MXPA06005195A - Folded absorbent product and method of producing same - Google Patents

Abstract

Absorbent structures are disclosed which may be incorporated into liquid absorbent products (10), such as diapers, adult incontinence products, feminine hygiene products, and the like. The absorbent structures are made from a fibrous material and include a pair of opposing lateral flaps (24, 26). The lateral flaps (24, 26) are folded onto the fibrous web. By folding the lateral flaps onto the fibrous web, greater basis weight areas may be formed on the absorbent structure. By varying the width of the lateral flaps, the basis weight differential may be increased and decreased. The lateral flaps also form the widest portion of the web material for facilitating folding during a continuous process. Through the system and process of the present invention, a fibrous web having a substantially uniform basis weight may be converted into absorbent structures having a differential basis weight with little or no waste produced. Further, the absorbent structures may be formed without having to subject the fibrous web to a scarfing process.

Description

A BENDABLE ABSORBENT PRODUCT AND METHOD TO PRODUCE THE SAME BACKGROUND OF THE INVENTION Many types of disposable consumer products such as diapers, training underpants, women's care articles, incontinence articles, and the like, utilize an absorbent pad structure to absorb and transmit body fluids. The absorbent pads are conventionally formed of an absorbent fabric, typically a fibrous non-woven fabric material. With a particular practice, the absorbent fabric is formed by employing conventional air-laying techniques wherein the fibers and typically a super absorbent material are mixed and carried in a stream of air and then directed to a forming surface to form the tissue. The absorbent tissue can then be directed for further processing and assembly with other components to produce a final absorbent article. An advantage of this practice is that the clipping waste can be immediately recycled by returning the waste to the upstream fiberization equipment and / or to the air placement equipment.

With another conventional technique, the preformed absorbent fabric layers or sheets are delivered to a manufacturing line from a preformed supply, such as a supply roll. The absorbent sheet material can be separated into adjacent strips having several shaped pad configurations "nested" with a repeat pattern wherein the shape of a pad is essentially nested in the shape of at least one adjacent pad immediately. The roll process of preformed absorbent material presents particular challenges. For example, the geographical separation of the base roll manufacturing machine from the recycling of impractical and cost prohibitive waste material. In this aspect, the aforementioned nesting feature has been desirable to reduce the amount of waste that is generated from the original absorbent tissue supply roll. However, with conventional nesting techniques and profiles, a large amount of clipping waste is still generated.

In some applications, it may be desirable to provide a superior basis weight of absorbent material in the crotch portion as compared to the front and back portions. This has been conventionally done by using a shape surface in a bag-forming process. The bags have a greater depth than other parts of the forming surface. Therefore, during the air forming process, the fibers and absorbent pads are collected in the bags creating areas of greater basis weight.

Unfortunately, the bags can not be filled completely without overfilling the bagless regions. Consequently, the fibrous tissue formed has to be culled in order to remove the absorbent material in the bagless regions. The culled fibrous material is then returned to the formation chamber and reused.

In addition to having to select the final product, the use of the bag-forming surface has other limitations. For example, proportions by basis weight are limited by the process. In addition, thinning can be carried out practically when several components are contained in the fibrous material that is used to form the absorbent layer. For example, thinning is not well suited for absorbent structures with very high absorbent / absorbent / absorbent material ratios with components such as meltblown fibers, which can be added in certain situations to improve integrity.

The present invention provides a method for producing longitudinally symmetric or asymmetric absorbent pad structures with minimum or zero waste.

The pad structures can be formed in an on-line process that produces absorbent garments or, alternatively, an absorbent material can first be formed and subsequently converted into the absorbent pad structures of the present invention for use in the absorbent garments. The absorbent structures made according to the present invention have areas of higher basis weight at the desired locations.

SYNTHESIS OF THE INVENTION Various features and advantages of the invention will be set forth in part of the following description, or may be obvious from the description or may be learned through the practice of the invention.

The present invention provides an improved method for making absorbent structures for use in various consumer disposable absorbent article applications, such as disposable diapers, children's learning pads, feminine care articles including but not limited to products. for between the lips, the incontinence articles, the swimming pads and the like.

For example in one embodiment, the present invention is directed to an absorbent article including an outer cover material, a liner and an absorbent structure positioned between the outer cover material and the liner. According to the present invention, the absorbent structure includes a front part, a back part and a middle part. The absorbent structure further includes a pair of opposed lateral fins that have been bent over at least the middle part of the absorbent structure. Each of the fins when in an unfolded state, extends beyond the width of the front. In addition, each of the fins has a width adjacent to the middle part that is from about 25% to 100% of the width of the middle part. For example, in one embodiment, the fins have a width adjacent to the middle part that is from about 33% to 100% of the width of the middle part, while in another embodiment, the fins have a width that is from around 50% to 100% of the width of the middle part.

Of particular advantage, by having a width extending beyond the width of the front part, each of the side flaps can be easily bent over the absorbent structure for example by a stationary bending device. Another advantage of the present invention is that the side flaps, when they are bent, produce areas of higher basis weight on the absorbent structure. For example, in most applications, the side flaps are folded over the middle part creating a middle part that has a basis weight that may be greater than the basis weight of the front or rear part. The difference in basis weight can vary widely depending on the manner in which the absorbent material is formed and the size and shape of the lateral fins. For example, the middle part may have a basis weight that is from about 25% or greater than about 300% or greater than the basis weight of the front and / or back part. Depending on the size of the fins, once the fins are folded, the middle part can include two layers of material or can include three layers of material.

Base weight differences can be formed on the absorbent structure according to the present invention of a fibrous fabric having an essentially uniform basis weight. Therefore, areas of higher basis weight can be formed on the absorbent structure without having to use a three-dimensional forming surface and without having to pick up the absorbent fibrous tissue after it is formed.

In other embodiments, however, the absorbent structures of the present invention can be formed of fibrous fabrics which, prior to the folding of the lateral fins, already have a base weight difference existing over the surface area of the fabric, including absorbent fabrics that they have been formed using a three-dimensional forming surface. By using an absorbent fabric that already contains a differential basis weight, the side flaps can be used to further increase base weight differences or to vary them in a desired manner.

Absorbent fabrics that can be used in the present invention in addition to absorbent fabrics having a uniform basis weight include absorbent fabrics having a thicker middle part than the front or back, absorbent fabrics having a thicker front or back. in relation to a middle part, the absorbent fabrics formed of a bag-forming fabric thereby having a relatively thicker area that can vary in thickness and basis weight in the machine-transverse direction, and absorbent fabrics containing depressions or wells that they are used to form base weight differences. As used herein, the direction of the machine refers to the direction of movement from the front to the back of the absorbent tissue, while the direction transverse to the machine refers to the direction of movement from side to side (see Figure 3).

The absorbent structure can have a global hourglass type shape. In particular, once the side flaps have been folded, the middle part can be narrower than the front part and the back part.

The length of the lateral fins may vary depending on the particular application. For example, in one embodiment, the side flaps may extend only to a part of the entire length of the absorbent structure. In this embodiment, the side flaps are connected to the middle part and are separated from the front by a first groove and separated from the back by a second groove. The first slits and the second slits may be essentially perpendicular to the longitudinal axis of the absorbent structure, may be diagonal to the longitudinal axis, or may have any suitable non-linear or arcuate shape.

In another embodiment, the lateral alterations may extend to the entire length of the absorbent structure. In this embodiment, the side flaps are separated from the front by a first pair of opposed slits and are separated from the back by a second pair of opposed slits. The first pair of opposed slits generally extends in the longitudinal direction along the front and are then directed inward towards the middle part. Similarly, the second pair of opposed slits generally extends in the direction of the longitudinal direction along the rear part and are then directed inward towards the middle part.

When the side flaps extend to the full length of the absorbent structure, several unique base weight differences can be formed in the product.

For example, absorbent structures can be formed so that a middle part comprises two or three layers. The front and back, on the other hand, can include composite areas of a single layer and composite areas of two layers.

Therefore, when formed of an absorbent fabric material having a uniform basis weight, once the side flaps are folded, the middle part can have a basis weight that is at least twice the base weight of the part areas. front and back, and, in one embodiment, at least three times the base weight of the front and back areas. In this embodiment, the front and back may also include areas of higher basis weight. For example, an area of the center of the front and the center area of the back may have a basis weight that is at least twice the base weight of the two opposite side areas on the front and two opposite side areas on the back.

Base weight differences can be modified and varied by varying the width of the folded side wings. In addition, the base weight differences can also be modified and varied by the use of an absorbent fabric that already contains the base weight differences as described above.

The present invention is also generally directed to a method for forming the absorbent structures described above. For example, in one embodiment, a strip of absorbent fabric material is carried along the direction of the machine. The absorbent fabric material is cut to form the opposing side flaps. Opposite lateral fins define a wider part of the absorbent tissue material.

Once formed, the opposite lateral fins are bent over the absorbent tissue material. The strip of fabric material is cut in a transverse direction in individual absorbent pads.

The strip of absorbent fabric material can be formed according to any suitable process. For example, the absorbent tissue material may be formed on an in-line manufacturing process such as an on-line air-forming process, or in an off-line manufacturing process such as an off-line air-laying process. The processes that can be used to form the absorbent tissue material include the air forming process, a coform process, or a wet laying process. The absorbent fabric material may have a basis weight, for example, from about 100 grams per square meter to about 2,000 grams per square meter. In a particular embodiment, the absorbent fabric material contains cellulosic fibers and super absorbent particles.

The invention will be described below in greater detail with reference to the particular embodiments set forth in the figures.

BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a perspective view of an incorporation of an absorbent article that is made in accordance with the present invention.

Figure 2 is a perspective view of another embodiment of an absorbent article that can be made in accordance with the present invention.

Figure 3 is a plan view of a bent absorbent article similar to one shown in Figure 2.

Figure 4 is a plan view with cut away portions of the absorbent article shown in Figure 3.

Figure 5 is a perspective view of an incorporation of an absorbent structure made in accordance with the present invention.

Figure 6 is a plan view of the absorbent structure shown in Figure 5.

Figure 7 is an unfolded plan view of the absorbent structure shown in Figure 5.

Figure 8 is a perspective view of a process for forming the absorbent structure illustrated in Figure 5.

Figures 9-11 are views of a strip of fabric material that is formed sequentially in a plurality of absorbent structures as shown in Figure 5.

Figure 12 is a perspective view of another embodiment of an absorbent structure made in accordance with the present invention.

Figure 13 is a plan view of the absorbent structure shown in Figure 12.

Figure 14 is a plan view of the absorbent structure shown in Figure 12 in an unfolded state.

Figures 15-17 are successive plane views of a strip of woven material being formed in a plurality of absorbent structures as shown in Figure 12.

Figure 18 is a perspective view of yet another embodiment of an absorbent structure made in accordance with the present invention.

Figure 19 is a plan view of an absorbent structure shown in Figure 18.

Figure 20 is a plan view of the absorbent structure shown in Figure 18 in an unfolded state.

Figure 21 is a perspective view of an embodiment of a process for forming the absorbent structure shown in Figure 18.

Figures 22-24 are successive plane views of a strip of woven material being formed in a plurality of absorbent structures as shown in Figure 18.

Figure 25 is still another embodiment of an absorbent structure made in accordance with the present invention.

Figure 26 is a plan view of the absorbent structure shown in Figure 25.

Figure 27 is a plan view of a section that can be used to form the absorbent structure illustrated in Figure 25.

Figures 28-30 are successive plan views of a strip of fabric material that is formed into a plurality of absorbent structures as shown in Figure 25.

Figure 31 is a perspective view of an embodiment of a process and a system for forming absorbent products according to the present invention.

DETAILED DESCRIPTION The invention will now be described in detail with reference to the particular embodiments thereof. The incorporations are provided by way of explanation of the invention and are not intended as a limitation of said invention. For example, the features described or illustrated as part of an incorporation can be used with another embodiment to give even a further incorporation. It is intended that the present invention include these and other modifications and variations as they fall within the scope and spirit of the invention.

The present method is particularly suitable for the manufacture of the cushion structures of a fabric of absorbent material, the pads are intended for use in various consumer disposable absorbent products, Such products include, but are not limited to, diapers, training underpants for children, women's care items (such as panty liners, pads and lip products), incontinence articles, swim shorts and the like. The invention is not limited to any particular type or composition of absorbent woven material, and may be practiced with any suitable absorbent woven material known to those skilled in the art. The absorbent woven material may include any structure and combination of components which are generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquids and certain body wastes.

The absorbent structures of the present invention generally include a front part, a middle part and a back part. In accordance with the present invention, the absorbent structures further contain a pair of opposed side wings that are bent over at least the middle part of the absorbent structure. The side flaps, when in the unfolded state, form the widest part of the unfolded fabric making it relatively easy for the stationary folding device to bend the flaps over the fabric as the fabric is carried in the longitudinal direction. In addition, the absorbent structures can be formed without producing any clipping waste.

By bending the side flaps on the absorbent fabric, larger base weight areas can be formed in the middle part of the absorbent structure which correspond to the crotch region of an absorbent product incorporating the absorbent structure. Of particular advantage, the difference in basis weight can be varied depending on the width and length of the lateral fins. In addition, the difference in basis weight can be formed without having to use a three-dimensional forming surface and without having to select the fabric after the tissue has been formed.

The absorbent fabric material used to form the absorbent structures may include, for example, cellulosic fibers (eg wood pulp fibers), other natural fibers, synthetic fibers, woven or non-woven sheets, canvas netting or other stabilizing structures, super absorbent material, binder materials, surfactants, selected hydrophobic materials, pigments, lotions, other odor control agents or the like, as well as combinations thereof. In a particular embodiment, the absorbent woven material is a matrix of cellulose fluff and super absorbent hydrogel forming particles. The cellulosic fluff may comprise a mixture of fluff of mother pulp. A preferred type of lint is identified with the trade designation CR 1654, available from US Alliance Pulp Mills of Coosa, Alabama, United States of America, and is a highly absorbent and bleached wood pulp containing primarily softwood fibers. As a general rule, the super absorbent material is present in the absorbent fabric in an amount of from about 0 to about 100% by weight based on the total weight of the fabric. The fabric has a density in the range of about 0.10 to about 0.50 grams per cubic centimeter.

Super absorbent materials are well known in the art and can be selected from natural, synthetic and modified natural materials and polymers. The super absorbent materials may be inorganic materials, such as silica gels or organic compounds such as crosslinked polymers. Typically, a super absorbent material is capable of absorbing at least about 15 times its weight in liquid, and desirably is capable of absorbing more than about 25 times its weight in liquid. Suitable super absorbent materials are already available from various suppliers. For example, the super absorbent FAVOR SXM 880 available from Stockhausen, Inc., of Greensboro, North Carolina, United States of America; and Drytech 2035 available from Dow Chemical Company, of Midland, Michigan, United States of America.

Subsequent to or after being cut from the strip of fabric material, the individual absorbent pads may be partially or completely wrapped or encompassed by a suitable nonwoven or tissue wrap that helps maintain the integrity and shape of the pad. For example, in one embodiment, the absorbent fabric material can be formed on a tissue or non-woven fabric and then subsequently wrapped to form individual absorbent structures.

The absorbent materials can be formed into a fabric structure by employing various conventional methods and techniques. For example, the absorbent fabric can be formed with a dry forming technique, an air laying technique, a carding technique, a meltblowing or spinning technique, a wet forming technique, foaming or the like, as well as combinations thereof. Layered and / or laminated structures may also be suitable. The methods and apparatus for carrying out such techniques are well known in the art.

The absorbent tissue material can also be a coform material. The term "coform material" generally refers to composite materials comprising a stabilized matrix or blend of thermoplastic fibers and a second non-thermoplastic material. As an example, coform materials can be made by a process in which at least one melt blown die head is arranged near a conduit through which other materials are added to the fabric while it is being formed. Such other materials may include, but are not limited to, fibrous organic materials such as wood or non-woody pulp such as cotton, rayon, recycled paper, pulp fluff, and also super absorbent fibers or particles, inorganic absorbent materials, polymeric short fibers. treated and similar. Any of a variety of synthetic polymers can be used as the melt spinning component of the coform material. For example, in some embodiments, thermoplastic polymers can be used. Some examples of such suitable thermoplastics that can be used include polyolefins, such as polyethylene, polypropylene, polybutylene and the like; polyamides; and polyesters. In one embodiment, the thermoplastic polymer is polypropylene. Some examples of such coform materials are described in U.S. Patent Nos. 4,100,324 issued to Anderson et al .; 5,284,703 granted to Everhart and others; and 5,350,624 issued to Georger and others; all of which are incorporated herein in their entirety by reference for all purposes.

It is also contemplated that elastomeric absorbent tissue structures may be particularly useful with the present invention. For example, an elastomeric coform absorbent structure having from about 35% to about 65% by weight of wettable short fiber, and more than about 35% to about 65% by weight of an elastomeric thermoplastic fiber can be used for define absorbent pad structures according to the invention. Examples of such elastomeric coform materials are provided in U.S. Patent No. 5, 645,542 incorporated herein in its entirety for all purposes. As another example, a suitable absorbent elastic nonwoven material may include a matrix of thermoplastic elastomeric nonwoven filaments present in an amount from about 3 to less than about 20% by weight of the material, with the matrix including a plurality of absorbent fibers and a super absorbent material each constituting around 20-77% by weight of the material. U.S. Patent No. 6,362,389 describes such nonwoven material and is hereby incorporated by reference in its entirety for all purposes. Absorbent elastic non-woven materials are useful in a wide variety of personal care items where softness and conformation, as well as absorbency and elasticity are important.

The absorbent fabric can also be a non-woven fabric comprising synthetic fibers. The fabric may include additional natural fibers and / or super absorbent material. The fabric can have a density in the range of about 0.05 to about 0.5 grams per cubic centimeter. The absorbent fabric can alternatively be a foam.

In a particular aspect of the invention, the absorbent fabric material can be provided with an absorbent capacity of at least about 8 g / g using 0.9% by weight of salt water (8 grams of 0.9% by weight of salt water per gram of absorbent tissue). The absorbent capacity of the absorbent fabric may alternatively be at least about 9 g / g and may optionally be at least about 15 g / g to provide improved benefits. Additionally, the absorbent capacity can be up to about 40 g / g or more to provide the desired performance.

In another aspect, the fabric of absorbent material can be provided with a tensile strength value of at least about 0.5 N / centimeter (Newtons per centimeter of "width" of the material, where the "width" direction is perpendicular to the force applied). The tensile strength of the absorbent fabric may alternatively be at least about 1.5 N / centimeter and may optionally be at least about 2 N / centimeter to provide the improved benefits. In another aspect, the fabric of absorbent material can be provided with a tensile strength value of up to a maximum of about 100 N / centimeter or more. The tensile strength of the absorbent fabric can alternatively be up to about 10 N / centimeter and can optionally be up to about 20 N / centimeter to provide the improved benefits.

The selected tensile strength should provide adequate processing of the fabric through the manufacturing process, and can help produce articles exhibiting desired combinations of softness and flexibility. In particular, the absorbent fabric material must have a tensile strength in the transverse direction to undergo stretching as described herein without resulting in a substantial degradation of the fabric integrity to the extent that the pad structures can not be also processed in absorbent articles. In some cases, the stretching of the fabric material in the transverse direction can provide a softer and more flexible material than the initial fabric. This is generally desired for initially rigid materials such as air-laid or stabilized wet materials.

The fabric of absorbent material is also selected so that the individual absorbent pad structures have a particular individual total absorbency depending on the article of intended use. For example, for infant care items, the total absorbency may be within the range of about 200-900 grams of a 0.9% by weight salt water solution, and can typically be around 500 grams of 0.9%. by weight of salt water. For adult care products, the total absorbency may be within the range of about 400-2,000 grams of 0.9% by weight of salt water, and can typically be around 1,300 g of salt water. For women's care products, the total absorbency may be within the range of about 7-50 grams of menstrual fluid or menstrual fluid simulator, and may typically be within the range of about 30-40 grams of menstrual fluid or menstrual fluid simulator.

Referring to Figures 5-6, an incorporation of an absorbent structure generally made in accordance with the present invention is shown. As shown in figures 5 and 6, in this embodiment, the absorbent structure 10 includes a front part 12, a middle part 14 and a back part 16. The absorbent structure 10 has a generally hourglass shape in the sense of that the middle part 14 is narrower than the front part 12 and the back part 16. If desired, however, the rear part 16 can also be narrower than the front part 12.

Referring to figure 7, a section generally that can be used to form the absorbent structure 10 as shown in Figures 5 and 6 is illustrated. As shown, the section 20 includes a pair of opposite lateral fins 22 and 24. The lateral fins 22 and 24 are each connected to the middle part 14 of the absorbent fabric. The side flaps 22 and 24 are separated from the front part 12 by a pair of front slits 26 and are separated from the rear part 16 by a pair of rear slots 28. In this embodiment, the slits 26 and 28 are all diagonal to the shaft longitudinally of the section 20. Specifically, the slits 26 are angled inward from the front 12 to the middle part 14 while the slits 28 are angled inward from the rear 16 to the mid-portion 14. In other embodiments, however, the slits 26 and 28 may be perpendicular to the longitudinal axis of the section 20 or may have any non-linear or arcuate shape.

In order to form the absorbent structure 10 as shown in Figure 5, the side flaps 22 and 24 are bent over the middle part 14. In this way, a larger base weight area is created in the middle part compared to the weight base of the front part 12 and the back part 16, assuming that the fibrous fabric used to form the absorbent structure has an essentially uniform basis weight.

Referring to figure 7, the lateral fins each have a width X, while the middle part has a width Y. In this embodiment, the width of the lateral fins is approximately one half the width of the middle part 14. Therefore , once the side flaps 22 and 24 are bent, the middle part 14 comprises two layers of material having a basis weight that is about twice the basis weight of the front part 12 and the back part 16, yes the section 20 is made of an absorbent material having a generally uniform basis weight. In other embodiments, the section 20 can be made of an absorbent material having differential preformed base weights. For example, the section 20 can be made of an absorbent material having a higher basis weight in the middle part than in the front and back. Alternatively, the absorbent material may have a base weight differential that extends in the transverse direction to the machine (address 86 shown in Figure 3). For example, the side flaps may have a basis weight greater than the middle part of the absorbent material. In another embodiment, the front and back may have a basis weight greater than the middle part. In other embodiments, the absorbent material can be formed using a three-dimensional forming surface that forms high-weight pockets in the fabric. In still other embodiments, wells or depressions can be formed in the tissue to form smaller basis weight areas. Therefore, the difference in basis weight between the middle part 14 and the rest of the absorbent structure 10 can vary widely depending on the particular application. For example, once the side flaps are bent, the middle part 14 can have a basis weight that is from about 25% to over 200% greater than the basis weight of the front or rear part.

When incorporated into an absorbent article, the middle part 14 generally forms the crotch area of the article. Having a higher basis weight in the crotch area of an absorbent product is generally desired.

Of particular advantage, the differential basis weight, the location of the suppressed base weight areas and even the fluid handling properties of the structure can be modified as desired by varying the width of the lateral fins 22 and 24. For example, the side flaps 22 and 24 can have a width X that can vary from about 25% to 100% of the width Y of the middle part 14.

For example, if the width of the side flaps 22 and 24 is less than 50% of the width of the middle part 14, a fluid channel is formed directly in the center of the product having a basis weight slightly less than the basis weight from the rest of the middle part. More importantly, the channel that is formed can be used to quickly collect fluids that are then absorbed into the rest of the middle part.

The alternate incorporations, the side flaps 22 and 24 can have a width that is greater than 50% of the width of the middle part 14. When the side flaps 22 and 24, for example, have a width greater than 50% of the width of the middle part, the side flaps will overlap the center of the absorbent structure 10. Where the flaps overlap, the middle part 14 comprises a three layer structure. Therefore, when the absorbent structure is formed of an absorbent material having a relatively uniform basis weight, bending the flaps creates a basis weight in the middle part that is three times the basis weight of the front part 12 or the back part 16 .

As described above, however, the absorbent materials of non-uniform basis weight can also be used in the formation of the absorbent structure 10. Thus the current base differential weight between the middle part 14, the front part 12 and the back part 16 can vary dramatically. In general, for example, the middle part may have a basis weight that is from about 25% to over 300% more than the basis weight of the rest of the absorbent structure.

For example, referring to Figures 12 and 13, another embodiment of an absorbent structure generally made in accordance with the present invention is shown. In Figure 14, there is illustrated a generally section 32 that can be used to form the absorbent structure 30. In Figures 12 and 14, like reference numbers have been used to indicate similar elements.

As shown in Figure 14, in this embodiment, the section 32 includes a pair of opposed lateral fins 22 and 24 having a width X that is essentially the same width X as the middle part 14. In this manner, both lateral fins 22 and 24 when folded extend across the full width of the middle part 14. Thus, a middle part is formed or created which has a three layer structure and can have a basis weight that is three times the base weight of the front part 12 and of the back part 16 if the absorbent structure is formed of an absorbent material having a relatively uniform basis weight. This difference in basis weight of 3 to 1 is formed according to the present invention of a fabric that can have an essentially uniform basis weight and without having to select the fabric.

Referring to FIGS. 12 and 13, due to the shape of the front slots 26 and the rear slots 28, the triangular portions 34 and 36 are also formed. Once the side flaps 22 and 24 are bent, the triangular portions 34 and 36 contain two layers of material and therefore have a basis weight that is twice the basis weight of the front part 12 and the back part 16.

As shown in Figures 7 and 14, the lateral fins 22 and 24 of both sections 20 and 32 form the widest part of the fibrous tissue. By forming the widest part of the fabric, the fins can be easily located and bent using a stationary bending device. In fact, due to the width of the fins, it may be necessary to mark the fabric before folding the fins, even though the marking lines may be formed on the absorbent tissue where the fins are to be folded if desired.

Referring to Figures 18 and 19, yet another embodiment of a generally absorbent structure 40 made in accordance with the present invention is shown. A section generally indicated with the number 42 used to form the absorbent structure is shown in Figure 20. Again, the same reference numbers have been used to indicate similar elements. Referring to Figure 20, in this embodiment, the side flaps 22 and 24 extend to the full length of the segment 42. In order to separate the flaps 22 and 24 from the front part 12, the section 42 includes a pair of additional slits. 46. The slits 46 extend in a longitudinal direction of the section 42 parallel with the longitudinal axis. Similarly, in order to separate the side flaps 22 and 24 from the back 16, the section 42 includes a pair of opposed slits 48 that are also generally parallel to the longitudinal axis of the section.

In this embodiment, the width X of the side flaps 22 and 24 is about 50% of the width Y of the middle part 14. Referring to figures 18 and 19, once the side flaps 22 and 24 are bent, the middle part 14 comprises two layers of material and may have a basis weight that is about twice the basis weight of the areas of the front 12 and of the areas of the back 16, in case the absorbent structure is formed of an absorbent fabric having a relatively uniform basis weight. In this embodiment, however, the front part 12 includes a central area 44 and the rear part 16 includes a central area 45 which are also composed of two layers of material and therefore may also have the same basis weight as the middle part. The side areas 50 of the front part 12 and of the side areas 52 of the rear part 16, however, remain as a single layer of material. Thus, the middle part 14, the central area 44 of the front part 12 and the central area 45 of the back part 16 all have an increased basis weight compared to the side areas 50 of the front part 12 and the side areas 52 from the back 16. In this embodiment, the central areas 44 and 45 generally extend to the size of the upper basis weight areas to provide greater liquid absorbency.

In the embodiments shown in Figures 18-20, the side flaps 22 and 24 similar to the embodiments shown in Figures 5-7, still comprise the widest part of the section 42. By being the widest part of the section 42, the side flaps 22 and 24 can be easily bent over the absorbent fabric as will be described in more detail below.

Referring to Figures 25 and 26, another embodiment of an absorbent structure indicated generally with the number 54 made in accordance with the present invention is illustrated. A section 56 is shown in Figure 27 which can be used to form the absorbent structure 54 shown in Figures 25 and 26.

Referring to Figure 27, in this embodiment, the side flaps 22 and 24 have a width X that is essentially equal to the width Y of the middle part 14. Similarly the embodiment shown in Figures 12-14, the width of the The lateral fins 22 and 24 can be varied so as to vary the differences in basis weight that are produced when the lateral fins are bent. For example, the side flaps 22 and 24 may have a width that is generally from about 25% to 100% of the width of the middle part. In the embodiment shown in figure 27, for example, the width X of the lateral fins is 100% of the width Y of the middle part 14.

Once the side flaps 22 and 24 are bent, the absorbent structure 54 is created as shown in Figures 25 and 26. As shown particularly in Figure 26, the resulting absorbent structure 54 includes a middle part 14, an area central part 44 of the front part 12, the side areas 50 of the front part 12, a central area 45 of the rear part 16, and the side areas 52 of the rear part 16. By bending the side flaps, the middle part 14 it contains three layers of material, the central areas 44 and 45 contain two layers of material, while the side areas 50 and 52 contain a single layer of material. Therefore, when formed of a fabric having an essentially uniform basis weight, the middle part 14 has a basis weight that is three times the basis weight of the side areas 50 and 52 while the central areas 44 and 45 have a weight base that is about twice the basis weight of the side areas 50 and 52. In other embodiments, however, the absorbent structure can be produced from a fabric and has areas of higher basis weight that are created during tissue formation. In these additions, the differences in basis weight between the middle part, the central areas and the lateral areas may vary depending on the desired result.

The absorbent structures illustrated in Figures 5, 6, 12, 13, 18, 19, 25 and 26 are particularly well suited for incorporation into an absorbent product, such as a diaper, an adult incontinence product, or a product for the hygiene of women. For example, referring to Figure 1, a panty-type absorbent article 60 is illustrated. Article 60 includes a frame 62 defining a front region 64, a back region 66 and a crotch region 68 interconnecting the front regions. And later. The frame 62 includes a body side liner 70 which is configured to contact the user, and an outer cover 72 opposite the body side liner which is configured to make contact with the wearer's clothing. An absorbent structure 74 (see Figure 4) is positioned or located between the outer cover 72 and the side-to-body liner 70. The absorbent structure 74 is made in accordance with the present invention and may for example be an absorbent structure as described in FIG. illustrated in figure 5, figure 12, figure 18, or figure 25.

Figure 2 illustrates an alternate incorporation of an absorbent article 60 similar to the absorbent article illustrated in Figure 1. Like reference numerals have been used to indicate similar elements. As shown, the absorbent article 60 shown in Figure 2, different from the embodiment shown in Figure 1, includes resonable sides. The absorbent article 60 shown in Figure 1, on the other hand, has the sides permanently attached. Both embodiments of an absorbent article define a three-dimensional pant configuration having a waist opening 76 and a pair of leg openings 78. The front region 64 includes the part of the article 60 which when worn, is placed on the front of the wearer while the back region 66 includes the part of the article which, when worn, is placed on the user's back. The crotch region 68 of the absorbent article 60 includes the part of the article which, when worn, is placed between the legs of the wearer and covers the lower torso of the wearer.

As further shown in detail in Figures 3 and 4, the frame 62 also defines a pair of longitudinally opposite waist edges which are designated as the front waist edge 80 and the rear waist edge 82. The front region 64 is contiguous with the front waist edge. front waist edge 80, and rear region 66 is contiguous with rear waist edge 82. Waist edges 80 and 82 are configured to surround the wearer's waist when using and defining waist opening 76. By reference, the arrows 84 and 86 show the orientation of the longitudinal axis and the transverse axis, respectively of the absorbent article 60 are illustrated in figures 3 and 4.

The illustrated absorbent frame 62 includes a pair of transversely opposed front side panels 88, and a pair of transversely opposed rear side panels 90. The side panels 88 and 90 can be formed integrally with the outer cover 72 and / or the side lining body 70 and / or the containment fins of the absorbent if present or may include two or more separate elements.

The side panels 88 and 90 desirably include an elastic material capable of stretching in a direction generally parallel to the transverse axis 86 of the absorbent article 60. Suitable elastic materials, as well as the processes for incorporating the side panels into the training underpants, are known those skilled in the art and are described, for example, in U.S. Patent No. 4,940,464 issued July 10, 1990 to Van Gompel et al., which is incorporated herein by reference.

As mentioned, the absorbent article 60 according to the present invention can be restrainable, thus including a fastening system 92 for securing the training underpants above the user's waist (see Figure 2). The illustrated fastening system 92 may include fastening components 94 that are adapted to attach responsibly to the fastening components that match 96. In one embodiment, a surface of each of the fastening components 94 and 96 includes a plurality of engaging elements projecting from that surface.

The engaging elements of these fastening components 94 are adapted to repeatedly engage and disengage the engaging elements from the matching fastening components 96.

In a particular embodiment, the fastening components 94 each include the hook-type fasteners and the matching fastening components 96 each include the complementary terry-type fasteners. In another particular embodiment, the fastening components 94 each include the curl type fasteners and the matching fastening components 96 each include the complementary hook type fasteners.

As noted previously, the illustrated absorbent article 60 has the front and rear side panels 88 and 90 positioned on each side of the absorbent frame 62. These transversely opposite front side panels 88 and the transversely opposed rear side panels 90 can be permanently attached to the composite structure comprising the absorbent frame 62 in the respective front and rear regions 64 and 66. Additionally, the side panels 88 and 90 can be permanently joined to each other using the appropriate attachment means, such as the adhesive bonds or the ultrasonic joints to provide a non-clamped absorbent article 60. Alternatively, the side panels 88 and 90 can be releasably attached to each other by the resurfacing system 92 as described above. More particularly, as best shown in Figure 3, the front side panels 88 can be permanently attached to and extend transversely beyond the linear side edges 88 of the composite structure in the front region 64 along the clamping lines 100. , and the rear side panels 90 can be permanently attached to and extend transversely beyond the linear side edges 98 of the composite structure in the rear region 66 along the clamping lines 100. The side panels 88 and 90 can be fastened using the fastening means known to those skilled in the art such as adhesive, thermal or ultrasonic bonding. The side panels 88 and 90 can also be formed as part of a component of the composite structure, such as the outer cover 72, the containment flaps if present, or the side-to-body liner 70.

Each of the side panels 88 and 90 may include one or more different pieces of material. In particular embodiments, for example, each side panel 88 and 90 may include the first and second panel parts that are joined in a seam, with at least one of the parts including an elastomeric material. Still alternatively, each individual side panel 88 and 90 may include a single piece of material which is bent over itself along an intermediate double line (not shown). Desirably the side panels 88 and 90 include an elastic material capable of stretching in a direction generally parallel to the transverse axis 86 of the absorbent article 60.

To improve the containment and / or absorption of the body exudates, the absorbent article 60 may include a front waist elastic member 102, a rear waist elastic member 104 and the leg elastic members 106, as known to those skilled in the art. in art (see figure 4). The waist elastic members 102 and 104 can be operatively attached to the outer cover 72 and / or the side-to-body liner 70 along the opposite waist edges 80 and 82, and may extend over part of or all of the edges of waist. The elastic leg members 106 are desirably operably linked to the outer cover 72 and / or the side-to-body liner 70 along the opposite side edges of the frame 62 and placed in the crotch region 68 of the absorbent article 60.

The elastic waist members 102 and 104 and the elastic leg members 106 can be formed of any suitable elastic material. As is well known to those skilled in the art, suitable elastic materials include sheets, threads or ribbons of natural rubber, synthetic rubber or thermoplastic elastomeric polymers. The elastic materials can be stretched and fastened to a substrate, fastened to a substrate folded or fastened to a substrate and then elastized or shrunk, for example with the application of heat; so that the elastic constriction forces are imparted to the substrate. In a particular embodiment, for example, the leg elastic members 106 include a plurality of coalesced, dry-spun multi-filament spandex elastomeric yarns sold under the trade name LYCRA and available from EI DuPont of Nemours and Company, of Wilmington, Delaware.

To improve the containment and / or absorption of any exudates from the body discharged from the user, the frame 62 may include a pair of containment fins 108 which are configured to provide a barrier to the transverse flow of exudates from the body. An elastic fin member 110 (see Figure 4) can be operatively linked with each containment fin 108 in any suitable manner as is well known in the art. The elasticized containment fins 108 define an unclamped edge which assumes a generally perpendicular and vertical configuration in at least the crotch region 68 of the absorbent article 60 to form a seal against the wearer's body. The containment fins 108 may be located along the transversely opposite side edges of the frame 62, and may extend longitudinally along the entire length of the frame or may only extend partially along the length of the frame. Suitable constructions and arrangements of containment fins 108 are generally well known to those skilled in the art.

The absorbent articles 60 as shown in Figures 1-4 can be made of various materials. The outer cover 72 can be made of a material that is essentially liquid and permeable, and can be elastic, stretchable or non-stretchable. The outer cover 72 may be a single layer of liquid and a permeable material, or may include a multilayer laminated structure in which at least one of the layers is liquid and permeable. For example, the outer cover 72 may include a liquid permeable outer layer and a liquid permeable inner layer that are suitably joined together by a laminated adhesive.

For example, in one embodiment, the liquid-permeable outer layer may be a non-woven polypropylene fabric bonded with spinning. The yarn-bonded fabric may have, for example, a basis weight of from about 15 grams per square meter to about 25 grams per square meter.

The inner layer, on the other hand, can be both impermeable to liquid and vapor, or it can be impermeable to liquid and permeable to vapor. The inner layer is desirably configured of a thin plastic film, although other flexible liquid impervious materials may be used. The inner layer prevents the waste material from wetting articles such as bed sheets and clothes, as well as the user and the caregiver. A suitable liquid impermeable film can be a polyethylene film having a thickness of about 0.2 millimeters.

A suitable breathable material that can be used as the inner layer is a microporous polymer film or nonwoven fabric that has been coated or otherwise imparted a desired level of liquid impermeability. Other "non-breathable" elastic films that can be used as the inner layer include films made from block copolymers, such as styrene-ethylene-butylene-styrene or styrene-isoprene-styrene block copolymers.

As described above, the absorbent assembly is positioned between the outer cover and a liquid-permeable body-side liner 70. The body-side liner 70 is desirably docile, soft-feeling and non-irritating to the wearer's skin. The body side liner 70 can be manufactured from a wide variety of woven materials, such as synthetic fibers, natural fibers, a combination of natural and synthetic fibers, porous foams, cross-linked foams, perforated plastic films or Similar. Various woven and non-woven fabrics can be used for the side-to-body lining 70. For example, the side-to-body liner can be made of a meltblown fabric or bonded with polyolefin fiber yarn. The body side liner can also be a carded and bonded fabric composed of natural and / or synthetic fibers.

The suitable liquid-permeable body side liner 70 is a non-woven bicomponent fabric having a basis weight of about 27 grams per square meter. The non-woven bicomponent may be a bicomponent fabric bonded with spinning or a bicomponent fabric bonded and carded. Suitable bicomponent short fibers include polyethylene / polypropylene bicomponent fiber. In this particular embodiment, polypropylene forms the core and polyethylene forms the fiber sheath. Other orientations of fibers, however, are possible.

The various processes that can be used to form the absorbent structures according to the present invention will now be described. For example, referring to Figure 8, an example process and a system generally 120 for forming the absorbent structures, such as the absorbent structure 10 as shown in Figure 5 is illustrated. In this embodiment, a continuous strip of an absorbent fibrous fabric formed of air 140 is produced and manipulated in individual absorbent structures or pads 10. It should be understood, however, that the fibrous tissue can be made according to several other processes instead of a process of formation by air.

As shown, a selected fibrous material is introduced into the system as fibers carried by air in a stream flowing in the direction towards a porous forming surface 128. The fibers, for example, can suitably be delivered from a block of cellulosic fibers, such as wood pulp fibers, or other source of natural or synthetic fibers which have undergone a fibrization treatment. For example, a hammer mill or other conventional fiberizer can be used. The particles or fibers of super absorbent material can also be introduced into the forming chamber 122 by using conventional mechanisms such as pipes, channels, spreaders, nozzles and the like.

The fibers and particles, in this embodiment, can be carried in any suitable gaseous medium. The references here to air as being the means of transport should be understood as being a general reference which covers any other operational transport gas.

The stream of fibers and particles carried in the air can pass through the forming chamber 122 to form a drum system generally indicated with the number 124. The forming chamber 122 can serve to direct and concentrate the fibers carried in air and the particles and providing a desired velocity profile in the air-borne stream of the fibers and particles.

As shown, the forming surface 128 of the forming drum system 124 is mounted on a rotating forming drum 126. The forming drum 126 is rotated in a selected direction of rotation, and can be rotated by the use of a drum drive shaft. which is operatively linked to any suitable drive mechanism (not shown). For example, the drive mechanism may include an electric motor or another which is directly or indirectly coupled to the drive shaft. Although the arrangement shown provides a forming drum that is arranged to rotate in a right-to-left direction, it should be readily apparent that the forming drum can alternatively be arranged to rotate in a left-to-right direction.

The forming drum 126 can provide a positioning zone 130 which is placed inside the forming chamber 122 and provides a vacuum positioning zone of the perforated forming surface 128. The vacuum placing area 130 constitutes a cylindrical surface portion and circumferential of the rotating drum 126. A difference in operating pressure is imposed on the surface of the laying area with vacuum under the action of a conventional vacuum generating mechanism, such as a vacuum pump, exhaust blower or other suitable mechanism which can provide a relatively low pressure under the forming surface 128. The vacuum mechanism can operatively remove the air from the arcuate segment of the forming drum 126 associated with the vacuum placing surface through an air discharge duct 138. The perforated forming surface 128 may include a series of forming sections which are n circumferentially distributed along the periphery of the forming drum 126. In desired arrangements, the forming sections can provide a selected repeat pattern that is formed in the fibrous tissue 140. The repeat pattern can correspond to a desired shape of a pad Individual absorbent that is intended for joining or other placement in a desired absorbent article.

Suitable forming drum systems for producing fibrous fabrics formed by air are well known in the art. For example, the patents of the United States of America Nos. 4,666,647; 4,761,258; 4,927,582; and the publication of U.S. Patent Application No. 2003/0042660 and U.S. Patent No. 6,330,135 all describe air forming systems and all are incorporated herein by reference.

Therefore, under the influence of the vacuum mechanism, a transport air stream is pulled through the perforated forming surface 128 inside the interior of the forming drum 126 and subsequently passed out of the drum through the discharge duct 138. Al gluing the airborne fibers and particles onto the perforated forming surface 128, the air component thereof is passed through the forming surface and the particle-fiber component is retained on the forming surface to form a non-woven fibrous web 140 about it. Subsequently, with the rotation of the forming drum 126, the formed fabric 140 can be removed from the forming surface by the weight of the fibrous fabric 140, by a centrifugal force and by a positive pressure produced, for example, by a flow of pressurized air to through a blow-out zone 142 and on a transfer cloth 143. The pressurized air exerts a force directly outwardly through the forming surface. In another embodiment, instead of or in addition to using any of the above tissue removal methods, a suction device may be placed under the transfer fabric 143 to also aid in the transfer of the formed tissue. Additionally, distinctive configurations of the forming surface in the associated components can produce a fibrous web 140 which can be more easily removed from the forming drum 126.

The forming drum 126 may be rotated about a series of stationary separators which may be present to form the forming surface 128, a plurality of different pressure zones. The pressure differences imposed on the perforated forming surface 128 can be produced by any conventional vacuum generating mechanism, such as an exhaust fan, which is connected to the air discharge duct 138 and is operatively connected to the structure of forming drum by using a conventional coupling mechanism. The interior space of the forming drum 126 may include a high vacuum forming zone which is in the general shape of an arcuate segment that is operatively located in the part of the forming surface 128 that is positioned within the forming chamber 122. In the shown, the high vacuum formation zone is located generally adjacent to the forming chamber.

The forming surface 128 may be provided along the outer cylindrical surface of the forming drum 126, and the forming surface may include a plurality of contoured forming surface portions that are circumferentially spaced along the outer surface of the forming drum. In operation, the air-laid fibrous fabric 140 can be formed from the stream of fibers carried by air as the gas flows through the openings in the perforated forming surface 128 and into the rotary forming drum 126.

As shown in Figure 8, the shape of the forming surface 128 produces the continuous strip of absorbent fabric material 140 which is composed of a succession of absorbent structures 10. Each absorbent structure is formed with side flaps 22 and 24.

After the fibrous tissue 140 is formed, the tissue is fed to a cutting device 144. The cutting device 144 forms the front slits 26 and the rear slits 28 in each absorbent structure 10. In this embodiment, the cutting device 144 comprises a roller containing a plurality of cutting blades.

It should be understood, however, that any suitable cutting device can be used. For example, a water cutting device, a laser beam cutting device or a large stamp moving up and down can be used.

From the cutter device 144, the material fabric 140 is fed to a bending device 146. In the embodiment shown, the bending device comprises a pair of stationary bending knives that fold the material fins 22 and 24 onto the absorbent fabric 140. As described above, since the side flaps 22 and 24 form the widest part of the woven material 140, the flaps are easily hooked by the stationary bender 146. It should be understood, however, that any suitable bending device can be used in the process of the present invention. The bending device for example may have movable parts that help to bend the side flaps. In a particular embodiment, for example the bending device may include the vibrating blades.

Referring to Figures 9-11, the continuous strip of material 140 is shown in which the side flaps 24 are first bent over the fabric material followed by the side flaps 22.

As the side flaps 22 and 24 are bent, the continuous strip of material is then fed to a second cutting device 148. The cutting device 148 forms a cut in the cross machine direction through the absorbent fabric material to form the pads individual absorbers 10. The cutting device 148 may be the same as or different from the cutting device 144. Once the pad or individual absorbent structure 10 is formed, the pads may then be incorporated into an absorbent article, such as the garment 60 as it was shown in figure 1.

As shown in Figure 8, the absorbent structures 10 are formed of a fibrous fabric having an essentially uniform basis weight. By bending the side flaps 22 and 24, an absorbent structure 10 with a differential basis weight can be formed without having to use a three-dimensional forming surface 128 and without having to thin the fibrous tissue after it is formed.

The basis weight of the fibrous fabric 140 can vary dramatically depending on the particular circumstances and the materials used to form the fabric. For many applications, for example, the basis weight of the fabric can range from about 100 'grams per square meter to about 1,000 grams per square meter.

Referring to Figures 15-17, the absorbent structure generally indicated with the number 30 as shown in Figure 12 can also be formed from a continuous strip of material 140. Figures 15-17 illustrate the side flaps 22 and 24 being folded on the absorbent tissue material. The succession of absorbent structures can then be cut in the direction of the cross machine to form the individual pads.

Referring to Figure 21, there is illustrated another example process or system 150 made in accordance with the present invention to form the absorbent structures, such as an absorbent structure 40. In this embodiment, the continuous strip of woven material is preformed into a process off-line and fed to a cutting device 144. The woven material 140 can be formed according to a process consisting of air, a coform process, a spinning process with melting, a fiber carding process, a placing process wet or by any other suitable means. Furthermore, it should be understood that the continuous strip of woven material can be cut by the cutting device 144 and then wound on a roll for further processing.

As shown, the cutting device 144 forms the slits 26, 46, 28 and 48 inside the absorbent tissue.

Since the side flaps 22 and 24 extend to the full length of each absorbent structure, in this embodiment, the side flaps 22 and 24 form a continuous strip along the entire length of the strip of fabric material 140. forming a continuous web of material that also forms the widest part of the absorbent fabric 140, is a relatively simple exercise for the bender 146 by folding the side flaps onto the woven material.

After the side flaps 22 and 24 have been folded, the fabric material 140 is fed to a second cutter 148 which cuts the strip of woven material into individual absorbent structures 40. The individual absorbent structures 40 can be directly fed in. of a process to form absorbent garments.

Referring to Figures 22-24, the bending of the fins 22 and 24 on the absorbent fabric material 140 is shown in a step-by-step manner. Referring to Figures 28-30, the folding of the side flaps 22 and 24 of the section 56 as shown in Figure 27 is also illustrated.

In several embodiments, other processing steps may occur on the absorbent fibrous fabric 140 as the individual absorbent structures are formed. For example, in an embodiment, the fibrous tissue can be densified by being fed through a device that removes volume. The device that removes volume can densify the entire tissue or only the lateral fins of the tissue. In other embodiments, the marking lines may also be formed on the fabric in order to assist in the bending of the side flaps over the middle part of the fabric.

In still other embodiments, an adhesive may be sprayed onto the fabric in order to secure the side flaps to the fabric. In general, any suitable adhesive can be used.

Once the absorbent structures are formed, the absorbent structures can then be fed into a process line to incorporate the structures into an absorbent garment, such as any of the products shown in Figures 1-4.

Referring now to Figure 31, there is illustrated an example embodiment of an assembly section 220 for making a continuous stream of discreet, partially assembled pants or garments. The specific equipment and processes used in the assembly section 220 can vary greatly depending on the specific type of garment that is being manufactured. The particular process and apparatus described in relation to Figure 13 is specifically adapted to manufacture the pull-and-up style absorbent articles 60 of the type illustrated in Figures 1 to 4.

The various components of the garment 60 can be connected together by any means known to those skilled in the art such as, for example, adhesive, thermal and / or ultrasonic bonds. Desirably, most of the components are connected using ultrasonic bonding for improved manufacturing efficiency and reduced raw material costs. A certain garment manufacturing equipment which is readily known and understood in the art, including frames and mounting structures, adhesive and ultrasonic bonding devices, conveyors, transfer rolls, idlers, tension rolls and the like, have not been shown in figure 31.

A continuous supply of material is provided 222 used to form the body liner from a supply source 224. The source of supply 224 may include for example a pair of spindles, a festoon assembly and optionally a dancer roller (not shown) to provide a side lining material. to the body 222 at a desired speed and tension.

Various components can be placed on and / or attached to the side facing liner material 222 as the material moves in the machine direction identified by the arrow 226. In particular, an emergence layer can be provided at an application station. 228 and placed on and / or joined to the body side facing material 222. The emergence layer may include either a continuous weave or discrete sheets. Additionally, a containment fin module 230 can be provided downstream of the supply source 224 for securing the containment fins pre-assembled to the side-to-body lining material 222. When several components are added in the assembly section 220 a continuously moving product assembly 232 is formed. The product assembly 232 will be cut down to form the partially assembled discrete garments 60.

A plurality of absorbent structures 10 are provided from a suitable source of supply. The supply source can be, for example, the air forming system and the air forming process as shown in the figure 8 or as shown in figure 21.

An assembly section 220 may include a device for applying side panels. For example, the continuous material fabrics 238 used to form the side panels 888 and 90 may be provided from suitable supply sources 240. The sources of supply 240 may include one or more unwinding mechanisms. The side panel material 238 can be cut into individual strips 242 and partially placed on the body side facing material 222 using an applicator device 244. In the cross machine direction the individual strips 242 desirably extend laterally. outwardly from the side facing material to the body 122 and overlap the lining material from side to body to allow the strips to be bonded to the side facing body and / or the containment fin material. Bonding can be achieved using adhesives as well as is well known in the art by any other means of attachment. In the machine direction 226, the position of the strips 242 can be recorded in relation to the absorbent assemblies 234 so that the product assembly 232 can be cut between the absorbent assemblies with each strip 242 of the side panel material 238 forming both the front side panel 88 and a rear side panel 90 of the consecutive garments 60.

A suitable applicator device 244 is described in the patents of the United States of America Nos. ,104,116 granted on April 14, 1992 and 5,224,405 granted on July 6, 1993 both to Pohjola, which are incorporated herein by reference. The applicator device 244 may include a cutter assembly 246 and a rotary transfer roller 248. The cutter assembly 246 employs a rotating knife roller 250 and a rotatable vacuum anvil roller 252 for cutting the individual strips 242 of the panel material. continuous side 238. The strips 242 cut by a knife on the knife roller 250 can be maintained on the anvil roller 252 with vacuum and transfer to the transfer roller 248.

The transfer roller 249 may include a plurality of rotating vacuum disks 254. The vacuum disks 254 receive the strips 242 of the material 238 of the cutter assembly 246 and rotate and transfer the strips to the lining material from side to body continuously in motion 222 When the strips 242 are placed as desired in relation to the side-to-body lining material 222, the strips are released from the discs 254 by extinguishing the vacuum in the discs. Discs 254 may continue to rotate toward cutter assembly 246 to receive other strips.

There are alternate configurations for securing the side panel material 238. For example, the material 238 used to form the side panels can be provided in a continuous form and cut in outline to form the leg openings 78. Still alternatively, the side panels 88 and 90 of the pants 60 may be provided by parts of the side-to-body liner 70 and / or the outer cover 72. It should be noted that the side panel application processes just described are exemplary only, and that the process may vary greatly depending on of the physical characteristics of the material and the nature of the process.

A continuous supply of material 256 used to form the outer cover 72 may be provided from a supply roll 258 or other suitable source. As the material is unwound, the outer cover material 256 can be married to the body-side facing material 222 such as by the use of a rolling roller 260. The absorbent assemblies 234 are thus placed in the form of a sandwich between the two. continuous materials 222 and 256. The inward portions of the strips 242 of the panel material 238 may also be placed between the body-side facing material 222 and the outer shell material 256. Various components such as leg elastics 106 or the waist elastics 102 and 104 can be attached to the outer cover material 256 at an application station 262 before the side-to-body liner and the outer cover materials 222 and 256 are joined. Alternatively the leg elastics or the elastics of waist can be attached initially • to the lining material side to body 222 or other material.

Outer cover 256 may be attached to the side shell panel composite using any means known to those skilled in the art. Where the adhesive is used, said adhesive can be applied on or before the rolling mill 260. Alternatively, the joining devices such as the ultrasonic or thermal linkers can be employed as part of the rolling mill 260 or at a downstream location 264 for joining the lining material side to the body 222, the side panel material 238 and the outer cover material 256.

The assembly section 220 may include the apparatus for providing / applying a garment fastening system 60. For example, the product assembly continuously in motion then advances to a fastener applicator station 266 wherein the fastening components 94 96 are attached to the strips 242 of the side panel material 238. The location of the fastening components on the composite is a function in part of the configuration of the assembly section 220. The illustrated assembly section 220 is configured so that the up-face surface of the product assembly 232 will become the outer surface of the underpants 60 and the down-face surface will become the inner surface. In addition, the illustrated assembly section 220 is configured to produce partially assembled garments 60 having the front waist region 64 of a front garment connected to the rear waist region 66 of a glue garment. The process can alternatively employ any combination of different orientations. For example, the face-up surface of the product assembly can form the interior surface of the finished garments. Additionally or alternatively, the rear waist region 66 of the front garment may be connected to the front waist region 64 of the gown, or the garments may be arranged in a front-to-front / back-to-back relationship. back. Still alternatively, the assembly section 220 can be constructed as a cross machine machine process wherein the longitudinal axis of each garment can be perpendicular to the machine direction 226 during part or all of the assembly process.

The continuous fabrics of fastener material 278 used to form the fastening components 96 (Figures 2 and 4) may be provided from the supply rolls 280 or other suitable sources. The fastener materials 278 can be cut into individual fasteners 96 by the cutting assemblies 282 or other suitable devices. The illustrated cutter assemblies 282 include the rotating blade rollers 284, the rotary vacuum anvil rollers 286, and the rotary backing rollers 288. The continuous fastener materials 278 can be cut by the blades onto the knife rollers 284, held on the anvil rollers 286 by vacuum, and placed on the upper surfaces of the strips 242 of the side panel material 238.

Similarly, the continuous fabrics of a fastening material 290 used to form the fastening components 94, shown in Figures 2 and 4, may be provided from the supply rolls 292 or other suitable sources. The first fastener materials 290 can be cut into the first individual fasteners 94 by the cutter assemblies 294 or other suitable devices.

Alternatively, a garment component 60 can serve as the fastening components, in which case the fastener application station 266 or the cutter assemblies 294 may not be necessary. The illustrated cutter assemblies 294 include the rotating knife rollers 296, the rotary vacuum anvil rollers 298, and the rotary backing rollers 300. The continuous fastener materials 290 can be cut by the knives on the knife rollers 296, held on the anvil rollers 298 by vacuum, and assorted on the bottom sides of the strips 242 of the panel material 238.

Other arrangements can be used to hold the fastening components 94 and 96. For example, the fastening components can be applied to the side panel material 238 before joining the side panel material with the side facing material to the body 222 and / or the other cover material 256; the fastening components can be applied to the side facing material 222 and / or to the cover material 256, whether the separated side panels are used or not; the parts of the other components such as the side-to-body liner and / or other outer cover can form one or more of the fastening components; the separate side panels or the integral side panels may themselves form one or more of the fastening components; the fastening components can be fastened as pre-engaged compounds or the like.

After the fastening components are placed on the strips 242 of the panel material 238, the joining devices 302 such as the ultrasonic binders can be used to attach the fastening components to the strips. For example, the strips 242 can be transported between a rotating ultrasonic horn and an anvil roller, which devices are placed on each side of the process at the location of the machine-transverse direction of the clamping components 94 and 96. The patterns Particular ultrasonic bonding including circular and individual joints which are compatible with mechanical fastening materials are described in U.S. Patent No. 5,660,666 issued August 26, 1997 to Dilnik, et al., which is Incorporated here by reference. Efficient arrangements for securing the fastening components with non-adhesive bonding devices are further described in U.S. Patent No. 6,562,167, filed May 15, 2001 by JD Coenen et al entitled "Methods for Making Garments. with Fastening Components "which is incorporated herein by reference. A secure hold, it may be desirable to hold the fastening components with both adhesive and thermal joints. Suitable adhesive adhesives are available from commercial vendors such as Findley Adhesive, Inc., of Wauwatosa, Wisconsin, United States of America.

In particular embodiments, the joining devices 302 can provide a uniform time bond of the fastening components to the side panel material 238. The degree of bonding, such as the number of joints per unit area or the strength bonded per area of unit, may be greater in certain specific areas compared to non-specific areas. Improved attachment in the target areas can be particularly beneficial near the waist and leg openings to reduce the delamination of the fastening components from the side panel material 238. Thus, the attachment devices 302 can be adapted for creating relatively more stiff joints and unions between the fastening components and the side panel material 238 when the side panel material 238 reaches a location in the direction of the particular machine 226. In a particular embodiment, the specific areas correspond to parts of the clamping components 94 and 96 near the waist edges 80 and 82. The joining devices 302 may be in register to provide a relatively higher degree of connection which begins while being disposed on a clamping component, continuous to through the region where the 232 product assembly will subsequently be cut, and t It stops after it has been placed on another fastening component. Alternatively, the joining devices 302 can destroy the fastening elements of the fastening components in the target areas, so that the fastening components will be less able to aggressively grip each other in the target areas.

The strips 242 of the side panel material 238 may be trimmed if desired, for example to provide the angled and / or arched edges and legs in the rear waist region. For this purpose, the assembly section 220 may include a die cutter roll 304 and a backing roll 306. In the illustrated embodiment, a portion of each strip 242 is cut away from a tail edge in order to form the end edges. of leg at an angle and / or arched in the posterior waist region.

The method and apparatus at this point provides a continuous weave of underpants partially assembled and interconnected in the direction indicated by arrow 226. This continuously moving product assembly 232 is passed through a cutter 308 which selectively cuts the tissue in partially assembled and discrete garments 60. Such carriers 308 are generally known to those skilled in the art and may include, for example, the combination of a cutter roll 310 and an anvil roller 312 through which the fabric is moved. The anvil roller 312 may include a hardened steel rotating roller while the cutting roller 310 may include one or more hardened and flexible steel blades held on another rotating roller.

The pinching force between the blade on the cutter roller 310 and the anvil roller 312 creates the cut. The cutting roller 310 can have one or more blades depending on the desired distance between the cuts. The cutter 308 may further be configured to provide spacing between the individual cut pieces after they are cut. Such spacing can be provided by transferring the cut pieces out of the cutter at a speed greater than the speed at which the fabric is provided to the cutter.

The discrete garments 60 can then be folded and packed as desired.

These and other modifications and variations of the present invention may be practiced by those skilled in the art, without departing from the spirit and scope of the present invention which is more particularly set forth in the appended claims. In addition, it should be understood that the aspects of the various incorporations can be exchanged both in whole or in part. In addition, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to limit the invention so far described in such appended clauses.

Claims (20)

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

1. An absorbent article comprising: an outer cover material; a lining; Y an absorbent structure positioned between the outer cover material and the liner, the absorbent structure includes a front part, a back part and a middle part, the front part has a width, the absorbent structure further comprises a pair of opposite side flaps folded by at least on the middle part of the absorbent structure, each of the fins, when in an unfolded state, extends beyond the width of the front part, each of the fins having a width adjacent to the middle part that is from about 25% to 100% of the width of the middle part.

2. An absorbent article as claimed in clause 1, characterized in that the absorbent structure has an hourglass shape, or a rectangular shape when in an unfolded state.

3. An absorbent article as claimed in clauses 1 or 2, characterized in that the side flaps are connected to the middle part and where each of the flaps is separated from the front by a first groove and separated from the back for a second crack.

4. An absorbent article as claimed in clause 3, characterized in that the absorbent structure defines a longitudinal axis extending from the front to the back, the first slits and the second slits extend in a non-linear manner in relation the longitudinal axis, or the first grooves and the second grooves are essentially perpendicular to the longitudinal axis, or the first grooves and the second grooves extend generally in a diagonal direction relative to the longitudinal axis.

5. A method for forming absorbent pads of an absorbent tissue material comprising: carrying a strip of the absorbent fabric material along a direction of the machine; cutting the absorbent fabric material to form the opposing side flaps, said opposing side flaps defining a wider part of the absorbent tissue material; folding the opposite lateral wings onto the absorbent fabric material; cutting the strips of the woven material in a transverse direction into individual absorbent pads, each individual absorbent pad includes a front part, a middle part, a back part, and a pair of opposed side wings, the side wings being folded over at least one Middle part of the absorbent pad, the side flaps have a maximum width of from about 25% to 100% of the width of the middle part.

6. A method as claimed in clause 5, characterized in that in order to form the side wings, the absorbent fabric material is generally cut in the machine direction along each side of the front of each absorbent pad and then cut in toward the middle part, the absorbent fabric material also generally cut in the machine direction along each side of the back of each pad and cut in toward the middle part, the fins remaining connected to the middle part.

7. A method as claimed in clauses 5 or 6, characterized in that before the step of cutting, the strip of woven material is supplied to an on-line manufacturing process of continuous absorbent article, wherein the step of cutting the strip of woven material in individual pads is carried out during the online manufacture of absorbent articles by incorporating the individual absorbent pads therein.

8. A method as claimed in any one of clauses 5 to 7, characterized in that the opposite side wings are folded over the absorbent fabric material before cutting the strip of woven material in a transverse direction inside the absorbent pads.

9. A method as claimed in any one of clauses 5 to 8, characterized in that of the side flaps, the absorbent woven material is generally cut in a direction of the machine transverse towards the middle part of the absorbent pad, the flaps remain connected to the middle part.

10. The article or method as claimed in any one of the preceding clauses, characterized in that the middle part is narrower than the front part, or narrower than the front part and that the back part.

11. The article or method as claimed in any one of the preceding clauses, characterized in that each of the fins has a wider section adjacent to the middle part and where each of the fins has a width adjacent to the part. medium which is from about 25% to 100%, prebly from 33% to 100%, prebly from 50% to 100% of the width of the middle part.

12. The article or method as claimed in any one of the preceding clauses, characterized in that the absorbent structure or the absorbent pad has a generally uniform basis weight when it is in an unfolded state.

13. The article or method as claimed in any one of the preceding clauses, characterized in that the absorbent structure or the absorbent pad have a non-uniform basis weight when they are in an unfolded state, the middle part having a higher basis weight than the from the front and from the back to the lateral fins, or the lateral fins having a base weight greater than the middle part, or that the front part and that the rear part having a base weight greater than the middle part.

14. The article or method as claimed in any one of the preceding clauses, characterized in that the absorbent structure or the absorbent pad has a basis weight of from 100 grams per square meter to about 2,000 grams per square meter.

15. The article or method as claimed in any one of the preceding clauses, characterized in that each of the side flaps has been bent, the middle part includes areas having a basis weight that is at least 150% higher the base weight of the front part and of the rear part, prebly at least twice the base weight of the front part and of the rear part, prebly at least three times the base weight of the front part and part thereof later.

16. The article or method as claimed in any one of the preceding clauses, characterized in that each of the side flaps have been bent, the middle part comprises two layers of material or three layers of material.

17. The article or method as claimed in any one of the preceding clauses, characterized in that the front part includes a central area and two opposite side areas and the rear part also includes a central area and two opposite side areas, and where once each of the side wings has been bent, the middle part, the central area of the front part and the central area of the back part each have a basis weight that is at least 150% greater than the base weight of the two opposite side areas of the front part and the two opposite side areas of the rear part, prebly at least twice the base weight of the two opposite side areas of the front part and of the two opposite side areas of the back part.

18. The article or method as claimed in any one of the preceding clauses, characterized in that the front part includes a central area and two opposite side areas and the rear part also includes a central area and two opposite side areas, and where once each of the side flaps has been bent, the middle part, the central part of the front part and the central area of the back part each comprises at least two layers of material while the two opposite lateral areas of the front and two opposite side areas of the back comprise only a single layer of material.

19. The article or method as claimed in clauses 17 or 18, characterized in that once each of the side flaps has been bent, the middle part has a basis weight that is at least three times the base weight of the two opposite lateral areas of the front part and of the two opposite side areas of the rear part, and the central area of the front part and the central area of the rear part have a basis weight that is at least double of the base weight of the two opposite lateral areas of the front part and two opposite side areas of the rear part. *

20. The article or method as claimed in any one of the preceding clauses, characterized in that the absorbent structure of the absorbent pad comprises super absorbent particles, or fibers of pulp and super absorbent particles, or a fabric formed by air . R E S U E N Absorbent structures are described which can be incorporated into liquid absorbent products, such as diapers, adult incontinence products, women's hygiene products, and the like. The absorbent structures are made of a fibrous material and include a pair of opposed lateral fins. The lateral fins are bent over the fibrous tissue. By bending the side flaps over the fibrous tissue, areas of greater basis weight can be formed on the absorbent structure. By varying the width of the lateral fins the differential base weight can be increased and decreased. The lateral fins also form the widest part of the woven material to facilitate bending during a continuous process. Through the system and process of the present invention, a fibrous fabric having an essentially uniform basis weight can be converted into absorbent structures having a differential basis weight with little or no waste produced. In addition, the absorbent structure can be formed without having to subject the fibrous tissue to the thinning process.