MXPA98006692A - Process to make a mechanical brazier having an aga appendix - Google Patents

Abstract

The present invention relates to a method for forming a plurality of fastener components comprising providing a composite fabric which includes a fabric of hook material, the hook material includes a base layer of hooks which has a middle section that it extends longitudinally located between the longitudinally extending side, laterally opposite first and second sections of the hook material fabric. Each of the side sections has a plurality of hook elements which are integrally formed with the base layer and extend outward from a base plane of the hook base layer, and the hook elements are configured, for operably engaging a selected cooperating curl material to provide an operative fastener. The middle section has a relatively lower density of the hook elements per unit area, compared to the side sections. The hook material fabric has a pantiliner section of carrier fabric fastened to extend laterally outward from each of the fabric side sections of the hook material. Each section of the carrier fabric material may have an extender fabric of panel material that is clamped to extend laterally outward of each section of the carrier fabric material. At least the fabric of the hook material is divided along a serpentine dividing line which extends generally longitudinally along the fabric of hook material and the composite fabric is selectively segmented to provide the plurality of fastener components.

Description

PROCESS TO MAKE A MECHANICAL BRAZIER HAVING A GRIPPING APPENDIX Field of the Invention The present invention relates to a technique for forming a fastening system. More particularly, the invention relates to a technique for forming an article having a side panel member connected to a fastening system which incorporates a distinctive grip appendage.

Background of the Invention Conventional absorbent articles, such as disposable diapers, have been constructed with elasticised waistbands. The particular article designs have incorporated a stretchable outer cover composed of an elastomeric fabric material, such as a bonded and stretched laminate which includes a layer of a non-woven fabric. Other conventional designs have included elastomeric or non-elastomeric side panel members connected to the side-side edges of an outer cover composed of a polymer film material, and the fasteners and fastening appendages have been connected to the side panels to ensure the article about a user. The fastener appendages have included mechanical fastening mechanisms such as the complementary components of a hook and loop fastener.

Conventional techniques for forming the articles which have fastening systems with panel members, however, have exhibited significant disadvantages when incorporated into high speed manufacturing operations. For example, it has been difficult to provide a technique to reliably and efficiently produce a mechanical fastener appendage which is easy to open and also resists unwanted premature opening. As a result of this, there has been a continued need for an improved manufacturing technique which can more effectively produce an article having a more reliable fastening system.

Brief Description of the Invention A process aspect of the invention provides a method for forming fasteners. The method includes providing a composite fabric which includes a first mechanical fastening component. The first mechanical fastening component includes a base layer which has a longitudinally extending middle section located between the longitudinally extending, first and second laterally opposite side sections of the first tissue of the mechanical fastening component. Each of the side sections has a plurality of first mechanical fastening elements which are integrally formed with the base layer and extend outwardly from a base plane of the base layer, and the first mechanical fastening elements are configured for operatively engaging a second cooperative and selected mechanical fastening component. The middle section has a relatively lower density of the first mechanical fasteners per unit area, compared to the side sections. The fabric of the first mechanical fastening component has a stretched section of carrier fabric material stretched laterally outward from each of the side sections of the first fabric of the mechanical fastening component. At least the fabric of the first mechanical fastening component is divided along a serpentine dividing line which extends generally along the fabric of the hook material. In particular aspects of the invention, an extender fabric of panel material has been fastened to extend laterally outwardly from each section of the carrier fabric material, and in other aspects, the composite fabric can be selectively segmented to provide the plurality of components of the fabric. bra The various aspects of the invention may advantageously provide an improved technique for forming a fastener system in which a fastening tab can provide a desired opening ease while also providing a secure closure which is resistant to premature and unwanted openings. With the technique, the fastening system can be manufactured at high speed, and the resulting fastener appendage can be provided more effectively and more efficiently with the grip appendage part - which is less likely to be caught or caught in surrounding objects. As a result, the present invention, in its various configurations, can provide an improved technique for forming an article having a more effective and reliable fastening system. The resulting article and the fastening system can have a more consistent quality and can provide more reliable operation.

Brief Description of the Drawings The invention will be more fully understood and the additional advantages will become more apparent when reference is made to the following detailed description and the accompanying drawings in which: Figure 1 representatively shows a perspective and schematic view of a part of the method and apparatus of the invention.

Figure 2 is a perspective view of another part of the method and apparatus of the invention.

Figure 3 representatively shows a schematic composite fabric and its associated components.

Figure 4 representatively shows a side end view, in schematic and expanded cross-section of the composite weave illustrated in Figure 3.

Figure 5 representatively shows another schematic composite fabric and its associated components.

Figure 6 representatively shows "a schematic and expanded side cross-sectional view of the composite fabric illustrated in Figure 5.

Figure 7 representatively shows an alternate configuration of the method and apparatus of the invention for making multiple composite tissues.

Figure 8 representatively shows an alternate fabric of a hook material.

Figure 9 representatively shows a cross-sectional and schematically expanded side end view of the fabric of hook material illustrated in Figure 8.

Figure 10 representatively shows a set of additional schematic composite fabric and its associated components.

Figure 11 representatively shows a cross-sectional and schematic expanded side end view of the composite fabric assembly illustrated in Figure 10.

Detailed description of the invention The method and apparatus of the present invention will be described herein in relation to its use for producing a fastener system for absorbent articles, particularly disposable absorbent articles. Such articles may be placed against or in proximity to the body of a user to absorb and contain various exudates discharged from the body, and are intended to be discarded after a period of limited use. Items are not intended to be washed or otherwise restored to reuse. While the present disclosure will be made particularly in the context of a diaper article, it should be understood that the present invention is also applicable to other articles, such as gowns, caps, drapes, covers, incontinence garments for adults, sanitary napkins, training pants for children and similar.

In particular arrangements, the present invention can be advantageously employed to more efficiently produce a fastening system for incorporation into an absorbent article such as a disposable diaper having a front waistband section, a rear waistband section and a waist section. intermediate which interconnects the front and back waistband sections. The article includes a backing sheet layer, and a liquid pervious top sheet layer which is superimposed on the backing sheet layer. An absorbent body is located between the backing sheet layer and the top sheet layer, and a fastening system is connected to the article in each laterally opposite end region of at least one of the front and back waistband sections. . Each fastening system may include a side panel member and the side panels may optionally be constructed to make elastomeric stretchable at least along a transverse and lateral direction of the article. The fastening tab to secure the article on a user is connected to each of the side panels.

The articles which include elastomeric side panels and selectively shaped fastener appendages are described in the United States patent application serial number 168,615 issued to T. Roessler et al., Entitled "DYNAMIC ENTALLE PANEL" and filed on 16 December 1993 (lawyer case number 10961); and in the United States patent application serial number 603,477 of A. Long et al., entitled "MECHANICAL CLAMPING SYSTEM WITH GRIP APPENDIX", and filed on March 6, 1996 (attorney's matter number 12563). Various techniques for forming fastening systems are disclosed in U.S. Patent No. 5,399,219 to T. Roessler et al., Entitled "METHOD FOR MAKING A DYNAMIC LINKAGE CLAMPING SYSTEM" and issued March 21. of 1995 (lawyer case number 11186); in the patent application of the United States of America series number 286,086 of D. Fries, entitled "A PROCESS FOR ASSEMBLING EASED PORTIONS OF EARS" and filed on August 3, 1994 (attorney's issue number 11169) and the request for U.S. Patent No. 08 / 415,383 of D. Fries et al., entitled "A ASSEMBLY PROCESS FOR A LAMINATED TAPE" and filed on April 3, 1995 (attorney's case number 11950). The full descriptions of the above-mentioned documents are incorporated herein by reference in a manner that is consistent (not in conflict) with the same.

The present invention can provide a distinctive technique for forming a fastener system having a composite fastener component and selected. The invention may further provide a distinctive technique for forming a selected article such as an elasticized disposable diaper which includes a fastening system. With reference to Figures 1, 2 and 3, a method and apparatus of the invention, shown generally at point 20, to form a plurality of fastener components 66 include providing a composite fabric 22 which includes a fabric of a first mechanical fastening component, such as a fabric of hook material 24. The first fabric of mechanical fastening component includes a base layer, such as the hook base layer 26 which has a longitudinally extending middle section. located between the longitudinally extending lateral, laterally opposite first and second sections 30 and 32 of the first tissue of mechanical fastening component. Each of the side sections 30 and 32 have a plurality of mechanical fastening elements, such as the hook elements 54, which are integrally formed with the base layer 26 and extend outwardly from a base plane which is generally defined by the base layer. The first mechanical clamping hook elements are configured to operably engage a second selected cooperative mechanical clamping component, such as a conventional crimping material. The middle section 28 of the first fabric of mechanical fastening components can have a relatively lower density of the first elements of mechanical fastening components per unit area, as compared to the side sections 30 and 32. The fabric of the first component of The mechanical fastener has extended sections of the carrier fabric material, such as the carrier fabric sections 38 and 40, fastened to extend laterally outward from each of the side sections 30 and 32 of the first fabric of the mechanical fastening component. In particular, the carrier fabric section 38 extends laterally outwardly from the lateral fastening section 30, and the carrier fabric section 40 extends laterally outwardly from the lateral fastening section 32. At least the fabric of the first component Mechanical fastening is divided along one. serpentine dividing line 62 which extends generally longitudinally along the fabric of the hook material 24.

In particular aspects of the invention, each section 38 and 40 of the carrier fabric material may have an extending fabric of panel material 56 fastened to extend laterally outward from each of the sections of the carrier fabric material. In other aspects, the composite fabric 22 can be selectively segmented along segmented lines 64 to provide the plurality of fastener components 66.

With respect to the arrangement shown, the first mechanical clamping component provides the hook elements 54 which are configured to operably engage the second selected cooperative mechanical clamping component provided by an operable crimping material. The middle section 28 of the hook material fabric 24 can have a relatively lower density of the hook elements 54 per unit area, as compared to the side sections 30 and 32. The hook material fabric has the sections that extend of the carrier fabric material such as sections 38 and 40, one of which is clamped to extend laterally outward from each of the side sections 30 and 32 of the hook material 24. At least the fabric of the Hook material 24 is divided along the serpentine dividing line 62 which generally extends longitudinally along the fabric of the hook material 24. It should be readily appreciated, however, that the terry material can be employed as the first component of mechanical fastening and that the. First mechanical fasteners can be provided by the curl elements. In a corresponding complementary form, the hook material can be used as the second mechanical fastening component.NM.

In the arrangement shown, the method is arranged to provide a composite fabric 22 having a stretched panel fabric 56 constructed of an elastomerically stretchable panel material fastened to extend laterally outward from each of the sections 38 and 40 of the material. carrier fabric 34.

The arrangement shown of the method and the apparatus also incorporates a unique weave on a surface from which it is laminated and secures a weave of hook material 24. As a result of this, the serpentine division line 62 operatively divides both the hook material 24 and the weave of carrier material 34. Alternatively, the fabric of hook material 24 can be placed between a pair of spaced laterally spaced carrier weights 34 and laminates operably and secured to carrier tissues. Accordingly, each of the individual carrier tissues has the first and second laterally opposite side regions. The first side region of each carrier fabric is attached to the fabric of the hook material 24, and the second side region of each carrier fabric is operably linked to the outer edge portion of its corresponding associated side panel fabric 56.

The method and apparatus shown representatively generally have a longitudinal machine direction 86 and a lateral cross direction 88. In any selected and particular location throughout the method and apparatus, the machine direction is the generally longitudinal direction along which a particular fabric (or composite fabric) of material is moving or transported to through the process. The transverse direction extends generally along the plane of the fabric of material, and is perpendicular to the direction of the particular machine established by the apparatus method at the selected location.

During the assembly process of the various components described, particular attachment or clamping mechanisms may be mentioned. It will be readily apparent, however, that many alternative mechanisms may also be employed. Such alternating techniques include, for example, ultrasonic bonding, thermal bonding, adhesive bonding, pressure bonding, laser bonding, microwave bonding and the like, as well as combinations thereof.

Regarding the configuration shown, the method for forming a plurality of fastener components includes providing a virtually continuous fabric of hook material along a selected longitudinal dimension 86. The hook material includes a hook base layer 26. which has a longitudinally extending middle section 28 located between the longitudinally extending, laterally opposite, first and second 30 and 32 sections of the hook material fabric. The side sections are configured with the mechanical clamping elements to provide the first and second primary clamping sections of the tissue 24. In the arrays representatively shown, each of the side sections 30 and 32 has a plurality of hook elements 54 the which are formed integrally with the base layer 26 and extend outwardly from a base plane which is generally defined by the hook base layer 26. The hook elements 54 are configured to operably engage a selected cooperating curl material. , such as the curl material composed of a woven or non-woven fabric, operatively woven. The middle section 28 has a relatively lower density of the hook elements 54 per unit area, as compared to the side sections 30 and 32. At least one virtually continuous fabric 34 of the carrier material is fastened to the fabric of the hook material 24. to provide an extension section of the carrier fabric material which extends laterally out of each of the side sections 30 and 32 of the hook material 24. A virtually continuous fabric of panel material 56 is fastened to extend laterally out of each spreader section of the carrier fabric material, thereby forming a composite fastener fabric 22. At least the fabric of the hook material 24 is divided along a serpentine dividing line 62 which extends longitudinally generally along the fabric of the hook material 24 The serpentine line 62 generally has longitudinally extending portions 61 and generally laterally extending portions 63 (Figure 3). The composite fastener fabric 22 is selectively segmented to provide by the plurality of fastener components 66.

With reference to Figures 1, 2, 3 and 4, supply means, such as the supply roll 57, provide a first panel fabric 56 composed of a selected panel material. The panel material can be virtually non-elastomeric or can be elastomeric. In particular configurations of the invention, the side panel material is composed of an elastomeric material which is elastically stretchable at least along the transverse direction 88 of the panel fabric 56. The panel material can, for example, be a stretched-attached-laminated material (SBL), a narrow-bonded-laminate (NBL) material, an elastomeric film, an elastomeric foam material or the like.

For example, elastomeric fibrous fabrics formed by meltblowing suitable for forming panel fabric 56 are described in U.S. Patent No. 4,663,220 issued May 5, 1987 to Isneski and others whose full description is incorporated herein. by reference. Examples of composite fabrics comprise at least one layer of a non-woven textile fabric secured to a fibrous elastic layer are described in European Patent Application EP 0 110 010 published on April 8, 1987 as EP 0 217 032 A2 , with the inventors listed as J. Taylor et al., the complete description of which is incorporated herein by reference. Examples of NBL materials are described in U.S. Patent No. 5,226,992 issued July 13, 1993 to N. Mormon, the complete disclosure of which is incorporated herein by reference. A particular narrow-bonded laminate (NBL) may be composed of a film of elastomer material placed in sandwich form between two layers of spin-bonded material. The fabric may be composed of a KRATON® elastomer available from Shell Oil Company, and the spunbonded layers may be composed of spunbonded polypropylene fibers.

A suitable separation mechanism, such as a cutter 52 is used to divide the panel fabric 54 into a first panel fabric section 74 and a second panel fabric section 76. In the illustrated configuration, for example, the cutter 52 it can separate the panel fabric 56 in the first and second sections which are virtually wide in the same transverse direction. Optionally, the separate fabric sections 74 and 76 may have widths in the transverse direction not the same, as desired. Each of the panel fabric sections has an inner side edge region 58 and an outer side edge region 60.

The relative positioning of the first and second fabric sections 74 and 76, respectively, is adjusted to a desired spacing along the direction transverse to the process frame 88 by operable steering means, as provided by a spreader mechanism 78. In the illustrated embodiment, for example, the spreader mechanism may include a conventional tumbler bar system which relocates and relocates the first and second fabrics of the side panel material at a desired spacing therebetween. For example, the spreader mechanism 78 may include a first pair of tilt bars which are inclined and biased in a manner well known in the art to produce the desired repositioning of the first panel woven section 74. The first section of panel fabric 74 moves in an S-shaped path to pass over its first upper turning bar and then pass back and under its second bottom turning bar to decenter by a predetermined distance outwardly from the second tissue section of panel 76.

Similarly, a second conventional set of tilt bars may be bent and biased at appropriate angles in a manner well known in the art to selectively reattach the second section of panel fabric 76. In particular, the second section of tis- The panel can move in another S-shaped path to pass over its first upper turning bar and then pass back and under its second bottom turning bar in a manner which directs the second section of panel fabric 76 to a position that is spaced a desired distance away from the first section of panel fabric 74.

Alternate spreading mechanisms include, for example, conventional guide roller systems, such as those distributed by FIFE Corporation, a business having offices located in Okiahoma City, Okiahoma; and arcuate rotating rollers, such as those distributed by Mt. Hope Machine Company, a business having offices in Taunton, Massachussetts. Examples of other spreading mechanisms include non-parallel roller or bar systems, arcuate non-rotating bars, slotted spreader rolls, crowned rolls and the like.

After the spreading mechanism has generated the spacing in the desired lateral cross direction between the first panel fabric section 74 and the second panel fabric section 76, the two panel fabric sections are directed to a second assembly means. , as provided by a system of assembly rollers 50.

A second supply means, such as a supply roll 23, supplies a fabric of the first selected mechanical fastening component, such as the illustrated fabric 24 of the hook material. The hook material fabric includes a base layer 26, and defines a first side section 30, a second section 32, and a middle section 28 which is interposed between the first and second side sections of the hook material fabric. In addition, the base layer 26 has a first surface 46 and a second opposingly located surface 48. The first surface 46 is typically designed to be facing inwardly of the associated article, and includes a plurality of fasteners projecting and engaging. extend from it. The arrangement shown of the supply roll 23 has the hook elements extending radially outwardly from the supply roll. In particular aspects of the invention, the fastening elements are formed integrally with the base layer 26 and may be composed of virtually the same material as the base layer. The desired configurations include the hook elements which are co-extruded or otherwise integrally formed of the base layer material.

In the various arrangements of the invention, the middle section 28 can be virtually free of the mechanical fastening elements. In particular configurations, the midsection may selectively include protuberances constructed (not shown) to improve the flexibility and / or tear strength of the fabric of material which is designated to provide the first mechanical fastening component.

In particular aspects of the invention, the fabric of the hook material 24 can be of the type mentioned as a micro-hook material. A suitable micro-hook material is distributed under the designation CS200 and is available from 3M Company, a business having offices in San Paul, Minnesota. The micro-hook material may have hooks in the shape of fungus "tops", and may be configured with a hook density of about 1,600 hooks per square inch; a hook height which is within the range of about 0.033-0.097 centimeters; and a lid width which is within the range of about 0.025-0.033 centimeters. The hooks are attached to a base film substrate having a thickness of about 0.0076-0.01 centimeters and a Gurley stiffness of about 15 mg.

Another suitable micro-hook material is distributed under the designation VELCRO CFM-29 1058, and is available from VELCRO U.S.A., Inc., a business having offices in Manchester, New Hampshire. The micro-hook material may have hooks in the form of angled hook elements, and may be configured with a hook density of about 264 hooks per square centimeter (about 1,700 hooks per square inch); a hook height which is within the range of about 0.030-0.063 centimeters; and a hook width which is within the range of about 0.007 to 0.022 centimeters. The hook elements are co-extruded with a base layer substrate having a thickness of about 0.0076-0.008 centimeters and the member of the hook material has a Gurley stiffness of about 12 milligrams.

In the configuration shown, the middle section of the hook material fabric 24 is substantially free of the hook elements 54. In other aspects of the invention, the average hook element density (frequency of occurrence) per unit area of the hook. the middle section 28 can not be more than about 75 percent (%) of the average hook element density within the primary attachment side sections 30 and 32. Alternatively, the density of hook elements in the middle section 28 can not to be more than about 70 percent, and optionally may not be more than about 60 percent of the density of hook elements within their adjacently located fastening sections 30 and 32 of the hook material 24 for provide the desired characteristics. In additional aspects, the average hook element density per unit area of the grip region 52 may not be less than about 25 percent of the average hook element density within the primary attachment side sections 30 and 32. Alternatively, the density of the hook elements in the grip region 52 may not be less than about 30 percent, and optionally may be no less than about 40 percent of the density of the hook elements within. of its adjacently located clamping sections 30 and 32 of the fabric of the hook material 24 to provide improved performance. The density of average hook elements can, for example, be adjusted by increasing or decreasing the spacing between the individual hook elements. Alternatively, the density of the average hook element can be adjusted by limiting the placement of the hook elements within the localized areas to create a selected patch pattern of areas of segregated "islands" which contain the hook elements. Island areas are distributed within a "sea" area that is virtually devoid of operable hook elements.

With reference to Figures 5 and 6, the fabric of the hook material 24 can be configured with a longitudinally extending complementary fastening region 104, which in the arrangement shown, is positioned virtually along the longitudinal centerline of the body. fabric 24. The complementary fastening region provides a resistance to relatively lower overall fastening, compared to the primary fastening sections provided in the side sections 30 and 32 of the base layer 26. The lower fastening strength it can, for example, be provided by reducing the effective area of the selected fastening component placed in the complementary fastening region, or by reducing the area density of the selected fastening elements located in the complementary fastening region. In particular aspects, the complementary clamping region 104 can be virtually cotermined with either or both of the longitudinally extending portions 61 and the laterally extending portions 63 of the serpentine dividing line 62. In other aspects, the region of Additional fastener 104 may be configured spaced outwardly from at least the longitudinally extending portions 61 of the serpentine dividing line by a selected spacer distance.

With reference again to Figures 1, 2 and 3, at least one carrier fabric 34 is delivered from a suitable source, such as the supply roll 35. In the particular configurations of the invention, the carrier layer material 56 may be composed of a virtually non-elastomeric material, such as polymer films, woven fabrics, non-woven fabrics, or the like, as well as combinations thereof. Alternatively, the carrier weave material may be composed of a virtually elastomeric material, such as a stretched-bonded-laminate (SBL) material, a tapered-bonded-laminate (NBL) material, an elastomeric film, an elastomeric foam material or similar, as well as combinations thereof. The elastomeric material is elastomerically stretchable at least along the side dimension 88. For example, the carrier fabric material may be composed of a spunbond-melt-blown-spunbonded (SMS) fabric having a Meltblown fiber core placed in sandwich form between two face layers of spunbonded fibers to provide a total composite basis weight in the range of about 50-67 g / square meter (about 1.5-2 ounces) /Square yard). As another example, the weave weave material can be completely composed of a nonwoven spunbonded web having a basis weight in the range of about 50-67 g / square meter (about 1.5-2 ounces / square yard) ).

As shown representatively, the carrier fabric 34 has a first major face surface 42 and a second major face surface 44. The carrier fabric also has a first side section 38, a second side section 40, and a middle section 36 which it is interposed between the first and second side sections of the carrier fabric, and is generally positioned along a longitudinal center line of the carrier fabric. The second surface 48 of the fabric of the hook material 24 is operably attached and laminated to the middle portion 36 of the first surface 42 of the weave fabric to provide a composite fastener fabric 72. An operative fastening mechanism, such as the adhesive applicator shown 82, generates a fastener for operatively fixing the fabric of hook material 24 on the associated carrier fabric 34, and a conventional assembly mechanism, such as a roller system 84, mounts the hook material on the carrier fabric. The applicator may be configured to generate any conventional adhesive array, such as a groove coating, a bead, a spray, a swirl pattern or the like, as well as combinations thereof. Desirably, the fabric of hook material is virtually centered along the transverse direction of the carrier fabric 34. The resulting assembly provides a composite woven laminate in which the hook elements 54 are in a generally exposed position. The composite fastener fabric 72 can then be operably operated and transported for further processing.

In the representatively shown configuration of the invention, suitable steering means, such as a conventional guide roller system (not shown), transports the fastener fabric 72 to a position which is interposed between the panel fabric sections 74 and 76. A suitable fastening mechanism, such as the shown system of adhesive applicator 90 and ultrasonic attachment 92, generates a fastener for securing composite fastener fabric 72 between laterally spaced and spaced panel fabric sections 74 and 76 to provide the composite fabric 22. More particularly, the adhesive applicator initially holds the outer edges of the composite weave 72 to the associated overlapping edges of each of the panel fabric sections 74 and 76. The inner edge region 58 of the first section of panel fabric 74 is fastened to the first overlapping side edge region 39 of the first lateral section 38 of the weave gone carrier 34, and the inner edge region 58 of the second panel fabric section 78 is attached to the second overlapping side edge region 41 of the second side section 40 of the carrier fabric. The arrangements shown laminate the panel fabrics on the first surface 42 of the carrier fabric 34. Alternatively, the panel fabrics can be laminated on the second opposing surface 44 of the carrier fabric. The sonic bonding can desirably be used to supplement the initial clips with sonic thermal joints. The sonic linker can also generate a clamp between the hook material 24 and the carrier fabric 34, which together have provided the composite fabric 72.

The composite weave can then be moved or otherwise directed for further processing. For example, the composite fabric 22 may be wound on the rollers, such as the storage rollers 124, or otherwise configured for transport to another remotely located manufacturing line which is used to produce garments or other desired articles. Alternatively, the composite base fabric 22 can be operably delivered directly on subsequent phases of a manufacturing line along a connection path A.

With reference to Figure 2, the composite base fabric 22 can be operably delivered to second spacer means, such as a die cutter system 94 or the like, to longitudinally divide the composite fabric into a pair of fastener fabric sections. compound 72a and 72b. The cutter can produce a serpentine division line period 62, virtually undulating regularly which is placed along a middle section of the composite base fabric 22. The serpentine line generally extends along the length of the longitudinal extension of the direction of the composite fabric machine 22 and include the side-to-side sections that are alternately traversed therefrom. Cross sections of the dividing line may optionally include retrograde portions thereof to provide distinctly shaped holding appendages 112. The division line 62 separates at least the weave from the hook material 24. In the configurations shown, the dividing line separates both the fabric of hook material and the fabric of the carrier material 34. In addition, the cross sections of the serpentine line are selectively arranged to virtually avoid extending into the distributions of the hook elements 54 located in the the first and second lateral regions 30 and 32 of the hook material fabric 24. Further details regarding the construction of the appropriate fastening appendages and fastening systems are, for example, described in the patent application of US Pat. United States of America previously mentioned series number 168,615 of T. Roessler and others, entitled "DIN MICO ENTALLE DIAPER" filed on December 16, 1993 (lawyer's case number 10961); and U.S. Patent Application No. 603,477 to A. Lomg et al., entitled "MECHANICAL CLAMPING SYSTEM WITH GRIP APPENDIX", filed March 6, 1996 (attorney's matter number 12563).

In the shown configuration of the invention, the composite fastener fabric sections 72a and 72b are operably directed to a conventional bending board system 76 to reposition the individual fastening appendages 112 in a storage position against a surface designated from its associated fastener fabric section 72a or 72b, as desired.

Phase adjusting means, as provided by the alignment tilt bars 116 and 118, overturns operably the fastener fabrics 70 and 72, and replaces the phase in the longitudinal machine direction of the appendages. of fastener on the first fastener fabric section 72a in relation to the fastener appendages on a second fastener fabric section 72b. In the reverse flipping operation, the fastening fabric sections 72a and 72b are laterally released and put upside down so that the fastening appendages 112 are changed from being located along the interior edge regions of the fastener fabrics. , and move to locate along the outer edge regions of the fastener fabrics. The additional repositioning phase operation is configured to operatively fix the corresponding corresponding pairs of the clamping lugs 112 in a substantial transverse frame alignment along the transverse direction of the process and the apparatus. So, the process and the apparatus provide at least one correspondingly opposite lateral pair of fasteners, which include a first fastener appendage from the first composite fastener fabric section 72a and a second fastener appendage of the second composite fastener fabric 72b. In the illustrated embodiment, the process is advantageously constructed to provide a series multiplicity of the laterally opposite and corresponding pairs of the first and second fasteners.

The substantially aligned first and second fastener fabric sections 72a and 72b can be prepared for further fastening to other components of the desired article.

In the illustrated configuration, for example, the composite fastener fabric sections 72a and 72b are directed to an applicator 120 which deposits a suitable adhesive over the regions of the composite fastener fabric sections that are designated for an additional fastener. Other fastening mechanisms, such as thermal points, sonic joints and the like may also be employed to supplement or replace the described adhesive fastener.

In further aspects of the method and apparatus of the invention, the first and second fastener fabric sections 72a and 72b are directed to a third separating mechanism, such as a cutter and swivel system 96, for positioning along the cross direction of the fastener fabric sections to form a plurality of individual fastener components 66. The individual fastener systems are directed to an assembly mechanism of suitable construction, such as a system of assembly rollers which may be configured for fastening the individual fastener systems on the face side facing outward or the face side facing the main body of an article fabric 68 as desired.

For example, intermittent cutting and phasing assembly means, such as a mechanism comprising a conventional vacuum slide roller system 110 and rotary and anvil knife systems 96, can be employed to connect the directionally aligned pairs in opposed and connected cross-section of the fastener components 66 to the laterally opposite side regions 98 of the article fabric 68. In the illustrated embodiment, for example, the cut-and-place assembly mechanism is constructed and arranged to operably connect a plurality in sequence of the fastener components in pairs 66 to the article fabric in a plurality of predetermined spaced apart locations along the machine direction of the article 68 fabric. An example of a suitable arrangement of a slip roller of Vacuum and rotary cutter is described in the patent of the United States of America or 4,795,510 issued on January 3, 1989 to M. Wittrock et al. entitled "PROCESS FOR APPLYING A REINFORCEMENT MATERIAL TO A DIAPER COVER MATERIAL" (attorney's issue number 8366), the disclosure of which is incorporated herein by reference in a way that is consistent with it.

The assembly mechanism operatively fixes the individual fastener components 66 on opposite sides 98 of the article fabric 68, and the opposing pairs of the individual fastener components 66 are virtually aligned along the transverse direction 88 of the article 68 fabric. In addition, the ultrasonic joints 126 can be employed to provide additional securing between the fastener components 66 and the article fabric 68. The article fabric can be further processed and separated into a plurality of individual articles through separation means. conventional In particular, the resulting article fabric 68 can be constructed to define an interconnected plurality of segments of individual articles 122, and a conventional cutting mechanism (not shown) can then separate the fabric of article 68 along preselected division lines 100. to produce the individual items selected. The separator step can be carried out by employing any conventional cutting mechanism, such as a rotary cutter or the like.

The invention may further include mechanisms for providing a fabric of backsheet material, and for placing at least one absorbent body at a selected location along a length in the machine direction of the backing sheet fabric. A plurality of absorbent bodies can, for example, being placed in regularly spaced and predetermined locations along the length of backing sheet fabric. Another mechanism can be delivered to a fabric of upper sheet material to put the absorbent body in the form of a sandwich between the fabric of the backing sheet material and the fabric of the upper sheet.

Other aspects of the invention may include a mechanism for securing at least one pair of elasticized restraining fins extending longitudinally to the tissue-side surface of the upper sheet. Suitable containment flap configurations are described in detail in U.S. Patent No. 4,704,116 issued November 11, 1987 to K. Enloe and entitled "DIAGRAMS WITH ELASTICIZED SIDE BAG", the disclosure of which is incorporated herein by reference. reference in a way that is consistent with it. Other containment fin configurations are described in U.S. Patent Application Serial No. 206,816 of R. Everett et al entitled "ABSORBENT ARTICLE HAVING IMPROVED EMERGENCY MANAGEMENT" and filed on March 4, 1994 (subject of attorney 11375), the disclosure of which is incorporated herein by reference in a manner that is consistent therewith.

With reference to Figures 7, 10 and 11, another aspect of the invention can provide a system for producing a set of multiple composite tissues 22. The method and apparatus shown to form the fastener components, is configured to provide the fabrics virtually continuous first and second of a first mechanical fastening component, such as the fabrics of the hook material 24a and 24b. Each of the first mechanical-fastening components includes a base layer, such as a base layer of hooks 26, which has a longitudinally extending middle section, such as the middle section 28 or 28a, located between the sections on the side extending longitudinally, laterally opposite first and second, such as the lateral edge regions, such as the lateral sections 30 and 32a or the side sections 30a and 32 of the tissue of the first mechanical fastening component. Each of the side sections has a plurality of first mechanical fastening elements, such as the hook elements shown 54, which are formed integrally with the base layer and extend outwardly from a base plane of the base layer of hooks. The first mechanical fastening elements are configured to operably engage a second cooperating mechanical fastening component, such as a curl material. The middle section may have a relatively lower density of said first mechanical fasteners per unit area, compared to said side sections. Optionally, the middle section of any of the fabrics 24 can be virtually free of operable hook elements or other mechanical fastening elements. At least one virtually continuous fabric of carrier material, such as the carrier fabric 34a or 34b, is attached to each of the first and second tissues of the first mechanical fastening component. Each of at least one weave of carrier material provides a section extending from the carrier fabric material, such as the carrier side section 38 or 40, which extends laterally outward from each of the side sections of each. one of the first and second weaves of said first mechanical fastening component. In addition, each of at least one weave of carrier material provides a first designated side edge region carrier, such as the side edge portion 39 of the side carrier section 38, and a second carrier side edge region designated such as a side edge portion 41 of the carrier side section 40. A relatively central and virtually continuous fabric of panel material, such as the panel fabric 75, is attached to the second side edge portion 41 of each of thereby less a fabric of carrier material, and a relatively outer fabric of the panel material, such as is provided by the panel fabric 74 or 76, is clamped to extend laterally outside the first side edge portion 39 of each of at least minus a weave of carrier material, thereby forming a set of composite fastener fabric 27.

In particular aspects, the technique of the invention may further include a relatively central tissue partition 75 of the panel material to provide the first and second composite fastener fabrics, such as the composite fabrics 22a and 22b. In other aspects, the technique of the invention may include a division of at least the fabric of the first mechanical fastening component, such as the fabric 24a and / or 24b, with at least one of the fastener fabrics composed as along a serpentine dividing line 62 which extends generally longitudinally along the fabric of hook material.

The configuration shown representatively includes supply means, such as the supply roll 57, which provides a first panel fabric 56 composed of the selected panel material. The panel material can be virtually non-elastomeric or can be elastomeric, as previously described.

A suitable separation mechanism, such as a cutter mechanism 52 or other cutters is used to divide the panel fabric 56 into a plurality of sections. For example, the panel fabric 56 can be separated in the first panel fabric section 74, the second panel fabric section 76, and at least one third panel fabric section 75. In the illustrated configuration, for example , the rider 52 can divide the panel fabric 56 into three sections, wherein the first and second sections have virtually identical widths in the transverse direction, and the third section 75 has a width in the transverse direction which is approximately double as large as that of the first and second sections. Optionally, any or all of the separate fabric sections 74, 75 and 76 may have relatively equal or uneven widths in the transverse direction, as desired. Each of the panel woven sections 74 and 76 have an inner side edge region 58 and an outer side edge region 60. The relatively medium third fabric section 75 has the first and second side edge regions 77 and 79 respectively .

The relatively lateral placements of the first, second and third fabric sections 74, 75 and 76 respectively, are desirably adjusted to a desired spacing along the transverse frame direction 88 of the process through operable steering means, such as it is provided by the extending mechanism 78. In the illustrated embodiment, for example, the spreading mechanism may include a conventional guide system which relocates and relocates each of the first and second tissues of the side panel material in a desired spacing away from the third tissue 75 of the side panel material. For example, the extender 78 may include any of the conventional spreader mechanisms described therein. After the spreader mechanism has generated the desired lateral cross-sectional spacings of the first and second panel fabric sections remote from the third centrally located panel fabric section 75, the three sections of panel fabric are directed to second assembly means, as provided by the assembly roller system 50.

With reference to Figures 7, 8 and 9 a second supply means, such as the supply roll 23, provides a fabric of the first selected mechanical fastening component, such as the illustrated fabric 25 of the hook material. The hook material fabric includes a base layer 26, and defines a first side section 30, a second side section 32, a generally central section 31, and a pair of spaced apart laterally spaced sections 28 and 28a. The middle section 28 is juxtaposed between the first lateral section 30 and the central section 31 of the fabric of hook material, and the middle section 28a is juxtaposed between the second side section 32 and the center section 31 of the hook material fabric. As previously mentioned, the base layer 26 has a first surface 46 and a second opposingly located surface 48. The first surface 46 is typically designed to face the associated article and includes a plurality of projecting fasteners. and they extend from it. The arranged arrangement of the supply roll 23 has the hook elements extending radially outwardly from the supply roll. In particular aspects of the invention, the fastening elements are formed integrally with the base layer 26 and can consist of virtually the same material as the base layer. The desired configurations include the hook elements which are co-extruded or otherwise integrally formed in the base layer material.

The shown configuration of the invention delivers the fabric of hook material 25 to a suitable divider mechanism, such as the shown cutter 102 which separates the fabric 25 into a group of two distinct fabrics 24a and 24b. The shown cutter cuts along a longitudinal center lines of the center section 31 of the hook material fabric to provide the sections 30a and 32a, as desired for the intended fabric configurations 24a and 24b. Alternatively, the center section 31 of the fabric 25 may include a line constructed of weakness which extends longitudinally along the fabric. The line of weakness is constructed to allow the fabric 25 to be selectively and reliably fractured or to tear along a designated separation line 33. The fabrics shown 24a and 24b are virtually identical to one another. Optionally, however, the cutter can be configured and arranged to provide the tissues 24a and 24b to differ from each other. After the splitting operation, the fabric set composed of the fabrics 24a and 24b are directed through a conventional spreading mechanism 106 which operatively places the tissues in a desired laterally spaced and spaced configuration, as has been appropriate for Subsequent processing.

With reference again to Figures 7, 10 and 11 at least one carrier fabric 34 is delivered from a suitable source, such as a supply roll 35. In the arrangement shown, the carrier fabric 34 is divided into a set of two. carrier fabrics 34a and 34b by a slitter 128 or other suitable separation mechanism, and the carrier fabrics are placed in a desired laterally spaced apart relationship by a suitable spreading device 130. Optionally, the set of carrier fabrics can be delivered from rolls of separate supply. As shown representatively, each of the carrier tissues 34a and 34b has a first front surface 42 and a second main front surface 44. Each carrier fabric also provides a first side section 38, a second side section 40 and an average section 36 which is interposed between the first and second side sections of the carrier fabric and is generally positioned along a longitudinal centerline of the carrier strand. The second surface 48 of the fabric 24a of the hook material is operably bonded and laminated to the middle portion 36 of the first surface 42 of the carrier fabric 34a to provide a first composite fastener fabric 72a, and the surface 48 of the fabric 24b of the fastener material. The hook is operably joined and laminated to the middle portion 36 of the first surface 42 of the carrier fabric 34b to provide a second composite fastener fabric 72b. An operative fastening mechanism, such as the adhesive applicator shown 82, generates a fastener for operatively fixing each of the hook material fabrics 24a and 24b to its associated weave 34a and 34b. Desirably, each fabric of hook material is centered virtually along the transverse direction of its corresponding carrier fabric 34. The resulting assemblies provide a set of composite fabric laminates to which the hook elements 54 are in a generally position. exposed. The assembled composite fastener fabrics 72a and 72b can then be operably operated and transported for further processing.

In the representatively shown configuration of the invention, suitable steering means, such as the shown system of guide rollers 84, transports the fastener fabrics 72a and 72b to positions in which they are operatively interposed between the panel fabric sections 74. , 75 and 76. In particular, the fastener fabric 72a is located to extend and spread between. sections of panel fabric 74 and 75, and the fastening fabric 72b is located to extend between the panel fabric sections 75 and 76. A suitable fastening mechanism, such as the shown system of adhesive applicator 90 and the ultrasonic attachment 92, generates a fastener to fix each of the composite fastener fabrics 72a and 72b between their corresponding pair of the laterally spaced and spaced panel fabric sections 74-75 and 76-75, respectively, to provide the composite fastener fabric assembly 27. More particularly, the applicator The adhesive initially holds the side edges of each of the composite fabrics 72a and 72b to the corresponding overlapping edges of its associated pair of the panel fabric sections 74-75 and 76-75, respectively. The inner edge region 58 of the first panel fabric section 74 is attached to the first overlapping side edge region 78 of the carrier fabric 34a and the second side edge region 40 of the carrier fabric 34a is attached to the first edge region. overlapping side 77 of the panel fabric 75. Similarly, the inner edge region 58 of the second panel fabric section 76 is fastened to the first overlapping edge region 38 of the weave 34b and the second side edge region 40 of the fabric carrier 34b is attached to the second overlapping side edge region 79 of panel fabric 75. Sonic linker 92 complements the initial clips with the ultrasonic thermal joints. The sonic linker can also be configured to generate a clamp between the hook materials 24a and 24b and the carrier tissues 34a and 34b, which together have provided the composite fabrics 72a and 72b respectively.

The composite tissue set 27 can then be moved or otherwise directed for further processing. For example, the composite fabric assembly 27 may be directed to another splitter mechanism, such as provided by the cutter 108, to separate the fabric assembly 27 into a set of two composite fabrics 22a and 22b. Each of the composite fabrics 22a and 22b can be wound onto the rollers 124 or otherwise configured to be transported to another remotely located manufacturing line which is employed to produce the garments or other desired articles. Alternatively, either or both of the composite base fabrics 22a and 22b can be operably delivered directly to subsequent phases of an associated manufacturing line (e.g., Figure 2) along an individual connection path A.

Having described the invention in considerable detail it will be readily apparent that various changes and modifications can be made without departing from the spirit of the invention. All such changes and modifications are contemplated as being within the scope of the invention as defined in the attached clauses.

Claims (19)

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

1. A method for forming fastener components, comprising: providing a composite fabric which includes a fabric of a first mechanical fastening component, said first fabric of mechanical fastening component includes a base layer which has a longitudinally extending mid-section located between the lateral sections extending longitudinally laterally opposite first and second of said first tissue of mechanical fastening component, each of the side sections has a plurality of first mechanical fastening elements which are integrally formed with said base layer and extend outwardly from a base plane of said base layer, said first mechanical fastening elements are configured to operably engage a second selected cooperative mechanical fastening component, said middle section having a relatively lower density of said first mechanical fastening elements per unit area, compared to gave As side sections, said fabric of said first mechanical fastening component has an extending section of carrier fabric fastened to extend laterally outwardly from each of the side sections of said fabric of said first mechanical fastening component; Y dividing at least said fabric of said first mechanical fastening component along a serpentine dividing line which extends longitudinally along the first tissue of mechanical fastening component.

2. A method as claimed in clause 1 characterized in that it comprises the selective segmentation of said composite fabric to provide said plurality of fastening components.

3. A method as claimed in clause 1 characterized in that a dispensing fabric of panel material has been clamped to extend laterally out of each section of the carrier fabric material.

4. A method as claimed in clause 1 characterized in that said method includes: providing a composite fabric which includes a fabric of hook material, said fabric of hook material includes a base layer of hooks which has a longitudinally extending middle section located between longitudinally extending side sections, laterally opposite first and second of said hook material fabric, each of the side sections has a plurality of hook elements which are integrally formed with the base layer and extend outwardly from a base plane of said base layer of hooks , said hook elements are configured to operably engage a selected cooperating loop material, said middle section has a relatively lower density of hook elements per unit area, compared to said side sections, said hook fabric has a cross section Carrier material carrier paver laterally clamped the outside of each of the side sections of said fabric of hook material; Y dividing at least said fabric of hook material along a serpentine dividing line which generally extends longitudinally along said fabric of hook material.

5. A method as claimed in clause 4 characterized in that an extender fabric of panel material has been clamped and laterally extended outwardly from each section of the carrier fabric material.

6. A method as claimed in clause 1 characterized in that said method is arranged to provide a composite fabric having a stretcher panel fabric of an elastomerically stretchable panel material fastened to extend laterally out of each section of the carrier fabric material.

7. A method as claimed in clause 1 characterized in that it further comprises a fastening of said fastener components in designated lateral regions of a woven article.

8. A method as claimed in clause 7 characterized in that it comprises a division of said woven article into a plurality of individual articles.

9. A method as claimed in clause 1 characterized by said method provides said serpentine dividing line in a configuration which virtually avoids spreading inside the tissue side sections of the first mechanical fastening component.

10. A method for forming a plurality of fastener components, comprising: To provide a virtually continuous fabric of a first mechanical fastening component, said first mechanical fastening component includes a base layer which has a longitudinally extending middle section located between the longitudinally laterally opposite lateral sections extending first and second of each other. said fabric of said first mechanical fastening component, each of the side sections has a plurality of first mechanical fastening elements which are integrally formed with said base layer and extend outwardly from a base plane of said base layer of hooks, said first mechanical fastening elements are configured to engage a second cooperative and selected mechanical fastening component, said middle section having a relatively lower density of said first mechanical fastening elements per unit area, in comparison to said later sections ales, fastening at least one virtually continuous fabric of carrier material to said fabric of said first mechanical fastening component to provide a paver section of the carrier fabric material which extends laterally outward from each of the side sections of the fabric of said first mechanical fastening component; fastening a virtually continuous fabric of panel material to extend laterally outwardly from each spreader section of the weave carrier material thereby forming a composite fastener fabric; and dividing at least said fabric of said first mechanical fastening component along a serpentine dividing line which extends generally longitudinally along said fabric of hook material.

11. A method as claimed in clause 10 characterized in that said method includes providing a virtually continuous fabric of hook material, said hook material includes a base layer of hooks which has a longitudinally extending middle section located between the hooks. lateral sections extending longitudinally, laterally opposite first and second of said fabric of hook material, each of the side sections has a plurality of hook elements which are integrally formed with said base layer and extend outward from a base plane of said base layer of hooks, said hook elements are configured to operably engage a cooperative and selected curl material, said middle section has a relatively lower density of said hook elements per unit area, compared to said side sections, fastening at least one virtually continuous fabric of carrier material to said fabric of hook material to provide a pantiliner section of carrier fabric material which extends laterally out of each of the side sections of said fabric of hook material; fastening a virtually continuous fabric of panel material to extend laterally out of each carrier fabric material extender section, thereby forming a composite fastener fabric; Y dividing at least said web of hook material along a serpentine dividing line which generally extends longitudinally along said web of hook material.

12. A method as claimed in clause 10, characterized in that said method is arranged to clamp a virtually continuous fabric of an elastomerically stretchable panel material to extend laterally out of said spreader section of the carrier fabric material, thereby forming said fabric composite bra.

13. A method as claimed in clause 10, characterized in that said method is configured to provide the first and second virtually continuous webs of the carrier material which are operably held to thereby provide said sections of carrier fabric material which extend laterally outside each of the side sections of said fabric of the hook material.

14. A method as claimed in clause 10 characterized in that said method provides said serpentine dividing line in a configuration which virtually avoids spreading inside the lateral sections of said fabric of the first mechanical fastening component.

15. A method as claimed in clause 10, characterized in that it further comprises fastening the fastener components in designated lateral regions of a woven article.

16. A method as claimed in clause 15 characterized in that it comprises a division of said woven article into a plurality of individual articles.

17. A method for forming fastener components comprising: providing the first and second virtually continuous fabrics of a first mechanical fastening component, said first mechanical fastening component includes a base layer which has a longitudinally extending mid-section located between the longitudinally extending, laterally opposed side sections first and second of said fabric of the first mechanical fastening component, each of the side sections has a plurality of first mechanical fastening elements which are integrally formed with said base layer and extend outwardly from a base plane of said layer. of hook base, said first mechanical fastening elements are configured to operably engage a second cooperative and selected mechanical fastening component, said middle section has a relatively lower density of said first mechanical fasteners per unit area, in comparison ation to said lateral sections, attaching at least one virtually continuous fabric of carrier material to each of the first and second tissues of said first mechanical fastening component, each said at least one weave of carrier material provides a spreader section of the carrier fabric material which extends laterally outward from each of the side sections of each of the first and second tissues of said first mechanical fastening component, and each said at least one weave of carrier material provides a first side edge region. carrier and a second designated side edge region carrier; fastening a relatively central and virtually continuous fabric of panel material to a second side edge portion of each of at least one weave of carrier material; Y holding a relatively outer fabric of the panel material to extend laterally outside the first side edge portion of each of at least one weave of carrier material, thereby forming a composite fastener fabric assembly.

18. A method as claimed in clause 17, characterized in that it further comprises dividing the relatively central fabric of the panel material to provide the first and second composite fastener fabrics.

19. A method as claimed in clause 18 characterized in that it comprises dividing at least said fabric of said first mechanical fastening component in at least one of said composite fastener fabrics along a serpentine dividing line which is generally extends longitudinally along the fabric of hook material. SUMMARY A method for forming a plurality of fastener components comprising providing a composite fabric which includes a weave of hook material, the hook material includes a base layer of hooks which has a longitudinally extending mid-section located between the longitudinally extending side, laterally opposite first and second sections of the hook material fabric. Each of the side sections has a plurality of hook elements which are integrally formed with the base layer and extend outward from a base plane of the hook base layer, and the hook elements are configured, for operably engaging a cooperative curl material selected to provide an operative fastener. The middle section has a relatively lower density of the hook elements per unit area, compared to the side sections. The hook material fabric has a pantiliner section of carrier fabric fastened to extend laterally outward from each of the side sections of the weave of the hook material. Each section of the carrier fabric material may have an extender fabric of panel material that is clamped to extend laterally outward of each section of the carrier fabric material. At times the fabric of the hook material is divided along a serpentine dividing line which extends generally longitudinally along the fabric of hook material and the composite fabric is selectively segmented to provide the plurality of components. of bra.