JP2001523537A - Method of bonding materials, especially materials used in absorbent articles - Google Patents

Abstract

(57) Abstract Used in the manufacture of articles, including but not limited to sanitary napkins, pantiliners, tampon-absorbing interlabial devices, diapers, incontinence devices, and absorbent articles such as wipes and the like. A method for bonding materials is disclosed. The disclosed method has many aspects. In one aspect, an improvement is made that allows the method to be used to bond through relatively thick materials (eg, materials having a thickness of 4 mm or more). In another aspect, a method is provided that has the ability to produce a virtually unlimited number of bonding patterns in the material to be bonded. In yet another aspect, the bonding method utilizes a compression step that improves bond formation. In yet another aspect, a bonding method is disclosed that utilizes a step of slitting a material through which a bond is formed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD OF THE INVENTION

Although the present invention generally relates to a method of bonding materials used in absorbent articles, the techniques described herein may be used to bond materials used in other types of articles. In a preferred embodiment, the present invention relates to a sanitary napkin, pantiliner, tampon, absorbent interlabial device.
vice), diapers, and methods used in the manufacture of absorbent articles such as incontinence devices.

[0002]

[Prior art]

Absorbent articles such as sanitary napkins, pantiliners, tampons, absorbent interlabial devices, disposable diapers, incontinence products, and bandages are designed to absorb and retain liquids and other emissions from the human body, as well as to the body and clothing. Is designed to prevent soiling.

In the manufacture of absorbent articles, it is generally necessary to bond the components that together form the absorbent article, to form the final product. Typical methods of bonding such materials include adhesives, heat and / or pressure,
Includes & ultrasonics.

[0004] However, some materials have their structural integrity.
) Or because of their composition, they cannot be bonded with these typical bonding techniques. One such type of material was found on November 9, 1993 in Des
US Patent No. 5,260,345 issued to Marais et al., December 1993.
US Patent No. 5,268,224 issued to DesMarais et al.
And U.S. Patent No. 5,387,20, issued February 7, 1995 to Dyer et al.
No. 7 high internal phase emulsion
s: Alternatively, an absorbent foam material made from "HIPE" foam). Such materials typically have low tensile strength and / or low structural integrity. Bonding to such materials using adhesives is difficult because their structural integrity is often not as strong as adhesive bonds. As a result, only those portions of these materials that are in direct contact with the adhesive will remain bonded to the other materials. The rest of the material will easily separate from the material to which it is bonded. Since such foams are thermoset polymers, such materials cannot be bonded using thermal bonding. Once they are formed, they cannot be re-melted. Instead, when heat is applied to such foam materials, they will carbonize rather than melt and flow as required for thermal bonding. Since thermoset foam materials do not have the ability to flow and fuse under pressure, such foam materials cannot be press bonded as well.

[0005] On September 25, 1984, issued to Haq, "Porous Polymereri
c Material Containing a Reinforcing
U.S. Pat. No. 4,473,611 entitled "And Heat-Sealable Material" describes one conventional effort to bond materials to highly porous polymeric materials prepared by polymerization of highly dispersed phase emulsions. It has been described. The Haq reference discloses the incorporation of a fibrous, granular, or microporous thermoplastic material into such a material, thereby providing it with the ability to form a heat seal. Articles such as wipes sandwich a modified porous polymeric material between two heat-sealable substrates and sandwich the first and second substrates in an intermediate, highly porous polymeric material. It is formed by heat sealing to a heat sealing reinforcing material. However, the method of making the porous polymeric material described in the Haq patent requires the addition of a thermoplastic material.

[0006] Other types of materials used in the manufacture of absorbent articles often comprise thermoplastic materials. Issued to Ball et al. On August 8, 1989, "Dynamic M
Technical Bonding Method and Apparat
U.S. Pat. No. 4,854,984 entitled "U.S. Pat. No. 4,854,984" discloses a method for dynamically mechanically bonding a plurality of thin layers to one another by feeding the thin layers into a pressure-biased nip between a pair of rolls. An apparatus is disclosed. The method described in the Ball et al. Patent has been used with great commercial success. Nevertheless, the search for improved methods of bonding materials continues.

[0007]

[Problems to be solved by the invention]

Thus, there is a need for improved bonding of materials, particularly those used in absorbent articles. For example, for improved methods of bonding materials used in absorbent articles that cannot be bonded by known bonding techniques, and especially to heat the materials in question for bonding other materials to them. There is a need for a method that does not require the addition of a plastic material. There is also a need for a method of bonding through relatively thick materials during the manufacture of absorbent articles. In addition, there is a need for a bonding method that can result in a virtually unlimited number of bonding patterns in the material to be bonded.

[0008]

[Means for Solving the Problems]

The present invention is generally directed to a method of bonding materials used in absorbent articles, but the techniques described herein may be used to bond materials used in other types of articles. May be done. All such uses of the methods described herein may be considered to be within the scope of the present invention. In a preferred embodiment, the present invention relates to a method as used in the manufacture of absorbent articles such as sanitary napkins, pantiliners, tampons, absorbent interlabial devices, diapers, incontinence devices and the like.

The present invention has many aspects. In one aspect, the invention relates to a method of bonding via an incompatible material during a process for forming a composite structure comprising several materials. As used herein, the term "incompatible material" refers to a material that is difficult to bond to other materials using conventional bonding techniques. In another aspect, the invention enables the method to be used to bond through relatively thick materials (eg, materials having a thickness of about 2, 3, or 4 mm or more). Regarding improvements. In another aspect, the present invention relates to a bonding method that can provide a virtually unlimited number of bonding patterns in the material to be bonded. In yet another aspect, the invention relates to a bonding method that utilizes a compression process to improve bond formation. In yet another aspect, the present invention relates to a bonding method utilizing a step of slitting a material, through which a bond is formed.

It is to be understood that the embodiments described herein are represented by preferred embodiments so that the length of the specification is not excessive. It should be understood that the invention is not intended to be limited to such embodiments. It should also be understood that the method aspects described herein can be combined in a single process, or they can be used individually or in any desired combination. In addition, the inventors consider that all such uses or combinations of these aspects have potential independent patentable inventions, and that such inventions are not It is to be understood that the range is intended to be as broad as the prior art will recognize. It is intended that the scope of the invention be limited only by the claims, and not by the preferred embodiments described herein.

[0011] Aspects of the method of bonding via an incompatible material preferably include: (a) providing a material having at least some incompatibility with bonding using conventional techniques; 1 bonding property (
(b) providing at least one other material having a higher bondability than the first bondability; and (c) the non-conforming material. At least a portion of the first and second surfaces of
The at least one of the at least one having a bonding property higher than the first bonding property;
Coating the material having a higher bondability covering at least a portion of the first surface of the non-conforming material with the second surface of the non-conforming material. Bonding the material having at least a portion thereof and having the higher bonding property with a plurality of bonds penetrating the incompatible material.

In this aspect of the method described herein, the non-conforming material preferably comprises an absorbent material. In one particularly preferred embodiment, the incompatible material comprises a thermoset polymeric absorbent foam material. Materials having higher bonding properties may comprise, but are not limited to, any suitable material including a web, a layer of glue, or a silicone coating of one or more materials. In one particularly preferred embodiment, where the incompatible material comprises a thermoset polymeric absorbent foam material, the material having a higher bondability comprises a nonwoven web.

[0013] The invention also relates to materials, in particular sanitary napkins, pantiliners, tampons,
Provided is a method of shaping a compressible material, such as an absorbent material, for use in absorbent articles such as absorbent interlabial devices, diapers, incontinence devices, wipes, and the like. In this aspect of the invention, the bond pattern is embossed into a compressible incompatible material, separating a portion of the incompatible material from the rest of the incompatible material and shaping the separated portion into a unique shape. The shaping aspects of the method described herein may involve one or more folding steps. Numerous other uses of the methods described herein will also be apparent.

This specification concludes with claims which individually point out and distinctly claim the subject matter regarded as forming the invention, which will be interpreted from the following description taken in conjunction with the accompanying drawings. I believe it will be better understood.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION

Although the present invention relates to a method of bonding materials for use in absorbent articles, the techniques described herein may be used to bond materials used in other types of articles. In a preferred embodiment, the present invention provides a sanitary napkin, panty liner, tampon, absorbent interlabial device, diaper, incontinence device,
And methods used in the manufacture of absorbent articles such as wipes.

The present invention has a number of aspects. In one aspect, the present invention relates to a method for bonding through incompatible materials during a process for forming a composite structure comprising several materials. As used herein, the term "incompatible material"
A material that is difficult to bond to another material using a conventional bonding technique. In another aspect, the invention enables the method to be used to bond through relatively thick materials (eg, materials having a thickness of about 2, 3, or 4 mm or more). Regarding improvements. In another aspect, the invention provides:
A bonding method that can provide a virtually unlimited number of bonding patterns in the material to be bonded. In yet another aspect, the invention relates to a bonding method that utilizes a compression process to improve bond formation. In yet another aspect, the present invention relates to a bonding method utilizing a step of slitting a material, through which a bond is formed.

It is to be understood that the embodiments described herein are represented by preferred embodiments so that the length of the specification is not excessive. It should be understood that the invention is not intended to be limited to such embodiments. It should also be understood that the method aspects described herein can be combined in a single process, or they can be used individually or in any desired combination. In addition, the inventors consider that all such uses or combinations of these aspects have potential independent patentable inventions, and that such inventions are not It is to be understood that the range is intended to be as broad as the prior art will recognize. It is intended that the scope of the invention be limited only by the claims, and not by the preferred embodiments described herein.

In a particularly preferred embodiment, the method of bonding materials described herein uses the bonding process to apply an external force to a portion of the article and shape it to form an absorbent article (or other material). Types of articles) or portions thereof may be used to provide a unique three-dimensional shape.

1. Description of one non-limiting embodiment of the method of the present invention: Use of absorbent material in making tubes for compound sanitary napkins The method of the present invention involves many different processes, including absorbent articles. It can be used to bond many different materials used in types of articles. Figures 1 to 8 illustrate one particularly preferred application of the method of the present invention. Figures 1-8 illustrate the process of making a tube of absorbent material placed on the body-facing side of the base pad to form a compound wound sanitary napkin. The compound wound type sanitary napkin includes a first menstrual pad (tube of absorbent pad) connected to a panty protector (base pad). The tube of absorbent material is bonded and shaped according to the method of the present invention. The final product is shown in FIG.

The figures show several steps that take place before (and after) the step of bonding the material comprising the tube of absorbent material. It should be understood that these several steps are optional and are shown as they are useful in making the absorbent product shown in FIG. Not all uses of the method of the present invention need to include these optional steps. It should be understood that the method of the present invention is not limited to the method shown in FIGS. 1-8, and that the method shown in FIGS. 1-8 is merely exemplary.

A. Component Assembly FIG. 1 shows a composite web of material 20 bonded using the method of the present invention and shaped into an absorbent tube used in the sanitary napkin shown in FIG. The composite web of material 20 shown in FIG. 1 provides a first material 22 that is incompatible with bonding using conventional techniques such as adhesives, heat and / or pressure, and ultrasonics.
Web. The web of first material 22 may also be referred to as a "bonding non-compliant material" or a "web of non-compliant material". Incompatible material 22
Has a first surface 22A and a second surface 22B.

The incompatible first material 22 may be any suitable material. Preferably, the web of incompatible material 22 is an absorbent material, but substantially non-absorbable incompatible materials can also be bonded using the method of the present invention. Incompatible material 22
The web of may, but need not, be compressible and / or elastic. Preferably, in this aspect of the invention, first material 22 comprises a compressible and elastic porous absorbent material. Also, the first material 22 is not limited to a material in web form. First material 22 may be in any suitable form.
For example, the first material 22 may be in the form of a mass of particles or fibers, a laminate, one or more layers, strips, sheets, blocks, or webs. Preferably,
It is in the form of a web to make the tube of absorbent material shown in the figures.

The web of incompatible material 22 has a first bondability (ease or degree of bonding to another material or bonding another material to it). The web of incompatible material 22 is not required, but may be completely incompatible with conventional bonding techniques. For example, it may be a material where other materials are not simply easily bondable using such techniques. The bondability of a material can be defined by measuring the force required to separate the material from a bond to another material or an attempted bond. Because of this provision, separation occurs under the forces that can cause the two materials to separate, or the structural integrity of incompatible materials during the process of trying to separate them, whichever happens first. .

A web of incompatible material 22 may be a material to which other materials are not readily bondable for one or more reasons. In most cases, such materials are
They are incompatible with conventional bonding techniques due to their structural integrity or composition. One type of incompatible material is a highly dispersed phase emulsion (or "HIP
E "foam) is a porous polymeric absorbent foam material. Absorbent foam materials having these characteristics are not limited to the following patents,
U.S. Pat. No. 5,26, issued to DesMarais et al. On Nov. 9, 1993.
U.S. Pat. No. 5,268,224 issued to DesMarais et al. On Dec. 7, 1993, and U.S. Pat. No. 5,387,207 issued to Dyer et al. On Feb. 7, 1995. This is described in patent documents including Such materials have low tensile strength and / or low levels of elongation at break.
ore breaking).

Since the structural integrity of such materials is often not as strong as adhesive bonding, it is difficult to bond other materials to these absorbent foam materials with adhesives. As a result, only a portion of the incompatible material that is in direct contact with the adhesive will remain bonded to the other material. The rest of the incompatible material will easily separate from the material to which it is bonded. In addition, the foam materials described in the above patents cannot be bonded to other materials using thermal bonding because these foams are thermoset polymers. Once they are formed, they cannot be re-melted. Instead, when heat is applied to these foam materials, they will char rather than melt or flow as required for thermal bonding. Since thermoset foam materials do not have the ability to flow and fuse under pressure, these foam materials cannot be press bonded to other materials.

Thus, a web of incompatible material 22 may be referred to as a material that is not easily bondable. In some cases, it may be referred to as a non-heat sealable, thermoplastic-free material and / or a material with low structural integrity. It should also be understood that the use of incompatible materials is only important in aspects of the invention that address how to bond incompatible materials. In other aspects of the method described herein, it is not necessary to use incompatible materials. In such other aspects, any suitable material may be used, including a wide range of absorbent materials.

In the embodiments shown in the figures, the web of incompatible material 22 is a web of absorbent foam material, such as one of the foam materials described in the aforementioned patents. The web of incompatible material 22 in the embodiment shown in FIG. 1 is at least partially wound into the web of second material 24. The web of second material 24 has a second bonding property that is higher than the bonding property of the web of incompatible material 22. That is, it can be immediately bonded with another material (or itself) using conventional bonding techniques. The web of second material 24 may be referred to herein as a "carrier web" or a "bondable web." In the embodiment shown in FIG. 1, the web of second material 24 is preferably a material 2 that is incompatible such that the web of second material 24 has an "e" -shaped fold in cross-section.
2 is completely wrapped around the web.

The web of second material 24 is bonded by heat or pressure, adhesive, or ultrasound to itself or at least some other material used in an absorbent article of the type described herein. Any material that can be made to work. Second
Webs of material 24 are woven and non-woven materials; polymeric materials such as open molded thermoplastic films, open or unopened plastic films, and hydroformed thermoplastic films; It may be made from a wide variety of materials such as porous foams, reticulated foams; reticulated thermoplastic films; and thermoplastic scrims. Suitable woven and non-woven materials include natural fibers (eg, wood or cotton fibers), synthetic fibers (eg, polymeric fibers such as polyester, polypropylene, or polyethylene fibers), composite fibers (ie, certain materials). Fibers with a core of another material surrounded by a sheath made of natural fibers and synthetic fibers. Preferably, in the embodiment shown, the second material 2
The web of 4 comprises, at least in part, a thermoplastic material. However, in other embodiments, particularly where an adhesive or other type of bonding is used, the second material 24 need not comprise a thermoplastic material. For example, the second material 24 may be a cellulosic material that can be bonded to itself by hydrogen bonding.

In still other aspects, the web of second material 24 may be replaced by a form of material other than a web of material. For example, the web of second material 24 may be replaced with a bondable layer or coating, such as an extruded glue coating or a polymeric coating applied to the web of incompatible material 22. Glues, especially hot melt adhesives, are similar to thermoplastic materials in that they can be bonded using this aspect of the method of the present invention. Some silicones
Especially if they have a sufficiently low melting point, they could be bonded as described herein. For this reason, the web of second material 24 is
It may be referred to as a "second material" to clarify that materials other than the web are included.

In the preferred embodiments shown in the figures, the second material 24 preferably comprises a material that is also suitable for use as a wrap for an absorbent material in an absorbent article. For example, the second material 24 may be provided as a containment web for containing the absorbent material in the absorbent article, as a cover or topsheet for the absorbent article, or as a backsheet for the absorbent article. Figure 1
For the embodiments shown in FIGS. 8 and 13, the second material 24 comprises a containment web made of a spunbonded nonwoven material. One particularly preferred spunbonded nonwoven material is North America of Washington, WA
product number 065MLPV60U (obtained from Fiberweb, Inc.
Or 19 g / yd ^2, called "P-9") (22.5g / m ²⁾ spunbond polypropylene nonwoven material. Other particularly preferred nonwoven materials are Pei, Germany.
is a spunbond polypropylene non-woven material commercially available from Corovin GmbH and known as COROLIND, which has two basis weights, 23
Available in gsm and 30 gsm.

The web of second material 24 is wound in an e-fold configuration around the web of incompatible material 22, but if a web of material is used, the web of second material 24 is incompatible It should be understood that the web of flexible material 22 is not limited to being wound in an e-fold configuration. The relationship between the web of incompatible material 22 and the web of second material 24 is preferably such that the web of material having a higher bondability than the web of incompatible material 22 has two webs of incompatible material 22. A relationship that is merely at least adjacent to opposing surfaces (eg, 22A and 22B shown in FIG. 1). Thus, in other aspects, the web of second material 24 may simply be partially folded or wrapped around the web of incompatible material 22. Second
The web of material 24 may be folded or wound around the non-conforming material 22 in any other suitable configuration. Other suitable structures include, but are not limited to, C-folds and the like.

Also, the web of second material 24 need not be limited to a single web wrapping a web of incompatible material. One (or more) web of material may be disposed adjacent to respective surfaces 22A and 22B of the web of incompatible material 22. For example, in another aspect, there are two separate webs of the second material 24, one of which is the respective surfaces 22A and 2A of the web of the incompatible material 22.
It may be arranged adjacent to 2B. The two webs of the second material 24 may be of the same type of material and have the same characteristics. In other embodiments,
The two webs of material located adjacent to respective surfaces 22A and 22B of the web of incompatible material 22 may be different. For example, they may be different types of materials, or they may be the same basic type of material but with different characteristics (such as calipers, etc.).

In still other aspects, the second material 24 need not be as wide or long as the web of incompatible material 22. For example, the second material 24 may be in the form of a strip, stripe, patch, or piece placed at the desired location at the bond location. In this way, the second material 24 comprises the incompatible material 22
It is only necessary to cover a portion of the first and second surfaces 22A and 22B of the web.

B. Optional Intermediate Steps (1) Formation of Incompatible Material into Granular Material In a preferred embodiment of the process for making the tube of absorbent material shown in FIGS. The web is second
Will be formed into a granular material while still inside the web of material 24. This is described in Ronald R. on February 20, 1998. Filed under the name of McFall et al., Entitled "Method of Making Slitted or Part
and the method described in commonly-assigned US patent application Ser. No. 09 / 027,379, entitled “Iclate Absorbent Materials”.

In such a case, the web of second material 24 is not only more bondable than the web of incompatible material 22, but also has a higher yield at break (yield) than the web of incompatible material 22. to break point). This operation (forming the incompatible material into a particulate material) is an optional step, preferably performed prior to performing the bonding step, which involves removing the tube of absorbent material for the sanitary napkin shown in FIG. Very preferred for making. It should also be understood that the step of forming the incompatible material into a particulate material is not limited to being performed before the bonding step. If desired, the step of forming the incompatible material into a particulate material may instead be performed simultaneously with or after the bonding step. The reason why this optional step is preferred is described in more detail below.

Any process for forming incompatible material 22 into a particulate material includes several steps. While there are several aspects to this optional process (and the equipment used therein), a preferred embodiment of the process and equipment is shown in FIG. FIG.
The process and apparatus shown in FIG. 1 are used to mechanically strain the incompatible material 22 to form the incompatible material 22 into a granular material.

The first step is to have a first break at break under tension provided.
Carrier Web ". (In the embodiment described herein, the web of second material 24 is provided as a carrier web.) A web of material to be formed into a particulate material, which in this case is a web of incompatible material, foam absorption Material 22) and the carrier web are then formed into a composite structure, such as composite web 20. The foam absorbent material 22 has a second break at break under tension, which is lower than the break yield of the nonwoven carrier web 24. Thus, the first two steps of forming the incompatible material 22 into a particulate material have already been performed in preparation for the bonding method described herein.

An apparatus for mechanically deflecting the composite web 20 is provided. The apparatus preferably comprises a device having at least one component with an embossed surface. Thereafter, the composite web 20 is preferably formed by using the apparatus to form the foam absorbent material 22 at least partially into a granular material without forming a carrier web (web of second material) 24 into the particulate material. Is subjected to a process of mechanically distorting the patterned surface by embossing it into the composite web 20.

The apparatus 30 for mechanically deforming the composite web 20 shown in FIG. 2 includes two sets of cylindrical rolls, a first set of rolls 32, and a second set of rolls 62. Each roll has a surface provided with a pattern. The patterns are preferably formed by a plurality of ridges and valleys on a roll defining a plurality of triangular teeth. Embossed rolls suitable for use as the first and second set of rolls 32 and 62 in the apparatus shown in FIG. 2 were issued to Chappell et al.
No. 5,518,801, entitled "Ke Behavior".

In the preferred embodiment shown, the rolls of the first set of rolls 32 preferably have triangular teeth formed by ridges and valleys oriented around the circumference of the roll. The teeth preferably have a cross section in the form of an isosceles triangle. If desired, the apex of the teeth may be slightly rounded. First roll set 32
The top roll 34 and the bottom roll 36 are aligned so that the ridge 38 of the top roll 34 is aligned with the valley 40 of the bottom roll 36. The triangular teeth forming the ridges on the top roll 34 and the valleys on the bottom roll are spaced such that the teeth do not touch each other or completely "mesh".

The teeth may have any suitable size and pitch. As used herein, the term "pitch" refers to the distance between the vertices of adjacent teeth. In the preferred embodiment shown in the figures, the depth (or height) of the teeth is preferably from about 0.1 inches to about 0.17 inches (about 2.5 mm to about 4.3 mm).
The pitch is preferably from about 1 mm to about 5 mm, more preferably about 1.5 m
m to about 2.5 mm. The pitch of the teeth determines the width of the chopped or cut piece of absorbent material.

Further, the bottom roll 36 has an axis X of the bottom roll on the surface of the bottom roll 36.
May be provided with a number of thin planar grooves 44 oriented parallel to and evenly spaced apart from each other. In this embodiment, the spaced grooves 44 of the bottom roll 36 preferably have a width of 2 mm. The "length" of the teeth of the bottom roll 36, measured around the circumference of the bottom roll between the spaced grooves, is 8 mm. Rolls 34 and 36 are preferably driven in opposite directions.

The triangular teeth on the top roll 34 and the valleys 40 on the bottom roll 36 are preferably spaced such that they partially mesh. The degree of meshing of the teeth of the opposing rolls is referred to herein as "meshing" of the teeth. The meshing of the teeth is based on the position where the teeth of each roll are in the same plane (0% meshing) and the apex of the teeth of one roll extends inward toward the valley of the opposing roll beyond that plane. Distance from the position indicated by the plane. Tooth engagement can be expressed as a percentage of the pitch (the distance between the vertices of the teeth on one roll) or as a measured distance. Maybe,
Since the height of the teeth is greater than the pitch, the engagement can be greater than 100% (eg, if the engagement is greater than the length of the pitch). Preferably, the engagement is between about 15% and 120% of the pitch length. The engagement, represented by the measured distance, is preferably between about 0.01 inches and about 0.07 inches (
About 0.25 mm to about 1.8 mm), and more preferably about 0.04 inches to about 0.06 inches (about 1 mm to about 1.5 mm).

As shown in FIG. 2, at the stage indicated by A, the composite web 20 is fed in the machine direction (MD) into the nip between the rolls 34 and 36. The web of second material 24 at this stage of the process serves as a carrier web. As a carrier web, it holds and contains a web of incompatible material 22 that is about to be slit into a particulate material. The web of second material 24 is wrapped around the web of non-conforming material 22 such that the web of second material 24 faces the patterned surface of rolls 34 and 36.

The rolls 34 and 36 are subjected to a process of mechanically straining the composite web 20 by embossing the patterned surface into the composite web 20. The mechanically distorting process does not slit the carrier web 24,
The non-woven carrier web (the web of the second material (the web of the second material) is greater than the yield at break of the web of the non-compliant foam absorbent material 22 such that the web of the non-compliant foam absorbent material 22 is at least partially slit. Applying a force smaller than the yield strength at break) with higher bonding properties)).

FIG. 2 shows the state of the composite web at stage B after passing through the nip between the first set of rolls 32. As shown in FIG. 2, the carrier web 24 will have an undulating pattern formed corresponding to the combination of patterns on adjacent rolls 34 and 36. However, the carrier web 24 is not slit or cut. The intermediate web of foam absorbent material 22 has a plurality of slits 50 formed therein. The slits 50 are oriented in the flow direction (or "MD"). In the embodiment shown, the slits 50 are discontinuous and separated by a band 52 of unslit material in the cross-flow direction (or "CD"). This is due to the groove 44 on the bottom roll 36. The web of foam absorbent material 22 has a lower yield at break than the carrier web 24 and breaks under tensile force (the process of straining), whereas the carrier web 24 does not break, so the foam The web of absorbent material 22 is slit, but the carrier web 24 is not.

At this point in the process (at stage B between the first and second set of rolls 32 and 62), additional operations can be performed on the composite web 20. For example, the composite web 20 may be cut to discrete lengths between first and second sets of rolls 32 and 62. In other aspects, the composite web 20 can be cut to discrete lengths by blades installed on one roll of the first set of rolls 32. The composite web 20 will be cut to a length corresponding to the desired tube length for the sanitary napkin shown in FIG.

Further, a web (or webs) of additional material, such as a continuous web of apertured film topsheet material 56, may be provided in the first and second roll sets 3.
2 and 62 may be joined to the composite web 20. Instead, such additional material is cut into individual pieces and the first and second sets of rolls 32 and 6
The two may be joined to the composite web 20. The joining of the opened film topsheet material 56 to the composite web 20 is shown in FIG. It has been omitted from FIG. 2 for simplicity. Opened film topsheet material 56 is bonded to composite web 20, preferably by an adhesive. This forms a structure referred to herein as "tube-formed composite" (or "tube-formed composite web") 88.

The second set of rolls 62 of the apparatus 30 for mechanically deflecting the composite web comprises top and bottom rolls 64 and 66, respectively. Each of these rolls also has a pattern on its surface. As shown in FIG. 2, the top roll 64 is
The top roll 64 has a ridge extending parallel to the axis X. The ridges define a plurality of triangular teeth 68. The top roll 64 may also have a number of spaced grooves 70 oriented around the circumference of the cylindrical roll.

FIG. 2 shows that as the composite web 20 leaves the nip between the second set of rolls 62, at least a portion of the foam absorbent material 22 creates a plurality of slits 80 oriented in the cross-flow direction. Shows further provided. This initial flow direction slitting and subsequent cross flow slitting results in absorbent material 22 formed or chopped into a plurality of particles 82. Foam absorbent material 22
Is the presence of grooves 70 in the second set of rolls 62 in addition to the band in the cross-flow direction of the material that is not slit due to the presence of the grooves 44 on the bottom roll 36 of the first set of rolls 32. Optionally, it may have an unslit strip 84 left there.

Furthermore, the nonwoven carrier web 24 is not slit, but has other patterns formed thereon. The entire pattern formed there is composed of the first and second patterns.
Analogous to a grid having a combination of indentations created by a set of rolls 32 and 62 of the same. The apertured film topsheet 56 will have a pattern similar to that of the second set of rolls 62.

FIG. 3 shows the composite web 20 after it has been delivered to the apparatus shown in FIG. As described above, the sheet of open film topsheet material 56 is preferably joined to a discrete length of composite web 20 between the first and second set of rolls. FIG. 3 shows that the sheet of open film topsheet material 56 preferably has about the same width as the cut individual length composite web 20 but a longer size. Once the tube of absorbent material has been made, the open film 56 can be easily attached to the sanitary napkin by attaching only its ends to the sanitary napkin, and the open film 56 can be a separate length of composite web material. Extend beyond both ends of the

In FIG. 3, it should be understood that the pattern imprinted on the nonwoven material 24 by the first and second sets of rolls has been omitted or simplified. in addition,
Incompatible foam absorbent material 22 is shown as having only particles 82 for simplicity (ie, an unslit strip is shown remaining in incompatible material 22). Absent). Such an embodiment provides continuous teeth to the rolls of the first and second roll sets 62 and the valleys 40 between the teeth.
And by omitting the groove 70.

(2) Optional Step of Folding Tube-Formed Composite Web The next step in making the tube of absorbent material for a sanitary napkin shown in FIG. Is to fold the tube-formed composite web 88, which is a combination of the above. These optional but preferred folding steps are illustrated in the following several figures.

FIG. 3 shows a longitudinally oriented fold line F, where the longitudinal side margin 90 of the tube-formed composite web 88 is first folded. FIG.
Shows the tube-formed composite web 88 after the side margins 90 have been folded along the fold line F in a first folding operation to form a "C" -shaped fold structure.

FIG. 5 shows the tube-formed composite web 88 after being folded in a second folding operation.
Is shown. As shown in FIG. 5, the tube formed composite web 88 is folded along its longitudinal centerline. As a result, the previously folded longitudinal side margins 90 are adjacent to each other and the tube-formed composite web 8
The longitudinal side margin 90 of the folded tube-formed composite web 8
8 is caught inside. As shown in FIG. 5, the folded longitudinal side margins 90 are located adjacent the longitudinal centerline L of the tube-formed composite web 88. The folded tube-formed composite web 88 shown in FIG. 5 is now ready to be bonded using the method of the present invention. (FIGS. 2 to 5
Are all optional, but are preferred steps for producing a tube of the absorbent material of the sanitary napkin shown in FIG. C.). Bonding (and shaping) of incompatible materials (1) Overview To bond (and shape) the incompatible absorbent foam material 22, the most common perception is that a material having a higher second bondability. (Non-woven fabric) 2
The fourth web is placed outside of the non-conforming material (absorbent foam material) 22.
The cross-section of the actual bonded structure (as shown in FIG. 7), apart from the purpose of this description, is the general relationship described above (a web of material having a higher second bondability is incompatible). (Which is located outside the web of material) is somewhat more complicated than preferably being present.

The second higher bonding material web, a non-compliant material having a nonwoven web 24 on the outside, the absorbent foam material 22 is preferably bonded with a plurality of autogenous bonds 94. Let me do. As used herein, the term "natural" refers to bonding without other additional materials such as adhesives and stitch threads (ie, additional to the component to be bonded). However, the method described herein is not intended to be limited to a method that eliminates such self-bonding adhesion enhancement or adhesive bonding itself.

The bonds 94 preferably penetrate the incompatible absorbent foam material 22. The bonds 94 preferably join a portion of the nonwoven web 24 on the opposite side of the foam material 22 that is incompatible with the other portions of the nonwoven web 24. In the embodiment shown in the figures, the bonding is provided as a step in the method of the present invention directed to bonding incompatible materials and also provides a tube of absorbent material having a unique three-dimensional shape. It is also offered.

[0059] In performing the method of the present invention, any suitable number of bonds 94 may be used. The bonds 94 may be located at any suitable location. FIG.
For the preparation of a tube of absorbent material for a sanitary napkin, as shown in 3, two to five bonds 94 are preferably used. In the embodiments shown in the drawings,
Three bonds 94 are used. The bonds 94 are preferably about 1.
It is spaced 75 inches (approximately 4.4 cm) and is located about 17 mm from the fold along the longitudinal centerline L of the tube formed composite web 88.

A preferred autogenous bonding process can be done using heat and / or pressure or by ultrasonic engineering. Techniques suitable for heat and / or pressure bonding, especially dynamic bonding, are described in detail below. A suitable technique for ultrasonic bonding is issued to Schaefer on February 7, 1984, and is referred to as Ultraso.
& Bond, titled "Nic Bonding Process"
US Patent No. 4,430,148 to Ble and Wil on April 25, 1989.
lhite, Jr. "Adhesive-Free Bondin
go of Continuously Moving Webs to for
m Laminate Web and Products Cut Ther
No. 4,823,783, entitled "from". Appropriate equipment for ultrasonic bonding is from Bruns, Danbury, Connecticut.
Commercially available from on Ultrasonics. The ultrasonic bonding apparatus is preferably equipped with a plate having pattern elements similar to those described below for the dynamic bonding process. However, it should be understood that ultrasonic bonding may be less preferred (as compared to the dynamic bonding process) for use with some of the higher caliper structures described herein.

The dynamic bonding process has some other benefits over the ultrasonic bonding process. First, it can be a continuous process that can be run at high speed. Conversely, ultrasonic engineering generally relies on at least one static head that provides a fixed dwell time to form a bond.
ead) requires the use of equipment. Therefore, in the ultrasonic bonding process, the web to be bonded must be stopped for a period to complete the bond. Second, ultrasonic bonding processes are not suitable for bonding through materials having a thickness that exceeds a certain amount (eg, up to about 4 mm or more). The dynamic bonding process described here, on the other hand, can be easily bonded through materials having such a thickness.

The slitting of the absorbent material 22 and its formation into a granular material in a previous step is advantageous in the bonding process. This is because the method used to form the slit or particulate material may provide a continuous, clear path for the bond to penetrate the absorbent material. This is especially true if the bonds are aligned with slits or gaps between particles. This is most likely to occur when slits or particulate material adheres to the carrier web. A conventional method of chopping the absorbent material and blowing it with compressed air into a closed tube would result in a random distribution of the chopped particles.
Such a method would not form a clear path for the bonding process described herein.

The dynamic bonding process involves bonding portions of a web of a second material (nonwoven coating) 24 on each side of the absorbent foam material 22 to each other, as described above. Opened film topsheet material 56 may have portions that are dynamically bonded to one another. In addition to or instead of bonding portions of the nonwoven coating 24 to each other, an open film topsheet material 56 may be bonded. In a dynamic bonding process, at least one material to be bonded (nonwoven coating 2
4 or open film topsheet 56 material) preferably comprises a thermoplastic material. (Even though portions of the open film topsheet material may be similarly bonded in the process, for simplicity the bonding is in that the portions of the nonwoven coating 24 are bonded together. It should be understood that this is described below.) FIG. 8 illustrates that a first portion 24A of the coating material 24 is bonded to a second portion 24B of the coating material, preferably via a tube-formed composite web 88. Figure 4 shows the process that is caused. The apparatus used to bond the tube-formed composite web 88 preferably comprises a pair of cylindrical rolls 110 and 112. Preferably, at least one of the rolls, the embossing roll 110, has a relief pattern on its surface. The embossing roll 110 is shown in a simplified manner in FIG. 8 and is shown in more detail in FIG. (However, FIG. 12 shows a roll having a relief pattern that is slightly different from the pattern shown in FIG. 8.) As shown in FIG. 12, the embossing roll 110 has a cylindrical surface 115 and an outer surface. A plurality of ridges or pattern elements (or
"Pattern element segment", "projection", or "nub"). The relief pattern formed by the pattern elements 116 may be of any suitable structure. It may be straight, curved, or consist of straight segments and curved segments. The relief pattern may be continuous or intermittent. The relief pattern may define an unlimited number of patterns and other types of designs. For example, it is a geometric shape,
Arrows, words, etc. can be specified. Also, the land surface 118 on the pattern element can be provided in a wide variety of suitable shapes. Suitable shapes for land surface 118 include, but are not limited to, oval and circular.

In the embodiment of the apparatus shown, the relief pattern comprises a plurality of spaced pattern elements 116 having a circular land surface 118. In the embodiment of the method shown in FIG. 8, the pattern elements 118 are arranged in a discontinuous linear structure.

Although the present invention is intended to be applied to any suitable shape and size bond, bond sizes which have been found to be suitable are about 0.25
It has a circular plan view structure having a diameter of from about 5 mm to about 5 mm or more. In one preferred embodiment, the bonds have a diameter of about 3 mm and about 8 m
It has an area of m ² .

The pattern element 116 has a side wall 119 which is preferably not perpendicular to the surface of the cylindrical roll. Preferably, the side wall 1 of the pattern element 116
19 is greater than 45 ° and less than 90 ° relative to the surface 115 of the cylindrical roll;
Preferably, the angle is 70 to 90 degrees. Due to the thickness of the material being bonded and the requirement to avoid tearing the coating material 24, it is preferable to change the orientation of the sidewalls 119 of the pattern element 116.

Another roll 112 is provided as an anvil member and may therefore be referred to as an anvil roll 112. The embossing roll 110 and the anvil roll 112 define a nip 114 between which pressure is biased. Preferably, the anvil roll 112 is smoothened. However, in other embodiments,
Both rolls 110 and 112 may have embossed patterns and / or pattern elements. The embossing roll 110 and the anvil roll 112 are preferably directed from each other at about 20,000 psi (about 140 MPa) to about 20 psi.
A predetermined pattern element load of 000 psi (about 1,400 MPa) is biased. In the embodiment shown in FIG.
4 are biased toward each other such that the pressure at 4 is preferably maintained at about 93,700 psi (about 656 MPa). In this manner, the material to be bonded is fed into nip 114, preferably at a relatively high speed.
The line velocity is preferably about 383 feet / minute (about 117 meters / minute).

The embossing rolls 110 and 112 are preferably driven in the same direction at different speeds such that there is a surface speed difference between them. The surface velocity difference preferably has a magnitude of about 2 to about 40 percent, more preferably about 2 to about 20 percent of a roll having a lower surface velocity. The anvil roll 112 is preferably operated at a surface speed greater than the surface speed of the embossing roll 110. However, at high line speeds, bonding can occur even at zero speed difference (ie, at the nip defining a roll with equal surface speed).

The multiple layers comprising the tube-formed composite web 88 are bonded by feeding it into a nip 114 between rolls 110 and 112. The preferred bonding process shown in the figures is to penetrate the tube-formed composite web 88 and spontaneously bond the first portion 24A of the nonwoven coating material to the second portion 24B of the coating material 24. The bonds 94 are made of the foam material 22
Are formed between opposing portions of the nonwoven web of higher second bondable material 24 located outside of the web.

While not wishing to be bound by any particular theory, the mechanisms believed to result in bonding of incompatible materials are as follows. The pattern elements 116 of the bonding mechanism compress the incompatible absorbent foam material 22. This local compression results in the incompatible absorbent foam material 22 tearing and separating from the pattern element 116 (pulling away from the pressure point). The bonding mechanism slices the incompatible material or pushes away particles of the incompatible material so that there is a clear path for the bondable materials to bond to each other. Preferably, very little (if any) foam material 22 is actually left at the bond sites.

In addition to penetrating incompatible materials with a bond, the method described herein has several other important features. These features allow high caliper materials to be bonded and facilitate the process providing a virtually unlimited number of bond patterns to the material to be bonded. The embossing roll 110 preferably has a conformable (or compressible) material 120 on its surface 115. The embossing roll 110 preferably has a pair of load supporting members 122 on its surface 115. The purpose of these components is described below.

The purpose of the conformable material 120 is to compress the material to be bonded such that the pattern elements 116 do not pierce the coating material 24. If a hole is pierced in the coating material, no bond will be formed or a weak bond will be formed because the coating material is not melted and forms a bond. The compression step may be performed before or simultaneously with the bonding. The use of a conformable material is particularly preferred when the material to be bonded is relatively thick. The compliant material may be omitted if the material to be bonded is thinner. FIG.
Shows that the compliant material 120 preferably surrounds the pattern element 116.

A comparison of FIGS. 9 and 10 shows how a compliant material is believed to work. FIG. 9 shows a relatively thick material passing through the nip 114 between the embossing roll 110 and the anvil roll 112 that has no compliant material surrounding the pattern element 116. As shown in FIG.
16 tends to pierce the material to be bonded, due to the large local stress on the material to be bonded, especially the coating material 24.

FIG. 10 shows a similar relatively thick material passing through a nip 114 between an embossing roll 110 and an anvil roll 112 having a compliant material surrounding a pattern element 116. As shown in FIG. 10, the compliant material 120 is
The space between the embossing roll 110 and the anvil roll 112 is occupied. The compliant material 120 is a material that is to be bonded to the pattern element 11.
6 results in a gradual compression. This brings both layers of the coating material 24 closer together during bonding without adding extra strain to the coating material 24. This allows the bond 94 to be formed without tearing the coating material 24 or piercing the foam material 22 located between the layers of coating material.

The way this works can be visualized by considering the following analogy: The principle needed is similar to the problem of attempting to secure a 6 inch (15 cm) thick piece of glass fiber-containing insulation to another material using a nail gun. If this were to be attempted when the glass fiber was not compressed, as the nail was protruded, it would pierce the insulation and pass completely through the insulation. However, if the glass fiber insulation was compressed before attempting to secure it with a nail gun, this would not occur and the nail would be able to secure the insulation.

The compliant material 120 preferably has certain characteristics. The compliant material 120 is preferably less compressible than the material to be bonded and more compressible than the surface 115 of the embossing roll 110. Therefore, the compliant material 120
Preferably has a lower hardness than the surface 115 of the embossing roll 110. Preferably, the compliant material 120 is between about 50 and Roc on the Shore A scale.
It has a hardness of about 62 on a kwell C scale (measured using a durometer), more preferably a hardness of about 50 to about 100 on a Shore A scale, and most preferably about 90 on a Shore A scale. With a hardness of (Roc
The hardness of about 62 on the kwell C scale is the hardness of the D2 steel constituting the surface 115 of the embossing roll 110. (The surface of the anvil roll 112 may preferably have any suitable hardness, but the surface of the anvil roll 112 is preferably
It has a hardness equal to or greater than 10 surfaces. The compliant material 120 may comprise any suitable type of material. Suitable materials include brass, rubber, and polymeric materials such as polyurethane. In a particularly preferred embodiment, the compliant material 120 comprises polyurethane.

The compliant material 120 is preferably wider than the material to be bonded. This allows it to equalize the pressure throughout the material to be bonded. The compliant material 120 may have any suitable caliper. Preferably, the caliper of the compliant material 120 is large enough to have some effect in avoiding the problem of piercing the coating material 24. The caliper of the compliant material 120 is preferably the pattern element 11
6 or less. The pattern element may, for example, have a height of about 2 mm. In one non-limiting embodiment, Shor having a height of about 1.5 mm
Compliant polyurethane materials having a hardness of about 90 A on the e A scale have been found to be suitable.

The compliant material 120 is preferably adhered to the surface 115 of the embossing roll. The compliant material 120 may be adhered to the embossing roll 110 in any suitable manner, such as by welding or adhesive.

The purpose of the load bearing member 122 is to balance the embossing roll 110 (ie, on the embossing roll 110 as the material to be bonded passes between the embossing roll 110 and the anvil roll 112). Equalizing the force). The use of the load supporting member 122 is particularly preferable when the pattern on the embossing roll 110 is “unbalanced” or “imbalanced”. By "unbalance" or "imbalance", at the nip 114 between the embossing roll 110 and the anvil roll 112, due to differences in the surface area of the lands 118 of the pattern elements and / or due to the distribution of the pattern elements 116. This means that the pattern elements 116 are distributed such that the pressure is not uniform around the circumference of the embossing roll 110.

The load supporting member 122 can be omitted when the bond pattern is balanced. However, as described in detail below, even when the bond pattern is balanced, greater flexibility in using pattern elements 116 having a greater height using load bearing members 122. It is desirable to provide

The load supporting member 122 may have any suitable structure. The load support member 122 may be in the form of a continuous ring around the embossing roll 110.
Further, the load supporting member 122 may be in the form of a discontinuous element. However, if the load-bearing members 122 are in the form of discontinuous elements, they are preferably embossed rolls in such a way that they substantially form a continuous ring around the circumference of the embossed rolls. The arrangement takes a zigzag arrangement around the circumference of 110. As shown in FIG. 12, the load bearing member 122 is preferably in the form of a continuous ring around the embossing roll 110.

In the embodiments shown in the figures, the load bearing members 122 are preferably located adjacent to respective side edges of the embossing roll 110. The load bearing members are preferably mounted laterally on the outboard of the surface 115 of the embossing roll 110 where the material to be bonded contacts (ie, they are preferably embossed). It is installed between the center of the roll 110 and both side edges of the embossing roll 110). This ensures that the anvil roll 112 can make direct contact with the load bearing member 122. It is believed that this contact occurs even as the material to be bonded is fed into the nip 114 between the rolls. This contact is believed to occur due to the compression of the material to be bonded in the nip 114 and the deformation of the rolls under strong forces applied to bias the rolls toward each other.

A comparison of FIGS. 11 and 12 shows in more detail how the load bearing member 122 is believed to function. FIG. 11 shows an example of an embossing roll 1110 without a load member of the type described herein. The distribution of pattern elements 1116 on embossing roll 1110 is "nested" and balanced. As used herein, the term “nested” refers to a pattern element 1 that exhibits some overlap when looking at a pattern traveling around the circumference of the embossing roll 1110.
116. This ensures that the anvil roll 1112 continuously climbs over the top of the pattern elements 1116 in the nip area 1114 and does not fall or sink between each pattern element 1116. Given that the pattern elements are not nested and that the anvil rolls 1112 sink between the pattern elements 1116, those rolls that are maintained close to each other at very high pressure and rotated at high speed will be the flat of the vehicle. Will work in a very rough way as well as a perfect tire.

In the roll 1110 shown in FIG. 11, the same group of pattern elements similar to the illustrated group exists on other portions of the roll. Also, pillows or pillow strips 1124 exist between groups of pattern elements. Another identical group of pattern elements is not shown in FIG. 11 since only a part of the surface of the roll is shown. However, it is sufficient to show a single group of pattern elements and pillows 1124 to describe the concept of the problem to be discussed. As shown in FIG. 11, when the patterns are balanced,
It is only necessary that any pillow or pillow strip 1124 be provided in a discontinuous (or intermittent) array around the circumference of the embossing roll 1110. Pillow 11
Reference numeral 24 is provided at a position where the pattern element 1116 does not exist.
This is because the entire force from the load mechanism is transmitted from the pattern element to the pillow 1124 when the embossing roll is rotating. The need for a balanced pattern means that the bonding area in the nip (i.e., the surface area of the portion of the roll that is in contact in the nip) must remain constant at any location around the roll. Means. If it were allowed to vary, the bonding pressures would also vary, resulting in inconsistent bonds.

FIG. 12 shows an example of an embossing roll 110 that can be used in aspects of the method described herein, which includes a pattern element 116 of a non-nested and imbalanced pattern thereon. have. Pattern element 11
Although only a portion of the roll 110 having a single group of six is shown in FIG. 12, the embossing roll 110 preferably has several similar spaced dots around the circumference of the roll 110. Is provided. (By "dot" it is meant that the pattern element has a circular land surface.) Each group of dots is distributed in a desired arrangement and forms a bond to the product under discussion. For example, each group of dots may be arranged in a linear pattern of three dots to bond the tube-formed composite web shown in FIG. For bonding the interlip device 1020 shown in FIG. 15, each group of dots may be a semi-circular array of four or five dots, as in the case of the group of pattern elements shown in FIG. .

For the purposes of this discussion, assume that there are groups of six dots around the circumference of the roll 110. In this example, all the pattern elements 116 have the same height. Three of the dot patterns have pattern elements 116 with lands defining a circular bonding surface having a diameter of 2 mm. The other three dot patterns have pattern elements 116 with a circular bonding surface having a diameter of 3 mm. The group of pattern elements 116 is formed by embossing rolls 11 such that each group of 3 mm diameter pattern elements follows each group of 2 mm diameter pattern elements.
Staggered around the surface.

Prior to the support member invention described herein, there is no convenient method known to the inventors for forming a bond using both a 2 mm diameter pattern element and a 3 mm diameter pattern element. Absent. For example, if a conventional roll arrangement is used, it is possible to form a bond with a 2 mm diameter element, but not with a 3 mm diameter element. If an appropriate pressure was selected to form a bond with a 2 mm diameter element, there would be insufficient pressure to form a bond with a 3 mm diameter element. The converse is also true (it is possible to form a bond with a 3 mm diameter element, but not with a 2 mm diameter element). If an appropriate pressure was selected to form a bond with a 3 mm diameter element, the pressure would be too high to form a bond with a 2 mm diameter element, resulting in a hole in the material to be bonded. There will be.

The support member 122 described here has been further developed. As mentioned above,
The support member 122 is preferably provided in the form of a continuous ring around the circumference of the embossing roll. To ensure dynamic balancing of the embossing roll 110, an amount of material equal to the surface area of the pattern element has been removed from the support member. As shown in FIG. 12, the support member 122 preferably has a small cutout area 126 on each side. The cutout area 126 is preferably located along the same long axis on the surface of the roll on which the pattern element is located. There are two cutout areas 126 for each pattern element 116. Each of the cutout areas 126 shown in FIG. 1 has a semicircular shape. The size of each of the cutout areas 126 is preferably equal to one-half the size of the surface of the pattern element located on a common long axis.

The support member 122 is provided on the surface of the embossing roll 110 and the pattern element 116.
It should have a hardness greater than or equal to. The support member 122 may comprise any suitable type of material. The support member 122 includes the embossing roll 1
Like the surface 10 and the pattern elements 116, it is preferably composed of D2 steel.

The support member 122 may have a caliper smaller, larger, or equal to the height of the pattern element 116. Preferably, the caliper of the support member 122 is equal to the height of the pattern element in order to simplify the configuration of the process. The pattern element 116 may have a height of, for example, about 2 mm. In one non-limiting embodiment, a support member 122 having a height of about 2 mm has also been found to be suitable. The support member 122 may have any suitable width. The support members 122 are preferably located along the respective portions of the longitudinally oriented zones of the surface of the embossing roll 110 (ie, oriented parallel to the roll axis) on the pattern elements 116 that are in the same zone. Land 1
It has a width that provides them with more than 18 total surface areas. In the embodiment shown in FIG. 12, the support member 112 has a width of about 6 mm (the cutout area 126
Measured through a portion of the support member 122 that does not include

The support member 122 can be integrally formed on the embossing roll 110, or
They may comprise separate elements that are adhered to the surface 115 of the embossing roll 110. The support member 122 is preferably formed integrally on the surface 115 of the embossing roll 110. If the support members 122 are bonded to the embossing roll 110, they may be bonded in any suitable manner, such as welding.

While not wishing to be bound by any particular theory, the support member 122 can be used because the pressure at the bonding area is no longer merely a function of the surface area of the pattern element or the presence or absence of the pattern element. Is believed to address bonding using unbalanced patterns. With the support member 122, the pressure in the bonding area
As well as the geometry of the support member 122 (i.e., height and surface area), as well as the material properties of the roll, particularly the embossing roll 110, and the material to be bonded. It is believed that when bonding occurs under the use of relatively high pressures, deformation of the roll, and in particular the pattern element 116, occurs. It is believed that the pressure in the bonding area results in a compression deflection in the pattern element 116. Also, the pressure at the bonding area may cause some deflection of the surface of the embossing roll 110 around the bottom surface of the pattern element. Local deformation of the anvil roll 112 at the point of contact with the pattern element 116 can also occur.

It is believed that the magnitude of the deformation in the pattern element 116 and its surrounding area is on the order of the thickness of the bond formed by the present process. In a preferred embodiment described herein, the bonds are about 0.0015
And have a thickness of from about 0.002 inches to about 0.002 inches. This deformation causes the anvil roll 112 to be supported even in the area where the pattern element 116 is present and the interposed material to be bonded is being fed into the nip 114 between the embossing roll 110 and the anvil roll 112. It is possible to maintain a constant contact with the member 122. For this to be possible, the applied force must be high enough to ensure constant contact between the support member 122 and the anvil roll 112. The support members 122 are therefore anvil rolls 1 that prevent further compression deflection of the pattern elements 116.
Serves as a "stop" for the 12.

The support member 122 may be designed to be strong enough so that once the anvil roll 112 contacts the support member 122, no further increase in bonding pressure on the pattern element 116 is possible. Assuming that the applied force does not increase, if the support members are very rigid, only the load acting on them will increase.

The balancing of the embossing roll 110 has a particularly important effect. This aspect of the present bonding method can be used to create a bond pattern with pattern elements having lands of different sizes around the circumference of the embossing roll. This aspect of the bonding method can also be used for those that are not subject to the previous mechanical limitations. The bond pattern need not have nested pattern elements, and the bond pattern need not be balanced. For example, in a conventional bonding process, generation of a nested and balanced complex pattern such as the pattern shown in FIG. 17 requires an extremely complicated design process. The embossing roll balancing eliminates the need to go through complex design work to ensure that the bond pattern is nested and balanced.

In addition, customized bonding patterns can be created to meet certain bonding needs or customer preferences rather than process limitations. In addition, the methods described herein can be used to provide an unlimited number of bond designs for aesthetic or other purposes. For example, use of the techniques described herein can be used to script or emboss a picture on the material to be bonded.

Furthermore, the use of the support members 122 in the present method allows pattern elements 116 having a much larger height to be used. The preceding pattern elements were typically about 0.015 inches (about 0.38 mm) high. As discussed herein, the pattern elements 116 extend up to 2 mm or more in height. This allows thicker materials to be bonded. However, providing a pattern element having a greater height to the embossing roll is not limited to use in bonding thick materials. Support member 1
Since 22 prevents pattern elements 116 from piercing the material to be bonded, it can also be used to bond through thin materials.

It is also believed that this aspect of the method results in an increased life of the embossing roll. Generally, relief embossing rolls wear due to stress on the pattern elements. The use of a support member is believed to reduce some of the stress by supporting some of these stresses and reducing the pressure on the pattern elements. As mentioned above, the support member may serve as a "stop" to prevent further compression deflection of the pattern element. It is believed that the pattern elements will not be distorted beyond their point of plastic deformation, since the support members may serve as "stops" to prevent further compression deflection of the pattern elements.

(2) Non-limiting variants of the bonding process There are many possible variants of the bonding method described here. A non-limiting number of these variants are detailed below.

For example, the methods described herein are not limited to use in bonding materials used in absorbent articles. The method described here, for example,
It may be used to bond materials used in the manufacture of packages or other types of articles, particularly where incompatible materials, polymeric materials, etc. are used. In addition, the central thin layer of material to be bonded may not be provided with incompatible material. It may comprise any suitable type of material, including but not limited to thermoplastic materials.

In addition, the bonding method described here is not limited to the illustrated roll arrangement. In other embodiments, for example, both of the rolls can be provided with pattern elements. In embodiments in which both rolls are provided with a pattern element, the pattern elements can be arranged in contact with each other. Alternatively, the pattern elements on one roll may be arranged to contact between the opposing roll surface and the pattern elements on the other roll surface. In addition, load bearing members may be provided on the anvil roll or on both the embossing roll and the anvil roll.

Also, many variations of the support member shown in FIG. 12 are possible. For example, the embossing roll 110 may provide some or all of the benefits described herein, with the support member having at least some portions that are not continuous. In addition, the shape of the cutout area of the support member need not be equal to half the shape of the pattern element.

A preferred method of dynamically bonding these materials is to use rolls 110 and 1
The method may further include a step of heating one or both of the twelve. When the rolls are heated, they are preferably heated to a surface temperature that is a predetermined temperature below the melting point of the thermoplastic material in the coating material 24.

In another aspect, the materials to be bonded may be compressed (or “pre-compressed”) before they are passed into nip 114 for bonding. For example, the material to be bonded can be sent to a pressurized nip between another set of rolls before the set of rolls 110 and 112 to pre-compress the materials to be bonded. The pre-compression may involve compressing the entirety of the material to be bonded, or may comprise local compression in the area of the tube-formed composite web 88 where the bond 94 is formed.

The pre-compression step can also be performed in connection with bonding in other types of bonding processes. For example, when ultrasonic technology is used, ultrasonic welding or "staker" generally causes some compression in the material to be bonded during the downtime required to form an ultrasonic bond. I will let you. Therefore, for conventional ultrasonic welding, a pre-compression step separate from the bonding process is not required.

In addition, for simplicity and clarity of the present invention, the equipment used in the bonding process is described herein as comprising cylinders 110 and 112. However, the cylinder is only a typical nip defining member. Therefore, it is not intended that the present invention be limited to the device itself having a cylinder.
In the same vein, the use of the term "pattern element" means that the described method can be used to replace a pattern consisting only of discontinuous spaced pattern elements with another pattern, such as a mesh pattern or a continuous or stretched bonding. It is not intended to limit the bonding to the exclusion of lines.

The methods described herein may further comprise any process limitations or steps described in US Pat. No. 4,854,984 issued to Ball et al. On Aug. 8, 1989. .

Another factor to consider when forming a bond using a dynamic bonding process is to distribute the load evenly over the pattern elements. This is most noticeable when a single bonding roll or surface is used to bond materials having different thickness portions. The different thicknesses may occur in several different situations. For example, the material to be bonded can be stamped or calendered so that it has regions of different thickness. Alternatively, the material to be bonded may comprise a laminate in which not all layers have the same length and / or width. In such cases, some of the bonds may have to penetrate more layers than others.

One way to evenly distribute the load on the pattern element in such a situation is to change the angle of the side wall of the pattern element 116. The angle of the side wall 119 of the pattern element 116 that penetrates a portion of the material or materials to be bonded having a greater thickness is the angle of the pattern element 116 that penetrates a portion of the material having a smaller thickness. Should be bigger than that. For example, the angle of the side wall 119 of the pattern element 116 through a thinner portion of the material to be bonded may be at an angle of about 50 °, and the angle of the pattern element 116 through a thicker portion of the material to be bonded. The angle of the side wall 119 may be about 70 degrees. Also, if necessary, pattern elements 116 that pass through thicker portions of the material to be bonded may have a greater height (or other pattern elements may be shorter).

As described above, the method of the present invention may include adhesives, cohesives, hydrogen bonding (eg, if one of the materials to be bonded comprises cellulose),
It can be performed using heat and / or pressure or using ultrasonic technology. However,
Preferably, either a dynamic bonding process or ultrasonic engineering is used. Such a process is particularly preferred when a bondable material, such as a web of second material 24, is treated with a chemical or compound that would interfere with conventional bonding methods (particularly adhesives). For example, these bonding processes are preferred when the second material is treated with a skin care formulation or a material that changes the hydrophilicity of the second material.

An example of the latter type of surface treatment is described in Yan-Per L, December 2, 1997.
ee et al., “Absorbent Articles Having I
improved Surfactant-Treated Hydrofil
P & G, US Patent No. 5,693,03, entitled "ic Topsheets".
No. 7. The dynamic and ultrasonic bonding processes described herein may be bonded by such a process or transfer sufficient heat to form a bond with the underlying material by such a coating or surface treatment. Either of them is possible. Alternatively, if such a surface treatment is applied intermittently, the pattern on the bonding device may be designed such that the bond penetrates through untreated portions of the material.

FIG. 7 shows that the bond has compressed, and more preferably displaced, the compressible foam absorbent material 22 at the local area where the bond 94 was formed. This isolates the three-dimensionally shaped portion 100 of the tube-formed composite web 88 from the rest 102 of the tube-formed composite web and separates the isolated portion 100 (as well as the entire tube-formed composite web 88). To form. The tube-formed composite web 88 is preferably shaped symmetrically on both sides. This is possible because the bonding only applies pressure to the tube forming composite web 88 where the tube forming composite web 88 is compressed by the pattern element 116 against the curved surface of the anvil roll. This aspect of the method of the present invention therefore differs from the embossing process which results in a structure with one embossed side and one flat side.

D. Attachment of Tube of Absorbent Material to Base Pad to Form Compound Wound Sanitary Napkin After the bonding process, the bonded tube-formed composite web 88 is preferably separated into a plurality of individual tubes of absorbent material. And each of them is placed on the front of a base pad to form a compound wound sanitary napkin.

As shown in FIG. 8, the apparatus used to cut the bonded tube-formed composite web 88 includes a pair of rolls 130 and 132. One roll, roll 130, has at least one, preferably a plurality of knife elements 134 on its surface. Knife element 134 is preferably configured to make a continuous, generally transverse cut into continuous bonded tube-formed composite web 88. The other roll 132 serves as an anvil member and may therefore be referred to as anvil roll 132. Knife roll 130 and anvil roll 132 also define a nip 136 therebetween. After the cutting step, individual tubes 88 of absorbent material are sent to conveyor 140 for attachment to a base pad to form a compound wound sanitary napkin.

In the case of the individual tubes of absorbent material shown in FIG. 7, the remainder of the tube-formed composite web 88, which is not held together by bonds, is unfolded prior to attachment of the tube-formed composite web 88 to the base pad. Spread out. Bonding and unrolling the remainder of the tube-formed composite web 88 provides the tube-formed composite web 88 with a narrower width where the portion of the tube-formed composite web 88 that forms the top of the absorbent material on the final product. To a desired cross-sectional shape. Preferably,
As shown in FIG. 13, the portion of the composite web 88 that forms the top of the absorbent tube on the final product is the ridge 106 that projects vertically from the top of the rest of the molded composite tube 102 (and the rest of the sanitary napkin). Is specified. As shown in FIG. 13, the bonding also provides a quilted pattern to the tube-formed composite web 88, where the tube-formed composite web 88 is wrinkled around the bond sites 94.

FIG. 13 shows a compound wound sanitary napkin 800 having a tube 88 of absorbent material bonded to the body facing side by the method of the present invention. In forming the compound wound sanitary napkin 800, the sanitary napkin may be provided as a panty protector (or "base pad") 820, and the tube 88 of absorbent material provided as the "first menstrual pad" It is located at the top of pad 820 and has at least both ends attached to it. Base pad 8
A sanitary napkin suitable for use as 20 is ALWAYS ULTRA, commercially available from Procter & Gamble, Inc., Cincinnati, Ohio.
Including sanitary napkins.

In a particularly preferred embodiment, the base pad 820 comprises an absorbent core comprising a tissue laminate comprising sandwiched superabsorbent hydrogel-forming material particles and a tissue, and a DRI-WEAVE apertured film covering the absorbent core. ALWAYS with
It has a variant like ULTRA sanitary napkin. Suitable tissue paper is Merf
Manufactured by In Hygienic Products. The tissue covering the absorbent core is preferably joined to the absorbent core by a spiral pattern of adhesive.

The tube 88 of absorbent material can be connected to the base pad 820 in any suitable manner.
Can be joined. Attachment of the tube 88 to the sanitary napkin 820 preferably includes extending the extension 58 of the topsheet material 56 to the base pad 82 at both ends of the tube.
Achieved by fusing to zero. In some preferred embodiments of such a compound wound sanitary napkin, there may be an attachment to the base pad 820 between the ends of the tube 88 of absorbent material and the base pad 820. The compound wound sanitary napkin tube may be attached to the base pad between its ends by any suitable attachment means, such as an adhesive.

The sanitary napkin 800 includes a first (or front) end region 828, a second (or rear) end region 830, and a central region 8 located between the first and second end regions.
32. As shown in FIG. 13, the tube of absorbent material 88 is contoured as a result of bonding from the front end region 828 of the sanitary napkin 800 to the rear end region 830 of the sanitary napkin. More particularly, the tube 88 of absorbent material has its highest caliper at the center of the sanitary napkin along the transverse centerline T and tapers to less caliper at both ends of the sanitary napkin. .

[0120] The bond pattern may be varied to produce a tube of absorbent material with increased caliper along the entire length or a portion of the sanitary napkin. For example, the bonding may be such that the increased caliper is restricted to a central region 832 of the sanitary napkin 800. Alternatively, the bond pattern may be used to provide increased caliper in the end regions or in a portion of the central region and a portion of the end regions.

[0121] 2. Other Embodiments of the Method of the Present Invention There are numerous other embodiments of the present invention. For example, in one alternative embodiment, the absorbent material in the tube of absorbent material need not be formed into a particulate material before it is bonded. That is, a solid piece of absorbent material can be used. However, bonding through an absorbent material, such as a homogeneous absorbent foam material, will be more difficult, especially if it is more than about 4 mm thick.

It is also possible to use the method of the present invention to bond through other types of materials, such as low density absorbent materials. For example, the method of the present invention can be used to bond through uncalendered air felt. If it is desired that the air felt be calendered, the air felt can be calendered after being wrapped and bonded in a bondable material by the method of the present invention.

However, the method of the present invention offers several advantages over simply embossing an absorbent article, such as an absorbent article with an embossed airfelt absorbent core. In such an absorbent article, the topsheet may be adhesively bonded to the airfelt absorbent core. The backsheet may be adhesively bonded to the air felt as well. Cellulose fibers in the air felt are supported by hydrogen bonds.
These hydrogen bonds suffer from the disadvantage that they tend to be dissociated by liquids.
Adhesives also suffer from the disadvantage that they tend to release by liquids and when certain surface treatments are applied to components of absorbent articles such as topsheets.

FIG. 14 shows another application of the method of the present invention. In the previous embodiment, the method of the invention involved placing the materials to be bonded on the outer surface of the incompatible material and bonding the materials to each other by penetrating the incompatible material. In FIG. 14, the method of the present invention is used to bond two mismatched materials to a bondable material located inside the mismatched materials.

FIG. 14 shows two webs 22 of incompatible material. The incompatible material webs 22 may comprise any of the incompatible materials described herein. Preferably, the webs of incompatible materials comprise an absorbent foam material.
Although it is difficult to attach such absorbent materials to other materials using an adhesive, in this embodiment, one layer of adhesive 98 raises each of the absorbent foam material webs 22 to a higher level. It is used to bond to a web 24 of a material having bonding properties. However, this adhesive bond runs the risk that the absorbent foam material may separate therefrom due to the poor structural integrity of the absorbent foam material. The web 24 of material having a higher bondability may be any of the second materials described herein. Preferably, the web 24 of material having a higher bondability comprises a nonwoven web.

As shown in FIG. 14, the web 22 of absorbent foam material to which the nonwoven web 24 has been adhesively attached is arranged with the nonwoven webs 24 adjacent and facing each other. The entire composite structure thus formed is then bonded to one another in the manner described herein. The composite structure is shown in FIG.
Can be bonded by passing through a nip between a pair of rolls as in the apparatus shown in FIG. This will form a bond 94 between the two nonwoven webs 24.

The bond 94 in this embodiment may be a “hidden” bond that is not visible from outside the absorbent foam material 22. The bond 94 may be concealed because the bond forming pattern element typically displaces a small amount of foam material. In addition, after bonding, the foam material 22 may be foamed over the bond area, making it less visible where the foam material has been displaced.

In addition, the methods described herein can be used for other purposes and to make other types of absorbent articles. For example, FIG. 15 shows an absorbent interlabial device 1020 bonded and shaped according to the method of the present invention. Absorbent interlabial device 1020 may comprise any suitable absorbent material, including any incompatible materials described herein. In the embodiment shown in FIG.
The absorbent interlabial device 1020 comprises a rayon core 1044 wrapped with a nonwoven web covering material 1046. Rayon is typically incompatible with conventional bonding techniques. However, as shown in FIG. 16, the method of the present invention bonds the rayon core 1044 by providing a bond 94 through the rayon between the nonwoven coatings 1046 on opposing sides of the absorbent interlabial material and Can be used to shape.

As shown in FIG. 16, the first portion 1046A of the coating material 1046 is preferably bonded to the second portion 1046 of the coating material via an absorbent rayon material 1044. The apparatus used to bond the coated absorbent material 1044 preferably comprises a pair of cylindrical rolls, an embossing roll 110 and an anvil roll 112. The cylindrical rolls 110 and 112 are the same as those shown in FIG. As in the embodiment shown in FIG. 8, preferably, at least one of the rolls 110 has a relief pattern on its surface. The embossing roll is configured to have a circular cylindrical surface 115 and a plurality of ridges or pattern elements 116 extending outwardly from surface 115. The land surface 118 of the relief pattern and pattern element 116 may be of any suitable construction. The sidewalls 119 of the pattern element 116 are preferably at an angle similar to that described in connection with the roll 110 shown in FIG.

Rolls 110 and 112 are preferably operated in a similar or similar manner as described above for the apparatus shown in FIG. 8 (without limitation, the range of surface velocity differences between the rolls, Range of nip pressure in between, including any possibility of heating one or both rolls, and replacing the rolls with other types of nip defining members)
.

In the embodiment of the device shown in FIG. 16, the relief pattern is a circular land surface 11.
8 comprising a plurality of spaced pattern elements (or "pattern element segments"). However, in the embodiment of the method shown in FIG. 16, the pattern elements 116 are arranged in a “half moon” structure. The pattern elements 116 are provided in an alternating pattern in which a bond 94 is formed on the opposite side of the long axis A1 of the "rope" coated with an absorbent material for each application of a bonding pattern.

The bonding process shown in these figures penetrates the sliver 1044 of the absorbent material and replaces the first portion 1046A of the coating material with the second portion 1046 of the coating material 1046.
46B is self-bonded.

The illustrated absorbent article embodiment demonstrates another benefit of the present invention. Bond 94
Can be arranged in a virtually unlimited number of patterns. These bonds 94 can be used to create a product having a virtually unlimited number of possible geometries. Bonding patterns can also be used to provide a degree of rigidity to the product along the lines passing through the bonds, thereby providing structural stability as well as shaping of the absorbent article. This line may be straight, curved, or partially straight and partially curved. Deep quilt-like grain may be created for liquid handling or appearance. The method of the present invention can be used in production lines operating at high speeds (e.g., 700-1,000 feet per minute) and is not limited to a particular pattern as in the sewing process.

FIGS. 17 and 18 show a satellite napkin 1320 that can be manufactured with several different features using the method of the present invention. FIG. 17 shows an absorbent article (extensible sanitary napkin indicated at 1320) where the method of the present invention is used to simultaneously perform several different operations in the process of making the absorbent article. Was. The sanitary napkin 1320 has a main body 1322. The main body 1322 includes a liquid-permeable topsheet 1324 and a liquid-impermeable backsheet 1 joined to the topsheet.
326 and an absorbent core 1328 located between the topsheet 1324 and the backsheet 1326. These components may be joined in any suitable manner that allows the combined sanitary napkin 1320 to be stretched. The sanitary napkin 1320 may include a pair of end seals 1329 formed by melting the top sheet and the back sheet together.
The sanitary napkin 1320 may also have wings or flaps 1330 extending from respective longitudinal edges of its body 1322.

The sanitary napkin 1320 shown in FIG. 17 has an absorbent core 1328 with a region 1334 formed into a particulate material 1336 by the methods described herein. As shown in FIG. 17, regions 1334 comprising particulate material are separated by non-forming bands 1338 oriented in both the longitudinal and lateral directions. In addition, the method of the present invention was preferably used to form strainable network regions in topsheet 1324 and backsheet 1326. The term "distortable network area" was issued to Chappell et al.
Materials Exhibiting Elastic-Like B
This is described in more detail in U.S. Pat. No. 5,518,801 entitled "eavior". The formation of a strainable network in the topsheet 1324 and the backsheet 1326 provides extensibility to these components of the sanitary napkin. The unformed bands of the strainable network in the topsheet 1324 and the backsheet 1326 provide these extensible components with elastic properties. The formation of the absorbent core 1328 into the particulate material can be accomplished by adding the absorbent core 1328 to the topsheet
And a shape that does not interfere with the extensibility of the back sheet 1326.

The topsheet 1324 and the backsheet 1326 can be unidirectional, more than one-directional, or X-
Extensibility can be provided in all directions in the Y plane. In the embodiment shown in FIG. 17, the sanitary napkin 1320 is extendable in both the vertical and horizontal directions. The sanitary napkin 1320 shown in FIG. 17 is preferably in the amounts specified in the disclosure of US Pat. No. 5,611,790 issued to Osborn et al. On Mar. 18, 1997 and entitled “Stretchable Absorbent Articles”. Can be extended.

FIG. 17 illustrates that the method described herein can be used to provide extensibility to a wing or flap 1330. The wings 1330 may be provided with extensibility in any of the directions defined for the topsheet and the backsheet. In addition, the sanitary napkin 13 may be provided on a device having a pattern different from that of the embossed surface in contact with the wing 1330 than that of the device in contact with the main body of the absorbent article.
By passing through 20, it is also possible to provide extensibility to wing 1330 in a different direction or amount than the topsheet and backsheet. The portions used to provide extensibility to the wings of the rolls may be placed close to each other if a mating roll is used, or the wings 13
If the 30 does not have as many layers as the body 1322, it may be more highly engaged.

The method of the present invention may also include embossing the components of the sanitary napkin and / or
Or used to bond to each other. FIG. 17 shows the sanitary napkin 13.
20 shows that twenty body facing surfaces may be provided with a plurality of embossments in the form of a melt bond 1340. Melt bond 1340 may be formed by providing a plurality of bonding elements to the embossing surface of a device used to form absorbent core 1328 into a particulate material. The bonding element may optionally be heated if necessary. Typically, to bond the components together, at least those components that are to be bonded to each other preferably comprise at least some thermoplastic material. In other embodiments, it may be desirable for the embossing surface to be provided with elements that simply emboss the body facing surface of the sanitary napkin and do not form a molten bond between its components.

The method of the present invention therefore forms the absorbent core 1328 into a particulate material, provides extensibility to the topsheet 1324 and the backsheet 1326, provides extensibility to the wings or flaps 1330, and The components may be embossed and / or bonded together and used to seal the ends of the sanitary napkin 1320. This can all be achieved with a single pass through a device similar to those shown in the figures. Further, as shown in FIG. 18, the bonding pattern may provide integrity by penetrating the topsheet completely to the backsheet and partitioning it into an absorbent material. For example, the absorbent material may comprise a thermally bonded airlaid material. In such embodiments, it may not be necessary to provide a conventional binder fiber or powder binder to maintain the integrity of the material.

The disclosures of all patents, patent applications (and patents derived therefrom as well as the corresponding foreign patent applications), and publications mentioned in this description are hereby incorporated by reference.
It is expressly recognized, however, that none of the documents incorporated herein by reference teach or disclose the invention. While particular embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention.

[Brief description of the drawings]

FIG. 1 is a perspective view of a composite web of material with incompatible absorbent foam material bonded using the method of the present invention and shaped into an absorbent tube for a sanitary napkin.

FIG. 2 is a perspective view of an apparatus used to form the absorbent material in the composite web shown in FIG. 1 into a particulate material in the process of making an optional but preferred absorbent tube.

FIG. 3 is a partially fragmented perspective view of the composite web shown in FIG. 1 after being fed into the apparatus shown in FIG. 2 and the incompatible absorbent foam material has been formed into a particulate material.

FIG. 4 is a perspective view of the composite web shown in FIG. 3 after a side edge has been folded in a first optional folding operation.

FIG. 5 is a schematic perspective view of the composite web shown in FIG. 3 after being folded in a second optional folding operation.

FIG. 6 is a schematic perspective view of the composite web shown in FIG. 5 after portions have been bonded to each other.

FIG. 7 is a simplified cross-sectional view of the web shown in FIG. 6 taken at one of the bonding locations along line 7-7 of FIG. 6;

FIG. 8 is a schematic perspective view of one embodiment of one step of a method used to bond a tube of absorbent material for a sanitary napkin with an embossing roll shown in a simplified manner.

FIG. 9 is a simplified fragmentary schematic showing the relatively high caliper material in the nip between an embossing roll and an anvil roll, where the embossing roll compresses around its raised element. Does not provide possible materials.

FIG. 10 is a simplified fragmentary schematic showing the relatively high caliper material in the nip between the embossing roll and the anvil roll, where the embossing roll compresses around its raised element. Offering possible materials.

FIG. 11 is a perspective view showing the surface of a conventional dynamic bonding roll having an intermittent load bearing member.

FIG. 12 is a perspective view showing the surface of an embossing roll used in one embodiment in a method of the invention having a continuous load bearing member.

FIG. 13 is a perspective view of a compound wound sanitary napkin having a tube of absorbent material bonded and shaped by the method of the present invention on the body-facing side.

FIG. 14 is a perspective view illustrating an alternative method of bonding two incompatible materials together using the method of the present invention.

FIG. 15 is a perspective view of an absorbent interlabial device bonded and shaped according to the method of the present invention.

FIG. 16 is a perspective view of a variation of the method of the present invention used to create an inter-lip device.

FIG. 17 is a partially fragmented plan view of a sanitary napkin made by the method of the present invention.

FIG. 18 is a schematic sectional view of a part of the sanitary napkin shown in FIG.

──────────────────────────────────────────────────続 き Continued on the front page (31) Priority claim number 09 / 031,352 (32) Priority date February 26, 1998 (Feb. 26, 1998) (33) Priority claim country United States (US) ( 81) Designated countries EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE), OA (BF, BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, GM, KE, LS, MW, SD, SZ, UG, ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, CA, CH, CN, CU, CZ, DE, K, EE, ES, FI, GB, GE, GH, GM, HR, HU, ID, IL, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR, LS, LT, LU, LV, MD, MG, MK, MN, MW, MX, NO, NZ, PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR, TT, UA, UG , US, UZ, VN, YU, ZW (71) Applicant ONE PROCTER & GANBLE PLAZA, CINCINNATI, OHIO, UNITED STATES OF AMERICA (72) Inventor Reeve, Jonathan Lee United States of America, 45241, Sincinnati, Ohio Carrageage Drive 4168 (72) Inventor Woods, Greg Lynn Hunters C, Cincinnati, 45242, Ohio, United States Park Drive 9224, Apartment Day (72) Inventor Coulner, Wilfried M. United States 45238, Ohio, Cincinnati, Anderson Ferry Road 1740 (72) Inventor Hammonds, John Lee United States, Ohio Dust Commander Court 7379, Hamilton, State 45011

Claims (26)

[Claims] 1. A method for bonding a plurality of materials during a manufacturing process of an absorbent article, comprising: (a) providing a first material, wherein the first material has a first bonding property; Comprising a first surface and a second surface; the method further comprising: (b) at least one having a bonding property higher than the first bonding property. Providing another material; and (c) providing at least a portion of the first and second surfaces of the first material with the at least one material having a bonding property higher than the first bonding property. And (d) reducing the material having a higher bonding property covering at least a part of the first surface of the first material by less than the second surface of the first material. When A material having a higher bondability than the covering portions, said first
Bonding using a plurality of bonds penetrating the material. 2. The method of claim 1, wherein the first material has at least some incompatibility with a conventional bonding process. 3. The method of claim 1, wherein said step (d) of bonding said plurality of materials comprises self-bonding said plurality of materials. 4. The step (d) of bonding the plurality of materials to each other.
4. The method of any of the preceding claims, comprising bonding the plurality of materials using pressure. 5. The method according to claim 1, wherein the first material comprises an absorbent foam material. 6. The method according to claim 1, wherein the at least one other material is a web of a non-woven material. 7. The method according to claim 1, wherein the at least one other material is a single web wound on both sides of the first material. 8. The method according to claim 1, wherein the at least one other material comprises a glue layer or a polymer coating. 9. A composite structure, comprising an absorbent material having at least some incompatibility with a conventional bonding process, wherein said incompatible material has a first bondability as well as a first bondability. And at least partially coated with at least one material having high bonding properties
Wherein the composite structure at least partially covers the first surface of the incompatible material at least partially covers the portion of the coating material at least partially on the second surface of the incompatible material A composite structure comprising one or more bonds to be bonded to a portion of the coating material, wherein the composite structure has a quilted appearance in the area of the bond. 10. A method of bonding via an absorbent material having at least some incompatibility with a conventional bonding process during a manufacturing process of an absorbent article, comprising: Providing an absorbent material having at least some incompatibility, said absorbent material having a first bondability, a first surface, and an opposing second surface; said method comprising the steps of: (B) providing at least one other material having a bonding property higher than the first bonding property; and (c) providing the second material of the absorbing material. Covering at least a part of the first and second surfaces with at least one material having a bonding property higher than the first bonding property; (D) applying a local force to the coated absorbent material to push away the absorbent material at the location where the force is applied, wherein the force is applied to a back-to-back surface of the absorbent material; (E) bringing said materials having a bonding property higher than said first bonding property into contact with each other at a position where said absorbent material has been displaced; Bonding the materials having a high bonding property to each other. 11. The absorbent material has a break point lower than the break point of the higher bonding material, and the local force is greater than the break point of the absorbent material. 11. The method of claim 10, wherein the absorbent material ruptures in at least one location without breaking the material having a bonding property that is less than the breaking point of the material having the bonding property. 12. The steps (d) and (e) of applying the local force to dislodge the absorbent material and bond the materials having higher bonding properties to each other are performed in a single operation. The method of claim 11. 13. A method of bonding a plurality of thin layers to one another, wherein at least one of the plurality of thin layers comprises a thermoplastic material, and (a) providing an anvil member and a relief embossing nip defining member. Process,
The relief embossing member has a surface with a plurality of outwardly extending pattern elements; the method includes the relief embossing member comprising a compliant material on its surface, the compliant material comprising: (B) at least partially surrounding at least some of said plurality of pattern elements; and (b) embossing said plurality of laminar layers with said anvil member and said relief in a partially facing relationship with each other. Advancing a pressure-biased nip between the embossing member; and (c) compressing at least a portion of the plurality of laminae and bonding at least some of the plurality of laminae to one another for lamination. Biasing the nip defining members toward each other at a pressure sufficient to form a body without puncturing the laminate. 14. A method of bonding a plurality of laminas to each other, wherein at least one of the plurality of laminas comprises a thermoplastic material, and (a) providing an anvil member and a relief embossing nip defining member. Process,
The relief embossing member has a surface with a plurality of outwardly extending pattern elements; and (b) providing the plurality of laminae in a partial face-to-face relationship;
The method further comprising: (c) compressing at least a portion of the plurality of laminae in a plurality of regions where the plurality of bonds of the plurality of laminae are to be formed. (D) defining the nip without puncturing the laminate at a pressure sufficient to cause the plurality of pattern elements to bond at least some of the plurality of thin layers together to form a laminate. Biasing the members toward each other. 15. The method of claim 14, wherein said compressing step (c) is performed prior to said bonding of step (d). 16. The method of claim 14, wherein said compressing step (c) is performed simultaneously with said bonding of step (d). 17. The method of claim 13, wherein at least one of the plurality of laminas comprises an absorbent material. 18. The method of claim 13, wherein the plurality of laminas have a combined caliper of about 2 mm or more. 19. A method of bonding a plurality of laminas to each other, wherein at least one of the plurality of laminas comprises a thermoplastic material, the method comprising: (a) providing an anvil member and a relief embossing nip defining member. Process,
The embossing member has a surface with a plurality of outwardly extending pattern elements; the method comprises: at least one of the anvil member and the embossing member comprising at least one holding member; At least one retaining member having a height sufficient to maintain contact with at least a portion of a surface of the anvil member when the embossing member and the anvil member are in the nip defined relationship; (B) advancing the plurality of laminas in a partially facing relationship to a pressure-biased nip between the anvil member and the embossing member; (C) at least some of said plurality of pattern elements bond at least some of said plurality of thin layers together to form a laminate; How comprising the step of biasing toward each other the nip defining members at a pressure sufficient to. 20. The method of claim 19, wherein the anvil member and the embossing member comprise a rotating roll. 21. The method of claim 20, wherein the at least one retaining member comprises a continuous ring around the circumference of at least one of the anvil member and the embossing member. 22. There is a difference in the surface area of the plurality of pattern elements around the circumference of the embossing roll, and the surface area of the at least one holding member is different from the plurality of patterns around the circumference of the embossing member. 22. A method according to claim 20 or claim 21 selected to balance differences in surface area of the elements. 23. The method of claim 21, wherein said at least one holding member has at least one cutout area therein. 24. The plurality of pattern elements include a plurality of lands having a surface area, and the at least one cutout area has a plan view size equal to the surface area of the lands of the plurality of pattern elements. Item 2
3. The method according to 3. 25. The at least one holding member having a preselected shortest distance between the axis of the anvil member and the axis of the embossing member, the plurality of pattern elements having a spacing therebetween. 22. A method according to claim 20 or claim 21, wherein the method is maintained even when in use. 26. The at least one holding member leaves the anvil member and the embossing member in contact even when the plurality of pattern elements have a spacing therebetween. A method according to claim 20 or claim 21.