IE45042B1 - Absorbent fibrous web - Google Patents

Description

The present invention relates to absorbent fibrous webs for use in the formation of disposable absorbent pads, such as absorbent pads which are parts of disposable articles.

A variety of absorbent articles of the disposable type have been 5 proposed for use in receiving and retaining body fluids, such as disposable diapers and sanitary towels. The articles may have a fluid-impervious backing sheet, a fluid-pervious top or cover sheet, and an absorbent pad between the backing and top sheets to capture body fluids which pass through the top sheet. The pads are commonly made from a fibrous cellulosic material which provides the desired absorbent characteristics.

Patent No. 45041 from which the present Patent has been divided, describes and claims an absorbent pad which consists of, or which comprises a layer of, a mass of cellulosic hydrophilic fibres with hydrophobic material dispersed throughout the thickness of the pad or layer in interfibre spaces defined by the said hydrophilic fibres, at least part of the hydrophobic material being comminuted thermoplastic film or strip material of a comminuted waste absorbent article which included that film or strip material.

According to the present invention, there is provided a supply feed roll for use in the formation of a disposable absorbent pad e.g. the pad of a disposable diaper, the feed roll comprising a compressed -24 3 Ο 4 3 web having a mass of hydrophilic fibres with a comminuted hydrophobic film or strip material dispersed throughout the thickness of the web in interfibre spaces defined by the hydrophilic fibres, at least part of the hydrophobic material being comminuted thermoplastic film or strip material of a comminuted waste absorbent article which included that film or strip material, said web being wound into said roll.

A method of making a supply feed roll for use in the formation of disposable absorbent pads and comprising the steps of:providing a source of hydrophilic and hydrophobic materials including a thermoplastic sheet material; comminuting the source of hydrophilic and hydrophobic materials; immediately forming the comminuted hydrophilic and hydrophobic material into a fibrous web containing a mixture of these materials; compressing and heating the fibrous web into a compressed web of hydrophilic and hydrophobic materials; and winding the compressed web into a roll as the supply feed roll is the subject of Patent.No. 45043 5 which also has been divided from the above-mentioned Patent No. 45041 The materials normally utilized in making disposable absorbent articles e.g. disposable diapers, are as follows. The fluid-impervious backing sheets are made of a thermoplastic hydrophobic material, such as polyethylene, the fluid-pervious top sheets are made of a fibrous non-woven material having a hydrophobic binder, while the absorbent pads are made of an absorbent cellulosic hydrophilic material, such as wood fluff. The diapers are usually provided with tape fasteners for securing the diapers about infants. Such fasteners have a backing commonly made of a thermoplastic or paper material and an adhesive coating on one surface of the fastener backing. The basic components of the diaper are products of expensive natural resources, namely trees and oil. Hydrocarbons derived from oil are utilized to make the backing sheets, and possibly the adhesive -3and hackings of the tape fasteners, while fibres formed from wood pulp are utilized to make the absorbent pads, the top sheets, and possibly the fastener backings of the diapers.

The manufacture of such articles is attended by waste resulting in disposal of large quantities of such valuable materials. For example, when manufacture of such articles is initiated on a machine, a substantial amount of the materials may be utilized before a satisfactory article is obtained for packaging and sale, and the initial portion of such materials produced during the setup procedure would normally be discarded as waste. Additional waste materials may be accumulated while the machine is not functioning properly, during unscheduled stops of the machine, after breakage of materials utilized in making the articles, or during changes of raw material sources supplied to the machine.

In each case, the waste and rejected materials have been utilized for purposes such as packing which ordinarily would not require such expenditure of valuable natural resources, or the materials have been burned or used as land fill.

A portion of the hydrophilic fibres in the absorbent pad which is the subject of Patent No. 45041 may be made from a waste absorbent article. Also, at least part of the hydrophobic material is made from a waste absorbent article, thus reducing the cost of the resulting absorbent.article to the consumer. Such waste materials may Constitute or be incorporated in a supply feed roll embodying the present invention.

The hydrophobic material may be formed from fused thermoplastic synthetic .polymer material. The fused material may enhance the effective fibre length of the pad, relative to the shorter hydrophilic fibres. The fused material may provide a more cohesive pad which has a greater absorbent capacity and loft.

The hydrophobic material may be fused in the supply feed roll and enhance the structural integrity of the roll. -4•13 0 4 2 The invention may be performed in various ways, and several embodiments will now be described by way of example with reference to the accompanying drawings in which:Figure 1 is a fragmentary plan view of an absorbent article, namely a disposable diaper, having an absorbent pad embodying the invention of said Patent No. 45041 ; Figure 2 is a fragmentary cross section taken along the line 2-2 of Figure 1; Figures 3ja and 3ti are fragmentary and somewhat diagrammatic elevational views, partly broken away, of an apparatus for making supply feed rolls, embodying the present invention; Figures 4a and 4b. are fragmentary top plan views, partly broken away, of the apparatus of Figures 3£ and 3b.; Figure 5 is an eleyational view of a feed roll winding portion of the apparatus shown in a different configuration from that illustrated in Figures 3b. and 4b.; and Figure 6 is a fragmentary elevational view illustrating apparatus for making disposable absorbent pads from a plurality of feed rolls. This apparatus is the subject of Patent No. .45044 which also has been divided from Patent No. 45041 .

Although for convenience the present description relates to disposable diapers and their manufacture, it will be understood that the absorbent articles may be of other types, such as sanitary towels or maternity napkins. Also, in the description below relating to the manufacture at least in part from waste materials of absorbent pads embodying the invention which is the subject of Patent No. 45041 , it will become apparent that the finished articles may be made from waste absorbent articles of the same type as the finished articles, or from waste absorbent articles different from the finished articles.

Referring now to Figures 1 and 2, there is shown a disposable diaper 20 having a fluid-impervious backing sheet 22, a fluid-pervious cover or top sheet 24 and an absorbent pad 26 between the backing and cover_............- _ -522 and 24, respectively, such that the backing sheet 22 covers the back surface 28 of the absorbent pad 26 while the top sheet 24 covers at least a portion of the front surface 30 of the pad. The backing sheet 3. 22 has side margins 32 which are folded over and secured to the sides of the top sheet 24. The diaper also has a top wadding sheet 34 between the front surface 30 of the pad 26 and the cover sheet 24, and a back wadding sheet 36 between the back surface 28 . of the pad 26 and the backing sheet 22. The wadding sheets 34 and. 36 serve to maintain the structural integrity and prevent balling of the absorbent pad 26 when ths pad becomes wet during use, The diaper 20 also has a pair of conventional . tape fasteners 38. The fasteners 3θ have a backing 40 with adhesive 42 coated on one surface of the s backing. The adhesive 42 on one end 44 of the fasteners 38 is attached to the backing sheet 22 of the diaper, while the adhesive on the other end 46 of the fasteners , Is releasably covered by a release sheet 48. During placement of the diaper on an infant, the release sheets 48 are removed from the other ends 46 of the fasteners 38, and the fasteners are utilized to secure the diaper about the infant. The diaper 20 may be . used in'its flat condition as shown, or may be folded . into a box-pleat configuration, or other suitable configuration, as desired.

The materials utilized to make the diaper are as follows. The backing sheet 22 is made from a thermo30. plastic material, such as polyethylene, while the top - 6 ¢59 42 sheet 24 is made of a nonwoven material which may include up to 20 percent by weight of a hydrophobic binder. Accordingly, the backing sheet is made of a hydrophobic material, while a proportion of the . top or cover sheet 24 is also a hydrophobic material. The remainder of the nonwoven top sheet is a fibrous material. The top and back wadding sheets 34 and 36, respectively, are made of an absorbent cellulosic fibrous material. The backings 40 of the fasteners . 38 may be made of a thermoplastic matei-ial, such as polyethylene, or of paper, while the adhesive 42 may have an acrylic fcr rubber base depending upon the particular characteristics cf the adhesive desired.

The release sheets 48 for the fasteners 38 may be . made of paper having a silicone release coating to provide a limited affinity of the sheets for the adhesive 42 on the backings 40, and permit ready removal of the release sheets from the adhesive.

The absorbent pads in conventional absorbent . articles such as disposable diapers are frequently made from a fibrous absorbent cellulosic material.

The absorbent pads 26 of the diapers 20 of the present .invention have a mass of hydrophilic fibres 50 with .comminuted hydrophobic - materials . 52 dispersed throughout the pad. The hydrophobic materials 52 occupy interfibre spaces defined by the hydrophilic fibres 50, and, due to resiliency of the hydrophobic materials even when wetted, increase the wet resiliency of the pad 26.

. In the absence of the hydrophobic materials, the - 7 hydrophilic fibres would he compacted when wetted and placed under loads, thus closing the interfibre spaces and impairing the absorbent function of the pad. However, the hydrophobic materials dispersed . in the pad assist in maintaining the interfibre spaces of the hydrophilic fibres open when the pad is wetted and placed under loads, thus preventing collapse of the interfibre spaces in the wetted pad, and. enhancing the absorbent function of the pad during extended use . of, the diaper. s Since conventional disposable articles are made from hydrophobic and hydrophilic materials·, as discussed above, the materials of such articles are compatible with the materials required in the absorbent « pads 26 of the present invention. Thus, absorbent articles which are normally discarded as waste in' the manufacture of finished articles, are . utilized in the absorbent pads of-.the present invention by . selecting suitable quantities of the waste materials . for making the pads. The hydrophilic materials contained in the waste articles: constitute at least a portion of the hydrophilic fibres in the absorbent pad 26, while the hydrophobic materials in the waste articles . constitute at least a part of‘the hydrophobic . materials 52 in the pad 26. The hydrophilic materials for the pad 26 may be obtained from the waste absorbent pad, a portion of the waste top sheet, the waste top and back wadding sheets, and possibly the waste backings of the tape fasteners. The hydrophobic materials for . the pad 26 may be obtained from the thermoplastic backing - 8*330 42 sheet, the hydrophobic portion of the top sheet, and possibly the backings of the tape fasteners.

It is desirable to make maximum use of the valuable materials contained in such waste articles, and, accordingly, the waste articles are used, as available, in making the new pads 26, since the materials would otherwise be discarded. When such waste materials are not available in sufficient quantity the pads 26 may be made in part from virgin or nonwaste hydrophilic and hydrophobic materials, as desired. It is also contemplated that waste articles which contain the pads 26 described and claimed in Patent No. 45041 , may be utilized to make further articles, by controlling the relative proportion of the hydrophobic and hydrophilic materials in the resulting finished articles. The desired structure of the absorbent pad 26 which is the subject of Patent No. ,45041 , containing relative proportions of hydrophilic and hydrophobic materials appropriate to achieve the desired characteristics of the pad, will be described in detail below.

Turning now to Figures 3a and 4a, an apparatus 60 is illustrated for making supply feed rolls, embodying the present invention, which feed rolls are utilized in making the absorbent pads 26 for the diapers 20.

As shown, the apparatus 60 has an endless conveyor belt 62 supported by a pair of rollers 64a. and 64b, the roller 64b_ and the belt 62 being driven by suitable drive means 66, such as a motor. The belt 62 has a length such that sufficient space is provided for -9placement, of bulk raw materials 68, w5iic)i are utilized to make tbe feed rolls, on an uncovered region 70 of at least part of the belt 62. As previously indicated, /the raw materials . 68 - are waste materials which have been rejected . from the manufacturing line, and may be/delivered to the apparatus 60 from the lines in various lengths, depending upon the condition during manufacture which caused the articles to be rejected. As desired, bulk waste or virgin hydrophobic and hydrophilic materials . may be placed, on the conveyor belt 62 at the region ?0s either separately or in combination, and in relative proportion appropriate to achieve the desired, proportions of hydrophobic and hydrophilic materials in the feed, rolls, and ultimately in the absorbent pads.· . ' The raw materials 68 are moved by the belt 62 toward a paddle 72 having a plurality of blades 74.

The paddle 72 is rotably driven by drive means 76, such as a motoi*, in a clockwise direction in Figure 3a, such that the ends of the blades 74, whioh are spaced . slightly from the belt 62, repetitively return an excess portion of the materials 68, if any, back toward the placement region 70 of the belt 62. Accordingly, the paddle blades 74 serve to limit the quantity of bulk materials which are passed beneath the paddle 72, . in order that a manageable amount of materials will be transported to shredding means, described below.

The materials 68 which pass beneath the blades 74 of -the paddle 72 are transported by the belt to a pair of spaced rolls 78 which are driven by drive means . 80, such as a motor, in opposite directions as indicated - 10 α 3 Ο 4 a by the direction of the arrows in the drawings. The materials 68 thus pass into the nip 82 between the rolls 78, where the materials are held while a shredder 84 tears the materials into relatively small hydro5. phobic and hydrophilic particles 85- The shredder 84 may be of any suitable type, such as a device having a plurality of spaced blades 88 mounted on a rotatable shaft 90, the blades 88 having projecting teeth 92 spaced around the periphery of the blades. The shaft . 90 and the blades 83 are rotated by drive means 86 in a counterclockwise direction in Figure 3a, such that the teeth 92 rip apart or shred the materials retained by the rolls 78, the shredded, particles collecting in a ehamoar 94 below the blades 88.

, As will be explained below, the shredded particles will tee later reduced to particles or fibres of yet smaller size. For convenience, various terms such as shredding, fiteerising and comminuting, will be used interchangeably to designate actions producing a . similar result, viz., breaking down and reducing the materials, such as pieces, particles or fibres, to particles or fibres of a smaller average size. This result may be accomplished by suitable devices which tear apart, shred, rip, pulverize,'or perform similar . functions. Such devices include shredders, hammermills, fiberizers, pin cylinders and other devices of similar nature designated by various terms in the art.

A closed air transport system 96 is provided for moving the particles 85 from the chamber 94 to a cyclone . separator’ 98, while preventing the particles from 1. * escaping to the atmosphere. A blower 100, driven by drive means 102 through belts 103, draws the particles from the chamber '94 through a connecting conduit-104, and blows the particles through a vertical conduit . 106 and a horizontal conduit 108 into the separator 98.

As shorn in the drawings,' the air and particles are moved in a generally spiral path inside the separator 98, such movement being induced by the air . arriving in the separator from the blower 100 and by air blown by a blower 110 through a conduit 112 into the horizontal conduit 108 and thence into the separator 98. As the entrained particles of various 3ize are driven in this circular path, the heavier particles ) . 15. move toward the central region of the separator 98, and eventually settle into a lower chamber 116, where ‘ they are collected. At the same time, the lighter ·' . particles, such as powder and dust, move to the outer « portion of the'circular trajectory, and eventually ί -, ... i, 20. pass through , a tube 118 to a filter 120 where they are collected, while the filtered air passes into ’ ’ the atmosphere through an exhaust tube 122.

The heavier particles are thus separated and deposited in the chamber 116 adjacent one end of an . endless horizontal conveyor belt 124. The belt 124 has a plurality of spikes 126 projecting outwardly from its outer surface... The spikes 126 may be arranged in lateral rows on the belt, the rows being suitably spaced completely around the longitudinal periphery of . the belt.' As shown, the belt is supported by a pair - 12 <ί £> Ο 4 2 of roller's 128a and 128b, the roller 128b being driven by suitable drive means 130, such as a motor. The particles which are deposited in the chamber 116 collect in a pile on top of and around the belt 124, and the . belt 124 transports them toward an endless belt 132, as indicated by the direction of the arrow in the drawings, which belt is disposed at an acute angle relative the vertical. Thus, so long as particles are located on the upper reach of the belt 124, the I . materials are continuously supplied by the belt 124 to the belt 132. If the particles collect in a considerable pile above the belt 124, the materials adjacent the upper reach of the belt 124 are dislodged from the pile, by the snikes 126, and are moved toward . the belt 132. -Since the belt 124 is slightly spaced from the lower end of the chamber 116, as shown, the spikes 126 on the lower reach of the belt serve to remove materials from below the belt for subsequent transportation to the belt 132.

. The belt 132 is supported by a pair of rollers 134a and 134b, and has a plurality of spikes 136 projecting outwardly from its outer surface in a configuration similar to that described for the belt 124. The belt 132 is driven by suitable drive means 136, . such as a motor, in a clockwise direction, as viewed in Figure 3a, such that the particles supplied by the belt 124 are lifted by-the spikes 136 toward the upper turn of the belt 132. Thus, movement of the belts 124 and 132 result in a supply of particles at the . upper turn of. the belt 132, for a purpose desoribed - 13 below. If a substantial pile of particles has collected in the chamber 116, a general shifting of the pile toward the upper turn of belt 152 will take place.

A portion of the particles which are lifted by . the belt 132 pass over the upper turn of belt 132 to the nip 142 between a pair of rolls 138. However, an endless belt 146, which is supported horizontally by a pair of rollers 148a and 148b, returns an excess portion of the particles lifted by the belt '132 for . subsequent conveyance. The roller 148b and the belt 146 are driven by drive means 149, such as a motor, in a clockwise direction, as indicated by the direction of the'arrow in Figure 3a. The right-hand turn of the belt 146 is spaced slightly from the belt 132 adjacent . the upper turn of the belt 132, Thus, a plurality , of spikes 150 projecting outwardly from the belt 146, which may be arranged as described in connection with the spikes on the belt 124, remove an excess quantity of particles from the belt 132, and drop the excess . particles .on the particle collection above the belt I 124 for subsequent recycling to the belt 132. At the same time, the belt 146 permits a limited quantity ' of particles to pass to the upper turn of belt 132.

Thus, the belts 146 and 132 co-operate to limit the . quantity of particles supplied to the rolls 138. The quantity of particles supplied to the rolls 138 may be. controlled by the relative spacing between the belts . . 146 and 132, and by the rotational speeds of the belts 124, 132 and 146.

. The rolls 138 are driven in opposite directions, ' , ? i . - 14 «3042 as indicated by the direction, of the arrows in Figure 3a, by suitable drive means 140, such as a motor.

Thus, the particles supplied by the belt 132 at the nip 142 of the rolls 133 are passed through the nip - to a fiberizer 152, such as a pin cylinder as illustrated. The quantity of fibres supplied by the rolls 138 to the fiberizer 152 may be controlled, in part, by the spacing between the rolls 138 and by the rotational speed of the rolls.

. The fiberizer 152 is driven in a clockwise direction in Figure 3a by suitable drive means 154, as indicated by the direction of the arrow, and reduces the particles passing from rolls 138 to a finer sise as relatively sma3,l particles, shreds and fibres, . including hydrophobic and hydrophilic materials. The fiberizer 152 also deposits the comminuted particles or fibres at a location 162 on the upper reach of an endless screen 1'56 as a fibrous mass. The screen 156 is supported by a .pair of rollers 158a and 158b, the . screen 156 and roller I58b being driven m a clockwise direction in Figure 3a by suitable drive means 160, such as a motor, such that the fibrous mass deposited on the screen is continuously transported away from the location 162, the fibrous mass being formed as a . fibrous layer or web 163 on the upper reach of the screen 156.

The blower 110 is connected through a conduit 164 to a vacuum inlet plate 166 which is supported beneath the upper reach of screen 156 in the location . 162, and serves as a source of vacuum. Thus, air is - 15 Γ I draw through the screen into the plate 166 throughout a longitudinal region of the screen at the location 162, and the vacuum thus draws the fibrous mass passing from the fiberi2er 152 against the screen.

· The thickness of the fibrous web 163 formed on the screen 156 is partly determined by the rotational speed of the screen 156, since a greater thickness of fibres will be collected on the screen at slower speeds of: the screen, while a lesser thickness of the . fibres will collect on the screen at higher speeds.

Also, the thickness of the web formed on the screen 156 may he controlled hy the blower 110, a higher degree of vacuum drawing an additional amount of fibres onto the screen,, resulting in a thicker web . on the screen. As explained below, the thickness of the web formed on the screen 156 ultimately determines the basis weight of the feedrolls formed by tne apparatus 60. Thus, the thickness of the web 163 and the basis weight of the feed rolls may be controlled . in various manners, as described above, by making suitable adjustments to the following: (a) the rotational speeds of the belts 124, 132, and 146; (b) the spacing between the belts 132 and 146; (c) the rotational speeds and spacing of rolls 138; (d) « the rotational speed of screen 156; and (e) the degree of vacuum produced by the.blower 110.

An excess of fibres from the web 163 may pass into the plate 166 due to the vacuum created by the blower 110. Such fibres pass through the conduit 164, . the blower 110, and the conduit 112 into the horizontal r- 16 conduit 108 and the separator 93, where they are again separated into heavier and lighter part:.'iclo3, as previously described. As the. fibrous ue'<> 163 on the screen 156 is transported a’-ay from the · fiberizer 152 and the location 162, any excess or loose particles or fibres from the web are removed by a relatively slight vacuum supplied by a blower 114 · through a conduit 170 to a vacuum inlet member 168, which is spaced slightly above the web 163 laterally . across the screen. The degree of vacuum is sufficiently small not to lift the web 163 from the screen 156. The loose fibres are transported through the conduit 170 and the blower 114 to the chamber 116 for subsequent passage to the’fiberizer 152.

. As illustrated·in Figures 3b and 4b, the fibrous web 163 is transported by the screen 156 onto an endless belt 172 which has asomewhat steeper slope than the screen 156. The belt 172 is supported by a pair of rollers 174a and 174b, tne roller 174b and * ** ί ** . the belt being driven by suitable drive means 176, such as a motor, in a clockwise direction in Figure 3b, such that the fibrous web 163 is moved toward the upper turn of the belt 172. A spraying device 178 sprays a liquid, such as water, onto the fibrous web . 163 as it is moved on the belt 172, in order to wet the web and facilitate integration of its fibres during a subsequent calendering procedure, as will be described below.

The fibrous web 163 then passes between a pair . of slightly spaced endless belts 180 and 182 v/hich compress the web and. reduce its loft. The belt 180 is supported by a pair of rollers 184a and J84b, while the belt 182 is supported by a pair of rollers 186a and 186b, the rollers 184b and 186b and belts . being driven in opposite directions by suitable drive means 188, such that the web is transported through the spacing between the belts 130 and 182 while being compressed.

A web 190 of tissue is unwound from a roll 192 . supported on a stand 193, end passes over a roller 194 to a location between the fibrous web 163 and the belt 182, suoh that the tissue web 190 is placed against the lower surface of the fibrous web 163.

If desired, a second web 196 of tissue may be placed . against the upper surface of the fibrous web 163, the tissue 196 being unwound from a roll 198 and being passed over a roller 200 to a location between the fibrous web 163 and the belt 180. Thus, the web 163 may be placed on a single tissue 190, or may be placed . between the tissues 190 and I96, as desired. In either event, the tissue serves as a carrier and surface structure for the fibrous web 163 after it passes from the belts 180 and 182.

The compressed fibrous web passes . through the nip 210 between a'pair of metal rolls 204 and 206 in a calender 202. The calender rolls 204 and 206 are driven in opposite directions by suitable drive means 208. The rolls 204 and 206 are also heated by a suitable means 211, such as a heat transfer system . for each roll utilizing hot oil to generate the desired - 18 ¢3043 temperatures at the surfaces of tho rolls.

Thus, the fibrous web ii. simultaneously heated and compressed by the calender rolls 204 and 206 as it passes through the nip 210 of the calender 202 - resulting in formation of a compacted web passing from the calender. The'compaction of the fibres in the web is facilitated by the liquid added to the web by the spraying device 178. Also, since a portion of the hydrophobic materials in the fibrous web are , ’ thermoplastic, the heated rolls 204 and 206 fuse the thermoplastic hydrophobic materials in the compressed web and bind the fibres together to provide structural integrity for the compressed web in addition to that provided at the surface of the . compressed web by the tissue lgO or tissues 190 and 196. and The compressed / compacted web is then passed around the outer surface of the roll 206 to a second calender 212 where the web is again heated and further . compressed. As shown, the calender 212 has a pair of rolls 214 and 216. which are driven in opposite directions by suitable drive means 218. The rolls 214 and 216 are also heated by the heating means in a manner as described in connection with the calender . 202. If desired, the calenders 202 and 212 may be operated at different temperatures, and, in a configura tion found suitable, the surface temperature of the rolls 204 and 20$ of calender 202 may be approximately ISO to 300°?, while the surface temperature of the roll . 214 and 216 of calender 212 may be approximately 300 to - 19 400°F.

The compressed web then passes from the nip 220 of the rolls 214 and 216 to a knife-over-roll device 221 where the web may be slit, if desired. The device . 221 has a roller 222 which provides a supporting surface for the web while it is being slit. The device 221 also has a rotatably mounted disc blade 224 which may be moved into position against the web to perform the slitting operation. The blade 224 . may be selectively moved to a vertical location spaced from the web by suitable means if the web is not to be slit. As explained below, when the web is slit by the device 221 a plurality of feed rolls are simultaneously formed, while a single feed roll is formed . if the web is not slit. More than two webs may be formed, as desired, by providing a suitable number of knife-over-roll devices, or other slitting means, spaced laterally across the web.

An apparatus 225 for winding feed rolls comprises . a pair of· laterally spaced fork members 232 pivotally mounted on a table 240 by pivotal supports 234. The fork members 232 may be moved hetween an upright position while formation of a feed roll is initiated, as.show in Figures 3b and 4b, and a horizontal posi25. tion during a later stage of the winding procedure, as show in Figure 5. The apparatus 225 .has a plurality of mandrels 226 on which the feed rolls are wound.

As illustrated in Figures 3b and 4b, each of the fork members 232 has a pair of tines 230 to receive the ends . of the winding mandrels 226 while the fork members are - 20 <£•3042 in an upright position. Subsequently, the ones of the mandrels 226 are supported on a surface 238 provided by a pair of spaced arms 239 in the table 2.40. The apparatus also has a resilient surface . winding roll 236 which is mounted for· rotational movement and driven in a clockwise direction in Figures 3b and 5' by suitable drive means 242.

The formation of feed rolls by the apparatus from the compressed web is as follows. If the web . has been slit by the device 221, a plurality of paper cores 228 corresponding to the widths of the slit webs are placed on a mandrel 226. If the web has not been slit, a single paper core is positioned on the mandrel 226. Next'the fork members 232 are . placed in their upright position, as shown in Figures 3b and 4b, and the mandrel 226 containing the core or cores 228 is positioned in the tines 230 of the fork members, while the end of the compressed web or slit webs is wound in a counterclockwise direction . around the paper core or cores one or more turns, such that the web lies between the mandrel and the surface of the winding roll 236.

The openings defined by the tines 230 are sufficiently deep to permit the mandrel 226 to bear . against the winding roll 236. Accordingly, the outer surface of the winding roll 236 friotionally engages the web, and surface movement of the roll 236 is imparted to the web and mandrel 226 through the core or cores 228. Since the mandrel is permitted . to rotate'in the tines 230, the rotational movement of - 21 1 the winding roll 236 in the clockwise direction results in a corresponding counterclockwise rotation of the mandrel 226 while the web is wound on the mandrel, · As the web is thus wound onto the mandrel, the dia5. meter of the new feed roll on the mandrel is gradually increased, such that the distance between the mandrel and the winding roll 236 is increased. However, the . new feed roll continues to bear upon the outer surface of the winding roll 236, thus maintaining . frictional engagement between the outer surface of the winding roll 256 and the web, resulting in initial formation of the feed roll while the mandrel 226 rises relative the winding roll 236.

Prior to the time·at'which·the mandrel 226 is 15. located at a position above the tines 230, a completed feed roll 244, which has the ends of its mandrel 226 resting on the support surface 238, is removed from the table 240 for storage and subsequent use. After the feed roll 244 has been removed, the fork members . 232 are moved to their horizontal position, as shown in Figure 5, such that the mandrel 226 of the new feed roll 246 rests upon the support, surface 238 of the table 240. In this configuration, the tines 230 of the fork members are located in a position to permit . freedom of movement and rotation of the mandrel 226 along the support surface 238.

Additionally, the new feed roll 246 continues to bear against the cuter surface of the winding roll 236, such that frictional engagement between the web . and the Winding roll is maintained, resulting in continued - 22 -33042 winding of the feed roll 246 while the feed roll and mandrel 226 rotate in a counterclockwise direction. As the diameter of the feed roll 246 increases, the axis of the mandrel is displaced toward the right of the table 240, as viewed in Figure 5. After a sufficient length of the web has been wound onto the mandrel, the web is severed transversely across the web, the fork members 232 are again pivoted to their upright position, as previously described in connection with Figures 3b and 4b, another mandrel is placed in the tines, formation of a new feed roll is initiated, and the completed feed roll is removed from the table. If the web has been slit into a plurality of webs by the device 221, a corresponding number of feed rolls are simultaneously formed on their respective paper cores.

Thus, feed rolls embodying the present invention are made by the apparatus 60 from an initial supply of bulk hydrophilic and hydrophobic materials. The waste materials are converted into a compressed web containing the hydrophobic and hydrophilic materials, and the compressed v/eb is wound into feed rolls for convenience in handling during storage and subsequent use in apparatus according to the invention which is the subject of Patent No. 45044 for making disposable absorbent pads embodying the invention Patent No. 45041 as described below.

To summarise the method described,a source of waste or bulk hydrophobic and hydrophilic materials is thus shredaedby a shredder into particles, while limiting the quantity of the materials supplied to the shredder. The shredded particles are transported by air from a first shredding location to a -23second separating location where the lighter and heavier particles are separated. The shredded particles are moved hy air in a generally circular path, the lighter particles are removed from the . path and are discarded, and the heavier particles are collected.

The collected heavier particles are transported to a fiberizer. where the particles are comminuted or fibei'ized into a fibrous web containing a mixture . of hydrophobic and hydrophilic materials, while limiting the quantity of particles supplied to the fiberizer. The comminuted particles passing from the fiberizer are placed on a movable member which provides,an endless supporting surface at the loca15. tion of placement, while moving the member relative to the location to form a layer on the member as the fibrous web.

The comminuted particles are drawn against the member by a source of vacuum, and the thickness of .- the fibrous web may be controlled by controlling the vacuum source to control the rate at which the particles are.drawn against the member by the source. The thickness of the fibrous web may also be controlled by controlling.the rate of movement of the member . relative the. location of placement on the member.

Excess fibres may be returned from the fibrous web to the circular path or to the collection of heavier particles.

Next, the fibrous web is wetted and placed against . a carrier* web, after which the web is compressed to ·- 24 reduce its loft. The web is then simultaneously heated and compressed one or more times to produce a compressed web in which the thermoplastic fibres are fused. The compressed web is wound into feed rolls subsequent to a slitting procedure, if desired, to vary the width of the feed rolls formed.

An apparatus 258 for utilizing the completed feed rolls 244 for making absorbent pads containing a mixture of hydrophilic and hydrophobic fibres is described in connection with Figure 6. This apparatus is the subject of the above-mentioned Patent No. 45044 .

The complete feed roll 244 is supported for rotational movement, such that the compressed web may be unwound from the roll 244 and passed into a fiberizing or comminuting apparatus 250, such as a hammermill. One or more additional feed rolls 252 containing a compressed web of virgin hydrophilic materials may also be supported for rotational movement, in Order that their webs may be unwound and passed into the apparatus*250 which simultaneously comminutes the compressed webs from the feed rolls 244 and 252. The apparatus thus reduces the webs to fibres or particles of hydrophobic and hydrophilic materials, and forms a fibrous web 254, which is passed onto an endless conveyor belt 255, supported and driven by a pair of rollers 258£ and 258b.. A carrier web 260, such as cellulose wading, is unwound from a roll 262, passed over a roller 264, and placed against the fibrous web 254 between the web 254 and the belt 256. The fibrous web 254 and the carrier web 260 then are transported by the belt 256 to an apparatus 266 of known type which -25cuts and forms tha webs into sections as absorbent pads. The pads, containing a mixture of hydrophobic ' and hydrophilic materials, are then made into suitable disposable articles such as diapers.

. . Thus, the feed roll 244 may be used in conjunction with feed rolls containing solely hydrophilic materials to form a fibrous web which is cut into sections as absorbent pads for the articles.

The relative proportions of the hydrophobic and . hydrophilic materials contained in tha pads may be determined in a number of manners, Initially, the relative amounts of the webs from the feed roll 244 and the other feed rolls 252 pulverized by the apparatus 250 may be controlled by the number of » hydrophilic feed rolls 252 utilized simultaneously with the feed roll 244. Also, the width of the feed roll 244 relative the width’of the feed rolls 252 may be controlled by the slitting device 221 described in connection with Figures 3b and 4b. Thus, varying . widths of feed roll 244 relative to a given width of the rolls 252 will result in corresponding varying proportions of the feed roll 244 and hydrophobic materials being introduced into the fibrous web 254 and absorbent pads.

· Additionally, as described in connection with Figures 5a and 4a, the thickness of the fibrous web 163 formed on the screen 156 may be suitably modified to control the thickness and basis v/eight of the compressed web which is formed into the feed rolls.

. Thus, as shown in Figure 6, the thickness of the compressed web from the feed roll 244 relative to a I - 26 a given thickness >of tho v;ebs in ths rolls 252 '-.ill also determine tne relative amount oi hydrophobic materials introduced into the fibrous web 254 and absorbent pads. Finally; the relative amounts of . hydrophobic and hydrophilic materials introduced into the feed roll 244·,' and thus into the pads, may be controlled by determining the relative proportions ofhydrophobic and hydrophilic materials placed on the belt 62 as the source of raw material 68, as . described in connection with Figures 3a and 4a, As already indicated;· at least.part of the bulk raw materials. 68 -are obtained from materials or articles which were previously rejected as waste from the . manufacturing line. Accordingly, for convenience in discussion below the raw materials 68 will be designated as waste articles, and the various components which constitute the waste article will be preceded by the term waste, -e.g. waste backing sheet, and . waste absorbent pad. The hydrophilic and hydrophobic materials contained in the web of the feed roll 244, described in connection v.dth Figure 6, may be termed waste feed material; while the hydrophilic material contained in the feed rolls 252 will be called virgin . feed material. The newly formed absorbent pads containing a mixture of hydrophobic and hydrophilic materials will be designated a new absorbent pad or new pad, while the completed absorbent article or diaper containing the new pad will be termed the new . absorbent article or new diaper, the components of - 27 the new article being preceded by the word new, e.g. new backing sheet.

Since the waste articles are converted to the waste feed material, the relative proportion of the . waste components contained in the waste article will be similar to that contained in the waste feed material. Accordingly, the relative proportions of hydrophobic and hydrophilic materials contained in ths waste feed material will be similar to the proportions of . the same materials contained in the waste articles. > Since the relative proportions of the waste and virgin feed materials introduced into the new absorbent pads may be determined, the proportions of the hydrophobic and hydrophilic materials contained in the new pad or . article may also be calculated.

As noted above, the various components of the waste article, such as the waste hacking sheet or pad, may he classified generally as being a hydrophobic or hydrophilic material, or as a material containing . known proportions of hydrophobic and hydrophilic materials, such as the top sheet. Accordingly, in determining the relative amounts of hydrophobic and hydrophilic materials in the new absorbent pads, it is convenient first to calculate the relative . quantities of the waste components introduced into the new pads or articles, which may be accomplished according to the following formulae: . where, W’ = Weight of particular waste component in cn a new article; Wtcn - Torsi weight of waste components in tho new article; 'cw = '/eight of the same component (V ) i« tha waste article; and 5. = Total weight of waste article. However, since W-fccn “ (Wtpn), then . (3) Wcn = (Wtpn) (ptcn). (ffcw) \ ’fcW) t where, ^tpn = weight of new absorbent pad; and Pt = (Wtcn)/(Wtpn) = proportion of waste and 15, 'x total materials In the new pad, or proportion of waste feed materials and total feed materials introduced into the new pad.

Additionally, . (4) Pcn = (W?n) (100) ' (WtpnJ Γ where P = Percentage by weight of the waste comc ponent in. the new pad relative the . total weight of the new pad) As an illustration, standard size waste diapers having a total weight of 33.5 grams may be utilized to make the new absorbent pads for the diapers or other„disposab1e articles. The weight of the . various components in each waste diaper is set forth in the following table: TABLE I Component Absorbent pad · Top Sheet Backing sheet V/eight (grams) 2.7 4.2 . - 29 0° Tape Fasteners Wadding Sheets 1.1 4.5 The percentage'of waste feed materials relative the total amount of feed materials introduced into the . new pad is selected to be 12 percent, and the weight of the new absorbent pads is also 21 grains. Accordingly, the weight of a given waste component, say the backing sheet, may be calculated from formula (3) as follows: · wcn = = 0.3i6g (33·5g) Thus,. the weight of the waste backing sheet contained in the new absorbent pad is 0.316 grams It will be apparent that the percentage by weight of the waste . backing sheet in the new absorbent pad is 1.5 percent, as determined by formula (4).

The weights and percentages of the various waste components in the new pad may be determined in a similar fashion, and are set forth in the following table: . TABLE II Component Weight in Waste Article (grams)....... Weight in New Fad Percentages of Component in New Pad Absorbent pad 21 1.580 7.52 Top sheet 2.7 0.203 0.97 Backing sheet 4.2 0.316 1,50 Tape Fasteners 1.1 0.083 0.40 Wadding Sheets 4.5 0.339 1.61 Total -33.5 . 2.521 12.00 . The total weight of the waste components in the new pad is 2.521 grams, and the percentage of total - 30 *3043 waste components in the new pad is 12 percent, as expected.

The relative quantities oi hydrophobic and hydrophilic materials in the new pad nay he readily . determined as follows. Assuming that the waste tape fasteners have a polyethylene hacking, the new absorbent pad will include approximately 0.083 grams of hydrophobic material, as contributed hy the fasteners including adhesive, Next, it is assumed that the . waste top sheet contains 20 percent hy weight of a hydrophobic binder, while the remainder of the top sheet is made of a hydrophilic material. Thus, it may he determined in connection with Table II that the weight of the hydrophobic portion of 'the top sheet · contained in the new pad is 0.041 grams. Finally, the weight of the hydrophobic backing sheet in the new pad has been determined as 0.316 grams. Accordingly, the total weight of hydrophobic materials in the new pad is the resulting sum of 0.440 grams, , while the remainder of the new pad is composed of hydrophilic materials, including waste and virgin feed materials, and has a weight of 20.56 grams.

Thus, the percentage by weight of the hydrophobic materials in the new pad to the total weight of the . pad is approximately 2.1 percent, while the percentage by weight of hydrophilic materials in the new pad is approximately 97-9 percent. It will be apparent that the percentage by weight of the virgin hydrophilic feed materials in the new pad to the total weight of . the pad is 88 percent, the weight of the virgin materials contained, in each of the new pads being approximately ι 18.48 grams. 1 As previously described, it is desired to place an amount of the hydrophobic materials in the new pad . such that the wet resiliency of the new pad or new article when placed under loads is increased, although the relative proportion of the hydrophilic materials in the nevz pad should not be decreased to an extent at which the total absorptive capacity of the pad is . impaired. It has been found that a suitable balance between tho hydrophobic and hydrophilic materials in the new pad to achieve these functions may be obtained by selecting the proportion by weight of the hydrophobic materials in the new pad to the total weight . of the pad to he in the range of 1 to 15 percent, while the proportion of the hydrophilic materials by weight is in the corresponding range of 85 to 99 percent. Although the proportions of the waste components contained in a given waste article will vary . somewhat depending on the structure of the article, the preferred proportions of the waste components from an average sized disposable diaper placed in the f . . » new pad of a similar diaper, as determined hy the ratio of the waste component weight in the new pad to the . total weight of the new pad, is set forth as follows: waste absorbent pad, 3»5 to 17.0 percent; waste top sheet, 0.5 to 2.5 percent; waste backing sheet 1.0 to 3.0 percent; waste tape’fasteners 0.1 to 1,0 percent; . / and waste wadding sheets 1.1 to 3.2 percent. A pre- , ti . ferred proportion by weight of the waste feed material - 32 to the total feed materials is in the range from 5.0 to 25.0 percent, while the corresponding proportion by weight of the virgin feed materials to the feed materials is in the range from 75.0 to 95.0 percent.

The thermoplastic hydrophobic materials, such as polyethylene, are fused into the feed rolls before these materials are comminuted into the new pads When the fused materials are comminuted along with relatively short hydrophilic fibres in the feed roll, the effective fibre length is increased to a greater extent than such a mixture with non-fused hydrophobic materials which is believed attributable to fusing to the thermoplastic materials of the hydrophilic fibres.

The longer fibres thus formed produce a pad with increased structural integrity, and greater absorbent capacity and loft.

Claims (1)

1. CLAIMS A supply feed roll for use in the formation of a disposable absorbent pad, comprising a compressed web having a mass of hydrophilic fibres with 5 comminuted hydrophobic film or strip material dispersed throughout the thickness of the web in interfibre spaces defined by the hydrophilic fibres, at least part of the hydrophobic material being comminuted thermoplastic film or strip material of a comminuted waste absorbent article which included that film or strip material, said web being wound into said roll.