docket no: G 85/26 rti A filoek of a Folded Web of Material for Producing Hygiene Products, e.g., Absorbent Pads The present invention relates to a block of a folded web of material for producing hygiene products as set forth in the preamble of claim 1, having adjacent strip-shaped web sections, the trailing web section ends of which. arc connected to a leading web section end of the respective adjacent web section with a rotation by 360' that compensates for the inherent twist, with the respective leading web section end of a first web section and trailing vveb section end of the last Web section kept free for an external connection.
A block of material of this type is known from DE 198 81 126 Tl. In this block, the individual, strip-shaped web sections are completely separated iato separate strips, except for the connection of the leading section ends to the nailing section ends of the adjacent sections_ As a result, the block has only a tow side stability and is very difficult to manipulate during the process of wrapping it in a wrapping cover.
it is furthermore known that, in the hygiene industry, to manufacture hygiene products, webs of material are wound onto large rolls and strips are cut from these rolls in predefined widths based on the desixed specification, and then subsequently wound onto rolls again sad delivered in this iaitu '00 DO 09:52 FAX +49 521 88043 KIRBY CD 0 003 Oc t-16-2000 10 :46am F rom-Btl'OWOy AIRD NE I IMRhCA 0 2 3 2 3 8 51 2 0 0 0 -1 226282089 ~ T-012 P. 003 F-663 form to the manufacturer of hygiene products, who then produces the end product from them. A
cost effective delivery and proc~essi~g of the fluffy materials in question is desired, however, rolls have a large shipping volume and frequently incur damage to the material, which results in relatively high costs. .
Furthermore, from US 1 985., 676, a folded web of paper is known, the adjacent, strip-shaped web sections of which are separated from one another by Ions cuts with only minute webs remaining, so that individual strip packages can be pulled off for processing.
It is the aim of the present invention to improve the above'mentioned block in its stability by means of the mutual support by the adjacent web sections, while providing for an easy unfolding of the strips.
This aim is met with the adjacent strip-shaped web sections being divided by a micro-perforation line, but coherently firxttty connected to one another in those areas, and separable along the inicro-perforation line for further processing in such a way that the individual strip-shaped web sections can be unfolded from the block, one after another and without interruption, from an unattached leading end of the web section.

19/10 '00 DO 09:52 FAX +49 521 88043 ~ 004 CA 02323851 2000-10-20 -~-~-~ KIRBY CD
Oct-i6-2000 10-47am From-BROiNDY AND NEIMARK 2026282089 T-012' P~004 F-6&3 Further designs are described in the subclaims.
Based on the invention, a block of material has been created that is formed of folded ~trins layers- t~~h by st~ructurer3 micros-perforation lines i.n adjacent an9~ coherent str~a~-The leading end_~ and the trailing ends of adjacent strip layers are connected with their same sides in a known manner by sewing so that the block in itself becomes an equal-sided, continuous strip of matezial for production, thus permitting the entire block to be worked offcontinuously.
This block of material, which is stable in itself is formed into a free-standing block with less work than required fox the previously known strip stacks, by means of a known precompression and finishing compression, and packaged in an inexpensive plastic wrap.
Multiple blocks of materials may advantageously be sewn together at their respective leading and trailing ends, so that a practically endless production process can be performed with many strung together material blocks that are connected to one another by sewing.

20,'10 '00 FR 09:19 FAX +y9 521 880aCA 02323851 2000-10-20 -'-'~ KIRBY CD ~ua2 Qa~,-?9-2000 Oi:l4pn F~on-BROWOY NEIIAARII 202T3T35ZB T-180 P.004/004 F-E15 Using a folding cylinder thtet is sQeci~eally designed for the perforating and folding process, zhe material, which is wound ort rjtaster robs, is already micro-perforated, creased, and laytled into strips with variably adjustable end widths relative to the entire processing width and stacked into 1.5 rn high rectangular blocks at the suppliers production fadlities. Those blocks of material are then precompressed to approximately 85% of their original height prior to further processing.
The perforated strips of material era sewn together (spliced) at their abutting edges, so that a continuous web ofmaterial results. A medical grade thread, verhich does not interfere with the processing of the material at the end manufacturer, is used in this scam, By using these functional warts, the waste ineuired during production hoe been reduced to a minimum.
The now continuous block afmaterial strips is compressed again, to approximately a 1 m height, i.e,, to 67% of its original height.
These blocks are now packaged into heat-scaled plastic bags that maintain the compression of the mdterial.

iarlU UU D~ 09:53 FAX +49 521 88043 CA 02323851 2000-10-20 '~~i KIRBY CD
I~j 005 Oct-16-200D 10:47am From-BRO~fDY AND NEIIdARK 2026282089 T-012 P.DOS F-663 - An embodiment of the invention, which will be expl~ed in detail below, is shown in the drawings, in which:
Fig. 1 shows a perspective of a eo~pl~tfrly cptt~press~d, packaged material block, blxk Fig. 2 shows a perspective of the gr~~Qrppressed of material that has been folded from a web of mare~ial and divided by ~~r~oratiQns ~ntQ coherent layers of strips, and sewn together at the leading and trailEpg strip ~n~3s, pomprising strips that are twisted at their leading ends dice to the equal-sided splicing, Fig. 3 shows a front view ofthe pack>lged matotial block Fig. 4 shows a front view of the precompressed material block with twisted material strips, Fig. 5 shows a side view ofthe folded material block, Fig. 6 shows a rear view of the material block, Fig. 7 shows a top view of the material block, -Fig. 8 shows a perspective of two material blocks that arc sewn together at their trailing and leading scrip ends, 19/10 '00 DO 09:5 FAX +49 521 68049 KIRBY CD
. . Oct-16-2000 10:41am Fram-6RONOY AND NEtWARH 2826282089 i'-Di2 P.008 F-rig: 9 . shows a schematic top view of two material strips lying upon one another with their same strip sides during the sev~ing process, FaB~ 1 o shoal s a schematic top view of two strips that are sewn together with their same sides across butting joints, fiig. 1 I shows a sectional side view of the strips that are sewn onto one another with their same sides, lying upon otEe another, fig. 12 shows a sectional side view of the strips that are folded apart into a continuous strip with the same sides np, Fig. 13 shows a top view onto the material block with strip connecting seams.
The block (MB) of a folded web of material (1) is divided into multiple adjacent coherent layers (3) of strips (4) by means of perforation lines (2) - micro-perforations ~
imparted in the longitudinal direction (L) of the web of material, The perforated block (MB) is precompressed in its height (~ to render it free-standing (Fig. 2, 4 throubh 7), and spliced, with the same stop sides (S), to the trailing strip end (4a) az~d the leading strip end (4b) of its adjacent strap layers (3) to form a strip (4) that is continuous through the entire block (MB), and then packaged, completely compressed in its height (Fil), into a plastic wrap (5) that maintains the block compression, so that it forms a free-standing block (MB) (Fig_ 1, 3).

18/10 '00 DO 09:53 FAX +49 521 88043 KIRBY CD f~. 007 Oct-16-2D00 I0:48am Froor-BRDPIDY AND NEIMARK 2026282089 T-012 P.OOT F-663 The trailing strip ends (4a) and the leading ends (4b) ate spliced with a medical grade thread with a so-called overedge seam (7) across butting joints (SS).
On one side of the block, the equal-sided strip seams (7) produce strips (4) that are rotated around themselves by 360° in the height direction (~ pf the block, as shown in Fig. 2 and 4 by the reference character (W), producing the equal-sidad endless strip (4).
The block (MB) has a rectangular three-dimensional shape with a larger expansion along the block height than in the cross directions.
Underneath and on top of the block (M$), a stabilizing layer'(8) is provided inside the plastic sleeve (5), preferably honeycombed cardboard, which covers the entire basic shape (upper and lov~rer surface of the block).
To produce the above block of material (l~), the black with its web of material (1) is provided with perforation lines (2) - a micro-perforation - in a machine by means of perfoz~ation wheels or discs that divide the web of material (1) into a plurality of material strips (4) of egual width that are coherent but can later be separated. Afterwards, the web of material (1) is folded by cuttiing means, such as rollers, cylinders or the like, and then has a rectangular block shape. ' The perforated and folded block (MB) is then precompressed in its height (H) to a certain dimension while providing standing stability, so that it receives a certain inherent stability.

09:53 FAX +49 521 88043 Oct-16-2000 10:4Bam From-BROIYDY AND NEIMARK 02323851 2000-10-20 -~-~-~ KIRBY CD (~ 008 2026282089 T-012 P.d08/014 F-663 Afterwards, the trailing end of the strip (4a) and the leading end of the strip (4b) of the adjacent layers of strips (3) are spliced equal-sided to form a strip (4) that is continuous through the entire block (MB) with the same (not alternating) strip sides (S).
A,fteiwards the block (MB) is completely compressed tA a packaging and transportation height (Hl) and packaged in a heat-sealed plastic wrap (5) that maintains the block compression and also encompasses the honeycombed cardboard (3).
For the splicing ofthe two adjacent strips (4) at their trailing strip end (4a) and leading end (4b), the strips (4) are separated at a certain length ac their perforation connection (perfocation lines 2) between adjacent layers (3) and then placed over one another with their same strip sides (S) xnd sewn together with the overedge seam (7) .- cross seam.
In the overedge seam (7), the thread (6) is stitched through the iwo strips (4a, 4b) in one stitch (6a), ai2er which an empty stitch (6b) is performed outside the strips (4a, 4b), etc., as shown in Fig. 9, which also shows the edges (4c) ofthe strip ends (4a, 4b) cut off.
When the strip ends (4a., 46) that are lying upon one another for sewing, are folded out by 180', the butting joint (SS) of the spliced strips (4) is obtained, and the cross seam (7), according to Fig.
10 and 12.
T'he equal-sided strip splicing is a joining top side/top side ofthe strips (4) so that the structure of the individual strips (4) i5 maintained. One ofthe strip sides may be smooth, .for example, and the other one textured, the two strip sides may have different~colors or one strip side may be provided -with a film (F) - Fig. 11, 12. In their spliced condition, the strip sides (S) ste always identical and on the same side of the strip.

19!10 '00 DO 09:54 FAX +49 521 88043 KIRBY CD (~ 009 Oct-16-2000 10:48am From-BRONDY AHD NEIIAARK
CA 02323851 2000-10-z02fi282089 T-012 P.009/014 F-E63 The perforated folded block (MB) has, e.g., a height (~ of approximately 1500 mm and the completely compressed block (MB) has a height (H1) of 1000 mm, with the width and depth of the block (MB) always remaining the same; and the width is approximately 840 mrn, and the depth approximately 730 mm. At this block size, the block (lv>B) has 12 strip layers, each with a width of 70 mm. The number of layers (n) may be selected differently, however, and so may the width, depth and height of the block.
The leading end (4b) of the first layer of strips (3) is guided directly into the production apparatus, ' particularly for the production of hygiene products, and the trailing strip end (4a) of the last layer of strips (3) is spliced to the leading end (4b) ofthe fast layer of strips (3) of a given further block (MB) for a continuous production, as shown in Fig. 8, practically permitting an endless production. A large number of materials may be used for the web of material (1), especially formed fabric materials; the packaging wrap (5) may be made of inexpensive plastic films, e.g., Pli bags. .. ..

Claims (6)

1. A block (MB) of a folded web of material for producing hygiene products, e.g., absorbent pads, having adjacent strip-shaped web sections (3), the trailing web section ends (4a) of which are connected to a leading web section end (4b) of the respective adjacent web section (3) with a rotation (W) by 360° that compensates for the inherent twist, with the respective leading web section end (4b) of a first web section (3) and trailing web section end (4a) of the last web section (3) kept free for an external connection, characterized in that the adjacent strip-shaped web sections (3) are each divided by a micro-perforation line (2),but connected there in a coherent firm connection, and separable along the micro-perforation line (2) for further processing in such a way that the individual strip-shaped web sections (3) can be unfolded from the block (MB),one after another and without interruption, from an unattached leading web section end (4b).

2. A block of material as defined in claim 1, characterized in that the connected trailing web section ends (4a) and leading web section ends (4b) are spliced with a medical grade thread (6), with a so-called overedge seam (7) across butting joints (SS).

3. A block of material as defined in claim 1 or 2, characterized in that the overedge seams (7) are arranged on one side of the block of material (MB) and the rotated portions (W) are aligned in the height direction (H) of the block.

4. A block of material as defined in one of the claims 1 through 3, characterized in that the black of material (MB) has a rectangular block shape.

5. A block of material as defined in one of the claims 1 through 4, characterized in that the block of material (MB) is packaged in a heat-sealed plastic wrap (5) in a height compressed form.

6. A block of material as defined in claim 5, characterized in that one each stabilizing layer (8), preferably made of honeycombed cardboard, lies underneath and an top of the block of material (MB) inside the plastic wrap (5).