IE46148B1 - Methods of making feminine hygienic pads - Google Patents

Description

This invention relates to feminine hygienic pads.

The term feminine hygienic pads as used herein is intended to denote a pad which can be used to absorb uncontrollable body discharges, for example by insertion in the interlabial space.

Feminine hygienic pads can, for example, be used by females to absorb uncontrolled discharges, such as urine, vaginal secretions, post-coital leakage, or menstrual staining.

Such pads must be carefully made of certain soft layered or non-layered materials and in some versions with filler materials so that certain dimensions of the pads are maintained. Such pads have in the past been difficult and relatively expensive to produce.

According to the present invention there is provided a method of making a feminine hygienic pad to absorb uncontrollable body discharges from a material of a predetermined width with opposed first and second longitudinal edges and opposed faces by inwardly folding one or more times said first longitudinal edge over one face of the material to provide a fold formed along an anterior leading edge and a first outer panel, inwardly folding one or more times said second longitudinal edge over said one face to form a second outer panel extending from a fold line defining a posterior edge of the second outer panel to an 614 8 opposite edge of the second outer panel along a line short of said anterior leading edge and stitching said second panel to said first outer panel and the underlying material by only a single row of stitching, said single row of stitching being adjacent the said opposite edge so that the pad has an anterior portion having the anterior leading edge and a wider posterior portion having the posterior edge.

In another aspect the present invention provides a feminine hygienic pad to absorb uncontrolled discharges formed of a sheet of material about a first line nearer one longitudinal edge to define a first folded panel having a first folded edge at said first line, and about a second line nearer to the other longitudinal edge to define a second folded panel having a first folded edge at said second line, said first and second panels being folded onto one side of said material, and one of said folded edges being placed adjacent to the folded edge of the other panel to define an anterior portion and a relatively wider posterior portion, and a single row of stitching along the line of said one folded edge for securing said one edge so that the free ends of said first and second panels remain unattached.

In order that the invention may be more clearly understood the following description is given merely by way of example with reference to the accompanying drawings in which: Figure 1 is a perspective view of a roll of layered material used in the making of the feminine hygienic pads; Figure 2 is an enlarged sectional view of a four layered material of the roll of material shown in Figure 1; Figure 3 is a perspective view of one fold of the layered material; - 4 Figure 4 is a perspective view of another fold of the layered material; Figure 5 is a perspective view of the folded material folded upon itself leaving a longitudinally narrow panel and leading edge; Figure 6 is a perspective view of the folded material shown in Figure 5 stitched adjacent its leading edge creating the complete geometric form of the first version of the pad; Figure 7 is a perspective view of the long pad after folding and stitching but before it is cut into the desired pad lengths; Figure 8 is a perspective view of another or second form of the material showing the manner of folding such material during the method of making the pad; Figure 9 is a perspective view of the material folded in four panels, shown in Figure 8, wrapped around a filler and stitched and finished as a pad; Figure 10 is a perspective view of a pre-shaped pad of pressed material used as an inner core for a pad; Figure 11 is a perspective view of the core shown in Figure 10 with a folded material wrapped around the core prior to stitching; Figure 12 is a perspective view of the core and the outer folded material shown in Figure 11 stitched and finished as a pad; Figures 13 and 14 are perspective views of other preshaped pads of pressed material that may be used as inner cores for the pad in place of the core shown in Figure 10; Figure 15 is a perspective view of the fourth form of the material showing the manner of folding such material during the method of making the pad; - 5 Figure 16 is a perspective view of the material as the next step of the folding operation; Figure 17 is a perspective view of the folded material of Figure 16 stitched together at its abutting edges and through the pad creating the complete geometric form of the fourth version of the pad; Figure 18 is a perspective view of the fifth form of the material showing the manner of folding such material during the making of this pad; Figure 19 is a perspective view of the material as the next step of the folding operation; Figure 20 is a perspective view of the folded material of Figure 19 stitched together at its abutting edges and through the pad creating the complete geometric form of the fifth version of the pad.

In a first method according to the invention of making hygienic pads, a flat piece of material 11 comes off a roll 10 or a folded bale generally commercially made about fortytwo or sixty inches wide; however, such rolls of material may be made in any width desired. The material is then cut to about 2 1/4 inches wide, as shown in Figure 1. Two methods of cutting may be used, namely the material of roll 10 may be cut laterally as it is unrolled, or the cut may be longitudinally through the roll. The material 11 of roll 10 is preferably comprised, as shown in Figure 2, of four to eight plies of a suitable cotton gauze, a synthetic material, or blend such as of cotton and cellulose fibres. The flat material 11 may be of a suitable thickness, such as 1.5 mm or 1/32 inch for four ply and 3/32 inch for eight ply material with an outer layer of cotton gauze 12 and inner layers 13 of pressed cotton, or other cellulose fibres. - 6 The steps of the method consist of folding the material along a line nearer one longitudinal edge (the right one as shown) about 5/8 inch from the edge, as shown in Figure 3 to create a panel 14 and an anterior leading edge 15. Another fold is made nearer the left longitudinal edge about 1/2 of an inch wide, as shown in Figure 4, to create the first part of an outer panel 16. The panel 16 and the material beneath it are folded over again to provide the posterior panel or portion 17, as shown in Figure 5, having an edge 19. A folding attachment (not shown) associated with a sewing machine can make the folds hereinbefore described automatically. Such folding attachments for sewing machines are known in the art and a special attachment for the special dimensions and number of folds desired can be readily made. Simultaneously, as the material is folded and fed beneath the presser foot of the sewing machine (not shown), the material 14, 16, 17 and 20 is stitched vzith a fine continuous zig-zag stitching line 18 about 1/8 inch from the leading edge 15 to fasten the edge 19 of the posterior portion or panel 17 to panel 14, thus defining the anterior leading edge 15 as a fixed portion about 1/8 inch in width to complete the geometric form as shown in Figure 6. Since the material used is taken from the roll of material 10, shown in Figure 1, the folded and stitched unit consists of a long pad, as shown in Figure 7 which is then cut into the small pads of the desired size, preferably of about two inches in length, as shown in Figure 6. .These short pads, shown in Figure 6, are then ready for further processing and eventual packing for delivery to the distributors.

In a variation of this method of folding the material, the panel 14 is again created by folding the material near its right longitudinal edge, about 5/8 of an inch therefrom. Λ6148 - 7 as shown in Figure 3, but the panel 16 is created by making a fold at the left longitudinal edge about 1 inch wide.

The panel 16 and the material beneath it is again folded over upon itself, to provide the posterior portion 17, about a line within such panel however rather than about a line generally coincident with the folded over free edge. Thus, the portion 17 is comprised of five filler panels instead of the four filler panels shown in Figures 5 and 6.

Pads of varying numbers of filler panels in the posterior portion 17 and anterior portion 14 can be created by varying the numbers of folds along the right longitudinal edge and the left longitudinal edge of the material. For example, a pad with six filler panels in the posterior portion 17 can be created by folding near the left longitudinal edge of the material 1 1/4 inches and folding it over again on itself to create a panel 5/8 of an inch wide.

The right longitudinal edge is then folded as described in Figures 4 and 5 to provide a posterior portion 17 with six filler panels.

The widths of the fold made along the right and the left longitudinal edges of the material can also be varied to create pads with various numbers of filler panels and varying curvilinear and planar cross-sections of varied thicknesses and pliabilities.

In a second method according to the invention, the folding process is shown in the steps illustrated in Figures 8 and 9. The material is supplied as a roll similar to roll 10 and may be folded over an absorbent or pressed cotton, rayon, viscose, polyester, or cellulose filler 123 to increase the absorptive capacity of the pad.

In such a form, as shown in Figure 9, where the filler material is used, the cotton gauze material 11 may have - 8 fewer layers of fibre so that the resultant pad is not too thick. The method used for making such interlabial feminine hygienic pads is similar to the first method described heretofore, except that a filler 123 is introduced into the material as it is being folded and before the material is stitched together. The filler may be of egg-shaped cross section, as shown in Figure 10, or oval, as shown in Figure 13, or rectangular as shown in Figure 14.

In this second form, as best shown in Figure 8, the material 11 is about 1 5/8 inches wide. The material 11 is folded about a line about 1/4 inch from its right longitudinal edge creating a panel 114 and an anterior leading edge 115. At the left edge, a fold 122 is made about 1/8 inch in width from the left free edge to create the underneath panel 116 as the part of the outer or posterior panel or body 117. The filler material 123, in the form of a ribbon, is fed onto the panel 126, which is only part of the posterior portion, just before the outer or posterior panel 117 with its underneath panel 116 is folded, and is then stitched with a fine continuous zig-zag stitching line 118 about 1/8 inch from the leading edge 115 thus fastening the edge 119 of posterior portion to panel 114 and creating the anterior leading panel 114 and edge 115 to complete the geometric form shown in Figure 9. The long pad with the filler therein, of which Figure 9 shows a small portion, is cut in about two inch lengths and is about 5/8 of an inch in width and comprises the finished interlabial feminine hygienic pad. These pads are packed in desired containers for delivery to distributors.

It is within the scope of this invention to use a pre-shaped pad made from pressed cotton, cellulose, or like material which is then wrapped with a folded gauze material. - 9 In Figures 10, 13 and 14 there are shown pre-shaped pressed cotton or cellulose inner core forms that may have cotton gauze material 211, of which one edge is folded, wrapped around them as shown in Figure 11 which may be referred to as a third form of the invention. This form is then machine stitched as shown in Figure 12 by stitching 218 along the edge 219 of the posterior portion or panel 217 about 1/8 inch from the anterior leading edge 215 creating a narrow leading thin panel 214. The material that wraps around the inner core, such as material 223, is about 1 5/8 inches in width. The first fold on the left side is about 1/8 of an inch wide, the next outer adjacent portion is about 1/2 inch, the outer portion falling below the opposite outer portion is about 5/8 of an inch wide and the last fold, at the right, is about 1/4 of an inch in width. The pad is about 3/8 of an inch thick, about 5/8 of an inch wide and about two inches long. The inner cores shown in Figures 10, 13 and 14 are preferably of the same length as the outer gauze wrapping. The long geometric form, hereinbefore described is cut into lengths of about two inches.

In Figures 15, 16 and 17, a fourth form of the pad is shown which is made by folding under the material 11, which is about 2 5/16 inches wide, near its right longitudinal edge with a fold about 1/16 of an inch in width to create a folded very narrow inner panel 323. The material at the right edge is again folded forming a longitudinal anterior narrow panel 314 having an inner edge 322 and an outer leading edge 315. Panel 323 underlies panel 314. Another fold is made at the left longitudinal edge about one inch in width, as shown in Figure 15 to create the first part of the outer panel or body 316. The panel 316 and the material beneath it is folded over again upon itself to - 10 provide the posterior panel or portion 317, as shown in Figures 16 and 17, creating a leading edge 319 with two longitudinal panels 324 and 325 beneath the posterior panel 317.

Edges 319 and 322 are positioned so that they abut one another. A fine continuous longitudinal stitching line 318, preferably of the zig-zag type, is made through the material, as shown in Figure 17, joining the two abutting edges 319 and 322 together creating the stitched anterior narrow leading panel 314 with its leading edge 315 and the filler panels 324 and 325 between the posterior portions 317 and 320, as shown in Figure 17.

In Figures 18, 19 and 20, a fifth form of the pad is shown which is similar in all respects to the fourth form shown in Figures 15, 16, and 17, except that the panel 325 is omitted. This method is suited for wrapping around a filler as shown in Figures 8 to 14. All the parts are numbered in a similar manner to the parts shown in Figures 15, 16 and 17 except that such parts bear the numbers in the 4001s instead of the 300's. The width of the material 11 as used in the fifth form is about 1 13/16 of an inch instead of 2 5/16 of an inch used in the fourth form of the pad shown in Figures 15, 16 and 17. Panel 423 is about 1/16 of an inch in width, panel 414 is about 1/8 of an inch in width and panel 417 is about 1/2 of an inch in width. The total width of the finished pad, as shown in Figure 20 is about 5/8 of an inch and the length is about two inches.

If desired, the panel 424 can be omitted by enlarging the panel 416 to bring its free edge onto the panel 414. - 11 Instead of gauze as the outer wrapping material for making the pad, a cellulose, or a synthetic material having gauze-like properties may be used.

When using unlayered material which is very thin 5 instead of layered material, the folding processes are the same as hereinbefore described except that the material is pre-folded several times to provide the desired thickness.

When cutting the material and the pads to the desired length, the type of cut can be pressed cut with some pinking so as to minimize the fraying at the cut edges.

Instead of using zig-zag stitching for the different forms, as hereinbefore described, straight chain stitching, or other types of known stitching may be used to hold the outer covering together at their ends to create the leading edges and leading edge panels also hereinbefore described.

It will be understood that the dimensions set forth above may be varied to some extent and that the method steps may also be varied, such as the making of the folds by means other than an automatic sequential folding, filling and stitching operation and that when folding is mentioned, it would include rolling of the material to achieve the desired folding.

Claims (11)

1. CLAIMS;1. A method of making a feminine hygienic pad to absorb uncontrollable body discharges from a material of a predetermined width with opposed first and second longitud5 inal edges and opposed faces by inwardly folding one or more times said first longitudinal edge over one face of the material to provide a fold formed along an anterior leading edge and a first outer panel, inwardly folding one or more times said second longitudinal edge over said one face to 10 form a second outer panel extending from a fold line defining a posterior edge of the second outer panel to an opposite edge of the second outer panel along a line short of said anterior leading edge and stitching said second panel to said first outer panel and the underlying material by only 15 a single row of stitching, said single row of stitching being adjacent the said opposite edge so that the pad has an anterior portion having the anterior leading edge and a wider posterior portion having the posterior edge.

2. A method according to Claim 1, wherein the folds 20 are performed with a folding device.

3. A method according to Claim 1 or 2, wherein the pads are made from a continuous strip of material which is cut into the pads after stitching.

4. A method according to Claim 1, 2 or 3, including 25 the step of inserting a filler material between the folds prior to the stitching.

5. A method according to any preceding Claim wherein said first longitudinal edge is folded inwardly once and said second longitudinal edge is folded twice over a major 30 portion of the width of the material into overlapping relation with the inwardly folded first panel. 4 614 8 - 13

6. A method according to Claim 5, wherein the second fold of the second panel is at its mid-line.

7. A method according to any one of Claims 1 to 4, wherein said second longitudinal edge is folded once across a major portion of the width of the material to bring said second longitudinal edge to a line short of the anterior leading edge, and said second longitudinal edge is stitched to the underlying material inward of the anterior leading edge.

8. A method according to any one of Claims 1 to 4 and 7, wherein said first outer panel has a turned under narrower panel.

9. Methods of making feminine hygienic pads substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.

10. A feminine hygienic pad made by a method according to any preceding Claim.

11. A feminine hygienic pad to absorb uncontrolled discharges formed of a sheet of material folded about a first line nearer one longitudinal edge to define a first folded panel having a first folded edge at said first line, and about a second line nearer to the other longitudinal edge to define a second folded panel having a first folded edge at said second line, said first and second panels being folded onto one side of said material, and one of said folded edges being placed adjacent to the folded edge of the other panel to define an anterior portion and a relatively wider posterior portion, and a single row of stitching along the line of said one folded edge for securing said one edge so that the free ends of said first and second panels remain unattached.