US20160128541A1 - Multilayer pads and methods of manufacture employing thermal bonding - Google Patents
Multilayer pads and methods of manufacture employing thermal bonding Download PDFInfo
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- US20160128541A1 US20160128541A1 US15/000,247 US201615000247A US2016128541A1 US 20160128541 A1 US20160128541 A1 US 20160128541A1 US 201615000247 A US201615000247 A US 201615000247A US 2016128541 A1 US2016128541 A1 US 2016128541A1
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Images
Classifications
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- A—HUMAN NECESSITIES
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- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
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- A47L13/10—Scrubbing; Scouring; Cleaning; Polishing
- A47L13/16—Cloths; Pads; Sponges
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
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- B25G1/102—Handle constructions characterised by material or shape the shape being specially adapted to facilitate handling or improve grip
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- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
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- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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- B32B2307/7265—Non-permeable
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1051—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by folding
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y10T428/24752—Laterally noncoextensive components
Definitions
- the invention relates generally to multilayer pads and methods of manufacture such as are disclosed in our earlier Woods et al U.S. Pat. No. 5,230,119, titled “Multilayer Laminated Pad;” U.S. Pat. No. 5,507,906 (now US Re. 36,601), titled “Method for Making Multilayer Pad;” U.S. Pat. No. 5,771,524, titled “Disposable Pad;” and U.S. Pat. No. 6,493,898, titled “Laminated pads and methods of manufacture employing mechanically folded handles,” the entire disclosures of which are hereby expressly incorporated by reference; as well as Zygmont U.S. Pat. No. 6,044,515, the entire disclosure of which is hereby expressly incorporated by reference.
- the pads disclosed in our earlier patents generally are manufactured by initially forming a two- or three-layer composite laminated sheet using adhesive or other attachment to combine base pad forming material, impervious barrier layer forming material, and handle forming material.
- the base pad forming material, barrier layer forming material and handle forming material are provided as respective webs of material from supply rolls, the webs each having a predetermined width (typically the same width for all three webs in the pads disclosed in U.S. Pat. No. 5,230,119; U.S. Pat. No. 5,507,906; US Re. 36,601 and U.S. Pat. No. 5,771,524), with lengths depending on the roll size.
- U.S. Pat. No. 5,771,524 generally discloses pads which have handles that may be referred to as “wings”.
- U.S. Pat. No. 6,493,898 generally discloses pads which have what may be referred to as “folded” handles.
- the exemplary adhesive attaching the web of base pad forming material and the web of barrier layer forming material to each other is applied as a full coating, such that these two web layers are continuously adhered to each other along their entire widths.
- the adhesive which joins the web of barrier layer forming material to the web of handle forming material is applied in longitudinal strips, which may be referred to as “zone coating.” A cutter is then used to cut through all three layers of the laminated sheets to produce individual multilayer pads.
- the cutter is aligned with reference to the adhesive strips securing the handle forming material to the barrier forming material, as well as with reference to uncoated areas between the adhesive strips, such that, in each of the resulting pads, a portion of the handle forming material layer is over an adhesive strip resulting in an adhered segment of the handle, and another portion (or portions) of the handle forming material layer within the shape of the cutter is over an uncoated area resulting in a free or graspable portion of the handle.
- the resultant graspable handle portion lies flat against the barrier layer prior to initial use, and pivots up for use.
- U.S. Pat. No. 6,493,898 (“folded” handles) discloses the manufacture of similar pads, while avoiding the need for zone coating to define adhered handle segments. Rather, the handle forming material is mechanically folded, employing a pleating/folding machine, prior to being adhered to the barrier layer. As alternatives, adhesive is applied to the barrier layer, or to the underside of the handle forming material subsequent to folding, or to the underside of the handle forming material prior to folding.
- a multilayer pad in one aspect, includes an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite the applying/wiping surface, and an outer periphery.
- the multilayer pad additionally includes a barrier layer having a lower surface attached by fusing to the base pad layer attachment surface, an upper surface and an outer periphery coextensive with the outer periphery of the base pad layer.
- the multilayer pad further includes a handle with an attached portion fused to a portion of the barrier layer upper surface, and at least one graspable free portion joined to the handle attached portion along a fold line defining an axis of the multilayer pad.
- the handle attached portion is attached to the barrier layer upper surface along at least one bond line parallel to the pad axis.
- a multilayer pad in another aspect, includes an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite the applying/wiping surface, and an outer periphery.
- the multilayer pad additionally includes a barrier layer having a lower surface attached by fusing to the base pad layer attachment surface, an upper surface, and an outer periphery coextensive with the outer periphery of the base pad layer.
- the multilayer pad further include a handle with an attached portion fused to a portion of the barrier layer upper surface, and at least one graspable free portion joined to the handle attached portion along a fold line defining an axis of the multilayer pad.
- the handle attached portion is attached to the barrier layer upper surface, and the barrier layer lower surface is attached to the base pad layer attachment surface along bond lines parallel to the pad axis.
- a multilayer pad in yet another aspect, includes an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite the applying/wiping surface, and an outer periphery.
- the multilayer pad additionally includes a barrier layer having a lower surface attached by fusing to the base pad layer attachment surface, an upper surface, and an outer periphery coextensive with the outer periphery of the base pad layer.
- the multilayer pad further include a handle with an attached portion fused to a portion of the barrier layer upper surface, and at least one graspable free portion joined to the handle attached portion along a fold line defining an axis of the multilayer pad.
- the barrier layer is continuously fused to the base pad layer, and the handle attached portion is attached to the barrier layer upper surface along at least one bond line parallel to the pad axis.
- FIG. 1 is a schematic representation of a machine for the in-line automatic manufacture of three-layer pads, which have what may be referred to as “L”-shaped handles, the machine of FIG. 1 including ultrasonic bonding equipment and automatic folding tooling;
- FIG. 2 is a three-dimensional view of a web of handle forming material embossed and slit into sub webs, a web of intermediate barrier layer material, and a web of base pad material adjacent to each other as processed in the machine of FIG. 1 , in a condition prior to fusing;
- FIG. 3 is a highly schematic representation of in-line steps to manufacture pads with “L”-shaped handles employing the machine of FIG. 1 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors;
- FIGS. 3A, 3B, 3C and 3D are views taken on lines 3 A- 3 A, 3 B- 3 B, 3 C- 3 C and 3 D- 3 D of FIG. 3 , representing pad precursors in end elevational view at various stages of manufacture prior to individual pads being cut out of a moving web;
- FIG. 3E is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence of FIG. 3 , except with the pad handle pivoted up;
- FIG. 3F is a side elevational view of the pad of FIG. 3E , taken on line 3 F- 3 F of FIG. 3E ;
- FIG. 4 is a schematic representation of a machine for the in-line automatic manufacture of two-layer pads, which have what may be referred to as “folded” handles, the machine of FIG. 3 including ultrasonic bonding equipment and automatic folding tooling;
- FIG. 5 is a highly schematic representation of in-line steps to manufacture pads with “folded” handles employing the machine of FIG. 4 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors;
- FIGS. 5A, 5B, 5C and 5D are views taken on lines 5 A- 5 A, 5 B- 5 B, 5 C- 5 C and 5 D- 5 D of FIG. 5 , representing pad precursors in end elevational view at various stages of manufacture prior to individual pads being cut out of a moving web;
- FIG. 5E is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence of FIG. 5 , except with the pad handle pivoted up;
- FIG. 5F is a side elevational view of the pad of FIG. 5E , taken on line 5 F- 5 F of FIG. 5E ;
- FIG. 6A is a representation of a single ultrasonic horn and anvil, which may be tooled to emboss, weld and slit various materials;
- FIG. 6B is a representation of an array of across-the-web ultrasonic horns and anvils, which may be tooled to perform various in-line processes;
- FIG. 7 is a schematic representation of a machine for the in-line automatic manufacture of three-layer pads, which pads either have “L”-shaped handles (as described hereinbelow with reference to FIG. 8 ), or have handles configured as “wings” (as described hereinbelow with reference to FIG. 10 ), the machine of FIG. 7 requiring only a single ultrasonic bonding station;
- FIG. 8 is a highly schematic representation of in-line steps to manufacture pads with “L”-shaped handles employing the machine of FIG. 7 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors;
- FIGS. 8A and 8B are views taken on lines 8 A- 8 A and 8 B- 8 B of FIG. 8 , representing pad precursors in end elevational view at two stages of manufacture prior to individual pads being cut out of a moving web;
- FIG. 8C is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence of FIG. 8 , except with the pad handle pivoted up;
- FIG. 8D is a side elevational view of the pad of FIG. 8C , taken on line 8 D- 8 D of FIG. 8C ;
- FIG. 9A is an end elevational view of an “L”-shaped handle in isolation similar to handle of the pad of FIGS. 8, 8C and 8D , but with the horizontal leg of the handle being significantly shorter than the upright portion,
- FIG. 9B is an end elevational view of a pad having the “L”-shaped handle of FIG. 9A , the handle being folded down in the configuration of FIG. 9B ;
- FIG. 9C is a plan view of the pad of FIG. 9C ;
- FIG. 9D is an end elevational view of the pad of FIGS. 9B and 9C , in the same orientation as FIG. 9B , but with the handle being folded up in the configuration of FIG. 9D ;
- FIG. 10 is a highly schematic representation of in-line steps to manufacture pads with “wing” handles employing the machine of FIG. 7 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors;
- FIGS. 10A and 10B are views taken on lines 10 A- 10 A and 10 B- 10 B of FIG. 10 , representing pad precursors in end elevational view at two stages of manufacture prior to individual pads being cut out of a moving web;
- FIG. 10C is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence of FIG. 10 , except with the wings of the pad handle pivoted up;
- FIG. 10D is a side elevational view of the pad of FIG. 10C , taken on line 10 D- 10 D of FIG. 10C ;
- FIG. 11 is a schematic representation of a machine for the in-line automatic manufacture of two-layer pads, which pads have what may be referred to as “folded” handles, similar to the handles of FIGS. 5, 5E and 5F made by the machine of FIG. 4 , the machine of FIG. 11 , like the machine of FIG. 7 , requiring only a single ultrasonic bonding station;
- FIG. 12 is a highly schematic representation of in-line steps to manufacture pads with “folded” handles employing the machine of FIG. 12 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors;
- FIGS. 12A, 12B, 12C, 12D and 12E are views taken on lines 12 A- 12 A, 12 B- 12 B, 12 C- 12 C, 12 D- 12 D and 12 E- 12 E of FIG. 12 , representing pad precursors in end elevational view at various stages of manufacture prior to individual pads being cut out of a moving web;
- FIG. 12F is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence of FIG. 12 , except with the pad handle pivoted up;
- FIG. 12G is a side elevational view of the pad of FIG. 12F , taken on line 12 G- 12 G of FIG. 12F ;
- FIGS. 13A, 13B, 13C, 13D and 13E illustrate, for purposes of example, five of the many ultrasonic welding/bonding patterns available.
- FIG. 14 is a schematic representation of a machine for the in-line automatic manufacture of two-layer pads using a co-extruded barrier-to-base layer material ultrasonically bonded to a layer of handle forming material, which pads either have “L”-shaped handles or have handles configured as “wings,” the machine of FIG. 14 , like the machine of FIG. 7 , requiring only a single ultrasonic bonding station.
- a thermal bonding, thermal fusion or heat fusion process is employed in embodiments of the invention to bond one or two layers of impervious film to a layer of non-woven base pad forming material, without the use of an adhesive of any kind.
- a cutter such as a die cutter, is then employed to cut through the layers to form individual pads.
- An embosser may be employed to emboss film used for the handle, making the handle easier to see, as well as providing a better grip).
- the presently-preferred thermal bonding, thermal fusion or heat fusion process is ultrasonic bonding (also known as ultrasonic laminating or ultrasonic welding). Accordingly, the embodiments of the invention described hereinbelow employ ultrasonic bonding or welding, by way of example and not limitation. When ultrasonic welding or bonding is employed, vibratory energy is converted to heat, which softens and may even melt the materials.
- Other potential sources of heat for thermal bonding include hot irons, hot air or other gas, a source of infrared energy, or other electromagnetic energy source such as a laser, all by way of example and not limitation.
- any technique which provides localized heat in predetermined patterns for bonding, welding or fusion may be employed.
- thermal processes may be employed in the die cutter, as well as in the embosser.
- individual pads may be cut out using, as examples, ultrasonic tooling or a laser.
- Thermal or heat-producing equipment may be employed to emboss film used for the handle
- Ultrasonic bonding or welding (also known as ultrasonic laminating or ultrasonic welding) is a joining technique that uses high-frequency ultrasonic acoustic vibrations to effect solid state welding of materials that have either the same or different melting point temperatures.
- An ultrasonic solid-state bond is as strong as the bonded materials themselves.
- Suitable ultrasonic bonding or welding equipment i.e., ultrasonic tooling
- Dukane Corporation 2900 Dukane Drive, St. Charles, Ill. 60174 (http://www.dukane.com/us/).
- Another source is Herrmann Ultrasonics Inc., 1261 Hardt Circle, Bartlett, Ill. 60103 (www.herrmannultrasonics.com).
- Information regarding ultrasonic bonding or welding is available from TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, United Kingdom, and ultrasonic welding is described on their webpage http://www.twi.co.uk/content/pjkultrason.html.
- Ultrasonic equipment may be tooled for a variety of specific operations, including in-line welding, embossing, slitting and sealing, either in single modules or arranged in an array across the web.
- FIG. 1 a machine 100 for the in-line automatic manufacture of three-layer pads employing ultrasonic embossing, slitting and bonding equipment is illustrated in schematic representation.
- the machine 100 of FIG. 1 may be employed to make pads having “L”-shaped handles as generally disclosed in Woods et al U.S. Pat. No. 5,230,119 and US Re. 36,601.
- FIG. 2 is a three-dimensional representation of three webs of material as processed in the machine 100 of FIG. 1 , a web 102 of fusible base pad forming material having a longitudinal axis represented by directional arrow 104 and a width 106 , a web 108 of fusible intermediate barrier layer forming material having a longitudinal axis also represented by the directional arrow 104 and the same width 106 , and a web 110 of fusible handle forming material having a longitudinal axis also represented by the directional arrow 104 .
- the web 110 is longitudinally split or slit into a plurality of narrower sub webs of handle forming material, for example two sub webs 112 and 114 .
- there is a lateral gap between the sub webs 112 and 114 of handle forming material which is an exaggeration; after typical slitting the sub webs 112 and 114 are closely adjacent.
- FIG. 3 is a corresponding highly schematic representation of in-line steps to manufacture pads with “L”-shaped handles employing the machine of FIG. 1 .
- the machine 100 includes a feed roll 120 feeding or supplying the web 102 of fusible base pad forming material, a feed roll 122 supplying the web 108 of fusible intermediate barrier layer forming material having a longitudinal axis and a width, and a feed roll 124 supplying the web 110 of fusible handle forming material.
- the material webs 102 , 108 and 110 are of thermoplastic materials, such as polypropylene.
- the web 102 of base pad forming material is an absorbent material, made of non-woven fibers such as polypropylene or polyester.
- a blend of fibers for the base pad 102 material may also be employed, for example including cotton (which by itself is non-fusible), but with a sufficient percentage of fusible fibers in the blend so that the resultant base pad material web 102 is fusible.
- the machine of FIG. 1 may be employed to manufacture pads in a single line as implied by FIG. 3 .
- pads are manufactured in-line in multiple longitudinal lines defining rows with multiple pad precursors 126 shown in dash lines extending across the width of the webs 102 , 108 and 110 .
- the rows extend perpendicularly to the longitudinal axis represented by the arrow 104 .
- two rows of pad precursors 126 are shown in FIG. 2
- more rows are processed in a typical commercial embodiment. Examples are disclosed in U.S. Pat. No. Re. 36,601; U.S. Pat. No. 5,771,524 and U.S. Pat. No. 6,493,898. Accordingly, it will be appreciated that the single line of pads in FIG. 3 is to illustrate the principles of the invention.
- FIG. 3 a representative combined web 130 is shown in plan view, including all three layers, and including pad precursors or precursor regions 132 , 134 , 136 and 138 representing stages or steps of pad manufacture by the machine 100 of FIG. 1 . It will be appreciated that the actual steps or stages represented by the pad precursors 132 , 134 , 136 and 138 are spaced out along the length of the FIG. 1 machine 100 , and are not actually immediately adjacent as perhaps implied by the representation of FIG. 3 .
- FIG. 3 also shows a finished pad 140 in plan view, which has been cut out from the representative combined web 130 .
- the pad 140 as manufactured has an embossed handle graspable portion 142 which is folded down as manufactured.
- FIG. 3E is an end elevational view of the pad 140 in its in-use configuration, with the handle graspable portion 142 pivoted up along a fold line 144 .
- embossing and slitting tooling 146 optionally embosses the handle forming material 110 providing texture to facilitate grasping the resultant pad handles, as well as slitting the initial web 110 of handle forming material into the sub webs 112 and 114 in the event a plurality of pad precursors extend across the web 130 .
- texture embossing 148 is represented by hatching.
- the embossing 148 is represented in FIG. 3 as discontinuous sections corresponding to pad precursors.
- the embossing 148 is actually continuous longitudinally along the web 110 of handle forming material, or, more particularly, along the sub webs 112 and 114 .
- Mechanical embossing and slitting tooling may be employed at 146 or, alternatively, ultrasonic embossing and slitting tooling may be employed.
- the three webs 102 , 108 and 110 are conveyed into adjacency, between a pair of rollers 150 .
- FIG. 3 pad precursor 132 and the corresponding view of FIG. 3A represent the condition at point 152 in the machine 100 of FIG. 1 . All three layers are present, but no bonding has occurred. Pads have not yet been cut out, existing as precursor regions only.
- a portion 156 of the handle forming material 110 is fused to the barrier layer forming material 108 , leaving a free portion 158 of the handle forming material.
- the free portion 158 includes the embossing 148 , and ultimately becomes the handle graspable portion 142 .
- the barrier layer material 108 is fused to the base pad material 102 .
- the FIG. 3 pad precursor 134 and the corresponding view of FIG. 3B represent the condition at point 160 in the machine 100 of FIG. 1 , immediately downstream of the first bonding station 154 .
- two bond lines are formed parallel to the longitudinal axis, a first bond line 162 near a lateral edge of the pad precursor 134 , and a second bond line 164 near the middle of the pad precursor 134 .
- the bond lines 162 and 164 are shown as solid lines, such is for purposes of illustration only.
- Various interrupted bond line patterns may be employed, resembling stitching, or even a series of points. It is important that a bonding pattern be selected which is sufficient for structural integrity but which, at the same time, does not result in pads which are unduly stiff.
- the next stage in the machine 100 of FIG. 1 downstream with reference to the first bonding station 154 , is a handle folding station 166 which folds over the free portion 158 of the handle forming material to uncover a portion 168 of the barrier layer material 108 previously covered by the free portion 158 .
- the FIG. 3 pad precursor 136 and the corresponding view of FIG. 3C represent the condition at point 170 in the machine 100 of FIG. 1 , immediately downstream of the handle folding station 166 .
- FIG. 3 pad precursor 138 and the corresponding view of FIG. 3D , which represent the condition of point 176 in the machine 100 of FIG. 1 , immediately downstream of the second bonding station 172 .
- rotary die cutting tooling for example cuts through all three layers of material, creating and freeing multilayer pads 140 at 180 .
- the finished pads 140 are collected and packaged in a conventional manner.
- a die cutter and collection mechanism is disclosed in greater detail in the above-referenced Woods et al U.S. Pat. No. 6,493,898.
- scrap rewind roll 182 collects the remaining scrap web material 184 .
- the scrap web material 184 includes remnants of all three layers, with multiple apertures where pads have been cut out.
- FIG. 4 a machine 200 for the in-line automatic manufacture of two-layer pads employing ultrasonic embossing, slitting and bonding equipment is illustrated in schematic representation.
- the machine 200 of FIG. 4 may be employed to make pads having “folded” handles as generally disclosed in Woods et al U.S. Pat. No. 6,493,898.
- FIG. 5 is a corresponding highly schematic representation of in-line steps to manufacture pads with “folded” handles employing the machine of FIG. 4 .
- a web 202 of fusible base pad forming material having a longitudinal axis represented by directional arrow 204 ( FIG. 5 ) and a width 206 ( FIG. 5 )
- a web 210 of fusible handle forming material having a longitudinal axis also represented by the directional arrow 204 , and having a width 216 .
- the width 216 of the handle forming material web 210 is approximately two times the width 206 of the base pad material web 202 .
- FIGS. 4 and 5 it is not absolutely necessary that the web 210 of handle forming material be longitudinally slit or split. However, in some embodiments, depending on the configuration of the downstream handle folding tooling, described hereinbelow, it may be advantageous to provide individual sub webs of handle forming material.
- the embodiment of FIGS. 4 and 5 does not require an intermediate barrier material layer.
- the machine 200 includes a feed roll 220 feeding or supplying the web 202 of fusible base pad forming material, and a feed roll 224 supplying the web 210 of fusible handle forming material.
- the material webs 202 and 210 are of thermoplastic materials, such as polypropylene.
- the web 202 of base pad forming material is an absorbent material, made of non-woven fibers such as polypropylene or polyester.
- a blend of fibers for the base pad 202 material may also be employed, for example including cotton (which by itself is non-fusible), but with a sufficient percentage of fusible fibers in the blend so that the resultant base pad material web 202 is fusible.
- the machine of FIG. 4 may be employed to manufacture pads in a single line as implied by FIG. 5 .
- pads are manufactured in-line in multiple longitudinal lines defining rows with multiple pad precursors extending across the width of the web 202 as disclosed in U.S. Pat. No. 6,493,898. Accordingly, it will be appreciated that the single line of pads in FIG. 5 is to illustrate the principles of the invention.
- FIG. 5 two webs are represented.
- the first is the web 210 of handle forming material.
- the second is a representative combined web 230 after a longitudinally extending pleat of handle forming material has been formed, thus effectively reducing the width of the web of handle forming material, and after the webs 202 and 210 are conveyed into adjacency.
- the representative combined web 230 is shown in plan view, including both layers, and including pad precursors or precursor regions 234 , 236 and 238 representing stages or steps of pad manufacture by the machine 200 of FIG. 4 . It will be appreciated that the actual steps or stages represented by the pad precursors 234 , 236 and 238 are spaced out along the length of the FIG. 4 machine 200 , and are not actually immediately adjacent as perhaps implied by the representation of FIG. 5 .
- FIG. 5 also shows a finished pad 240 in plan view, which has been cut out from the representative combined web 230 .
- the pad 240 as manufactured has an embossed handle graspable portion 242 which is folded down as manufactured.
- FIG. 5E is an end elevational view of the pad 240 in its in-use configuration, with the handle graspable portion 242 pivoted up along fold lines 244 and 245 .
- embossing tooling 246 embosses the handle forming material 210 providing texture to facilitate grasping the resultant pad handles.
- Texture embossing 248 is represented by hatching.
- the embossing 248 is continuous longitudinally along the web 210 of handle forming material, even though the embossing 248 is also represented in FIG. 5 as discontinuous sections corresponding to the pad precursors 234 , 236 and 238 .
- Mechanical embossing tooling may be employed at 246 or, alternatively, ultrasonic embossing tooling may be employed.
- the two webs 202 and 210 are conveyed into adjacency, between a pair of rollers 250 .
- FIG. 5A represents the condition at point 252 in the machine 200 of FIG. 4 . Both layers are present, but no pleating or bonding has occurred, so the handle forming material web 210 is wider than the base pad material web 202 . Pads have not yet been cut out, existing as precursor regions only.
- the handle layer material web 210 is formed into a longitudinally extending pleat 256 including two facing segments 258 and 259 and a folded edge 260 , the pleat 256 defining a handle graspable portion precursor.
- the height of the pleat 256 is less than one-half of the width of the pad 240 being manufactured.
- a pair of longitudinally extending handle attached portion precursors 262 and 264 are formed, joined to the pleat 256 along the fold lines 244 and 245 .
- the pleat 256 is folded down to one side generally over the handle attached portion precursor 262 , while leaving a portion 266 of the precursor 262 exposed near a lateral edge (since the height of the pleat 256 is less than one-half the width of the pad 240 being manufactured.)
- the other handle attached portion precursor 264 is fully exposed.
- the FIG. 5 pad precursor 234 and the corresponding view of FIG. 5B represent the condition at point 268 in the machine 200 of FIG. 4 , immediately downstream of the first handle folding tooling station 254 .
- the other handle attached portion precursor 264 is fused to the base pad forming material layer 202 , at least immediately adjacent the fold line 245 , and preferably in additional bonding regions.
- the exposed portion 266 of the handle attached portion precursor 262 is fused to the base pad forming material layer 202 .
- the FIG. 5 pad precursor 236 and the corresponding view of FIG. 5C represent the condition at point 272 in the machine of FIG. 4 , immediately downstream of the first bonding station 270 .
- first bonding station 270 at the first bonding station 270 , three bond lines are formed parallel to the longitudinal axis, a pair of outer bond lines 274 and 276 near lateral edges of the pad precursor 236 , and a first inner bond line 278 adjacent the fold line 245 .
- bond lines 274 , 276 and 278 are shown as solid lines, such is for purposes of illustration only.
- Various interrupted bond line patterns may be employed, resembling stitching, or even a series of points. It is important that a bonding pattern be selected which is sufficient for structural integrity but which, at the same time, does not result in pads which are unduly stiff.
- the next stage in the machine 200 of FIG. 4 downstream with reference to the first bonding station 270 is a second handle folding tooling station 280 which folds the pleat 256 over to the other side to fully expose the one handle attached portion precursor 262 .
- the one handle attached portion precursor 262 is fused to the base pad forming material layer 202 at least immediately adjacent the fold line 244 , along a second inner bond line 284 , which is similar to the bond lines 274 , 276 and 278 .
- FIG. 5 pad precursor 238 and the corresponding view of FIG. 5D represent the condition of point 286 in the machine 200 of FIG. 4 , immediately downstream of the second bonding station 282 .
- rotary die cutting tooling for example cuts through both layers of material, creating and freeing multilayer pads 240 at 290 .
- the finished pads 240 are collected and packaged in a conventional manner.
- a die cutter and collection mechanism is disclosed in greater detail in the above-referenced Woods et al U.S. Pat. No. 6,493,898.
- scrap rewind roll 292 collects the remaining scrap web material 294 .
- the scrap web material 294 includes remnants of both layers, with multiple apertures where pads have been cut out.
- FIG. 6A schematically represents a single ultrasonic horn and anvil set 296 for use when pads are manufactured in a single line.
- the set 296 may be tooled to emboss, weld and slit materials.
- FIG. 6B schematically represents an array 298 of across-the-web ultrasonic horns and anvils for use when pads are manufactured in multiple longitudinal lines.
- FIG. 7 a machine 300 for the in-line automatic manufacture of three-layer pads employing ultrasonic embossing, slitting and bonding equipment is illustrated in schematic representation.
- the machine 300 of FIG. 7 may be employed to make pads having “L”-shaped handles as generally disclosed in Woods et al U.S. Pat. No. 5,230,119 and US Re. 36,601, or handles resembling “wings” as disclosed in Woods et al U.S. Pat. No. 5,771,524.
- FIG. 8 is a corresponding highly schematic representation of in-line steps to manufacture pads with “L”-shaped handles employing the machine 300 of FIG. 7 .
- FIG. 10 is a corresponding highly schematic representation of in-line steps to manufacture pads with “wing” handles employing the machine 300 of FIG. 7 .
- Three webs of fusible material are processed in the machine 300 of FIG. 7 , a web 302 of fusible base pad forming material having a longitudinal axis represented by directional arrow 304 and a width 306 , a web 308 of fusible intermediate barrier layer forming material having a longitudinal axis also represented by the directional arrow 304 and the same width 306 , and a web 310 of fusible handle forming material having a longitudinal axis also represented by the directional arrow 304 .
- the web 310 of handle forming material be trimmed in width so that the handle material does not extend all the way across the width of a pad being manufactured. More particularly, for making pads with “L”-shaped handles as in FIG. 8 , the web 310 of handle forming material is trimmed on one side, resulting in the FIG. 8 web 312 . For making pads with “wing” handles as in FIG. 10 , the web 310 of handle forming material is trimmed on both sides, resulting in the FIG. 10 web 314 .
- the machine 300 includes a feed roll 320 feeding or supplying the web 302 of fusible base pad forming material, a feed roll 322 supplying the web 308 of fusible intermediate barrier layer forming material having a longitudinal axis and a width, and a feed roll 324 supplying the web 310 of fusible handle forming material.
- the material webs 302 , 308 and 310 are of thermoplastic materials, such as polypropylene.
- the web 302 of base pad forming material is an absorbent material, made of non-woven fibers such as polypropylene or polyester.
- a blend of fibers for the base pad 302 material may also be employed, for example including cotton (which by itself is non-fusible), but with a sufficient percentage of fusible fibers in the blend so that the resultant base pad material web 302 is fusible.
- FIG. 7 may be employed to manufacture pads in a single line as implied by FIGS. 8 and 10 .
- pads are manufactured in-line in multiple longitudinal lines defining rows with multiple pad precursors extending across the width of the webs 308 and 310 . Accordingly, it will be appreciated that the single lines of pads in FIGS. 8 and 10 are to illustrate the principles of the invention.
- FIG. 8 a representative combined web 330 is shown in plan view, including all three layers, and including pad precursors or precursor regions 332 and 334 representing stages or steps of pad manufacture by the machine 300 of FIG. 7 .
- FIG. 10 a similar representative combined web 335 is shown in plan view, including all three layers, and including pad precursors or precursor regions 336 and 338 representing stages or steps of pad manufacture by the machine 300 of FIG. 7 . It will be appreciated that the actual steps or stages represented by the pad precursors 332 and 334 ( FIG. 8 ) and 336 and 338 ( FIG. 10 ) are spaced out along the length of the FIG. 7 machine 300 , and are not actually immediately adjacent as perhaps implied by the representations of FIGS. 8 and 10 .
- FIG. 8 also shows a finished pad 340 with an “L”-shaped handle in plan view, which has been cut out from the representative combined web 330 .
- the pad 340 as manufactured has an embossed handle graspable portion 341 which is folded down as manufactured.
- FIG. 8C is an end elevational view of the pad 340 in its in-use configuration, with the handle graspable portion 341 pivoted up along a fold line 342 .
- FIG. 10 also shows a finished pad 343 with a “wings” configuration handle in plan view, which has been cut out from the representative combined web 335 .
- the pad 343 as manufactured has a pair of embossed handle graspable portions 344 and 345 which are folded down as manufactured.
- FIG. 10C is an end elevational view of the pad 343 in its in-use configuration, with the handle graspable portions 344 and 345 pivoted up.
- embossing and slitting tooling 346 optionally embosses the handle forming material 310 providing texture to facilitate grasping the resultant pad handles, as well as slitting or trimming the initial web 310 of handle forming material to form the narrower web 312 of FIG. 8 or the narrower web 314 of FIG. 10 .
- texture embossing 348 is represented by hatching.
- the embossing 348 is continuous longitudinally along the web 310 of handle forming material, even though the embossing 348 is also represented in FIGS. 8 and 10 as discontinuous sections corresponding to the pad precursors 332 , 234 and 336 , 338 .
- Mechanical embossing and slitting tooling may be employed at 346 or, alternatively, ultrasonic embossing and slitting tooling may be employed.
- the three webs 302 , 308 and 310 are conveyed into adjacency, between a pair of rollers 350 .
- at least one side edge portion of the intermediate barrier layer material web 308 is exposed near a pad precursor lateral edge, made possible because the handle material web 310 is trimmed in width.
- FIG. 8 pad precursor 332 and the corresponding view of FIG. 8A represent the condition at point 352 in the machine 300 of FIG. 7 when pads with “L”-shaped handles are being manufactured. All three layers are present, but no bonding has occurred. Pads have not yet been cut out, existing as precursor regions only. Significantly a side edge portion 354 of the barrier layer material web 308 is exposed.
- FIG. 10 pad precursor 336 and the corresponding view of FIG. 10A represent the condition at point 352 in the machine 300 of FIG. 7 when pads having “wing” configuration handles are being manufactured. All three layers are present, but no bonding has occurred. Pads have not yet been cut out, existing as precursor regions only. Significantly two opposite side edge portions 356 and 358 of the barrier layer material web 308 is exposed.
- An advantageous characteristic of the machine 300 of FIG. 7 is that there is a single bonding station 360 . This is made possible by the exposed side edge portions 354 ( FIG. 8 ) or 356 and 358 ( FIG. 10 ), which in turn results from the web 310 of handle forming material being trimmed in width.
- a portion of the handle forming material 310 is fused to the barrier layer forming material 308 , leaving at least one other portion of the handle forming material 310 free to define a graspable portion precursor.
- FIG. 8 pad precursor 334 and the corresponding view of FIG. 8B represent the condition at point 366 in the machine 300 of FIG. 7 , immediately downstream of the bonding station 360 .
- three bond lines are formed parallel to the longitudinal axis.
- the outer bond line 368 and the middle bond line 372 bond all three layers, including the portion 362 of handle forming material.
- the outer bond line 370 fuses only the barrier layer 308 and the base pad layer 302 .
- the bond lines 368 , 370 and 372 are shown as solid lines, such is for purposes of illustration only.
- Various interrupted bond line patterns may be employed, resembling stitching, or even a series of points. It is important that a bonding pattern be selected which is sufficient for structural integrity but which, at the same time, does not result in pads which are unduly stiff.
- FIG. 10 pad precursor 338 and the corresponding view of FIG. 10B represent the condition at point 366 in the machine 300 of FIG. 7 , immediately downstream of the bonding station 360 .
- the bonding station 360 When making pads having “wing” handles as in FIG. 10 , at the bonding station 360 , three bond lines are formed parallel to the longitudinal axis. A pair of outer bond lines 380 and 382 near lateral edges of the pad precursor 338 , and another bond line 384 near the middle of the pad precursor 338 . The outer bond lines 380 and 382 fuse only the barrier layer 308 and the base pad layer 302 . The middle bond line 384 bonds all three layers, including the portion 374 of handle forming material.
- the resultant “wing” handle may be viewed as having a “V” configuration, with the bonding line 384 in the center of the “V”.
- the bond lines 380 , 382 and 384 are shown as solid lines, such is for purposes of illustration only. Various interrupted bond line patterns may be employed, resembling stitching, or even a series of points. It is important that a bonding pattern be selected which is sufficient for structural integrity but which, at the same time, does not result in pads which are unduly
- FIGS. 9A, 9B, 9C and 9D illustrate a hybrid form of pad 386 which may be made by the machine 300 of FIG. 7 .
- the handle of pad 368 generally is of “L” configuration, but with the horizontal portion of the handle significantly shorter than the upright portion.
- the pad 386 may be viewed as a “wing” handle pad where one of the two “wings” is missing. Accordingly, it will be appreciated that the pad 386 of FIGS. 9A, 9B, 9C and 9D is manufactured in essentially the same manner as the pad 343 of FIG. 10 .
- rotary die cutting tooling for example cuts through all three layers of material, creating and freeing multilayer pads 340 or 343 at 390 .
- the finished pads 340 or 343 are collected and packaged in a conventional manner.
- a die cutter and collection mechanism is disclosed in greater detail in the above-referenced Woods et al U.S. Pat. No. 6,493,898.
- scrap rewind roll 392 collects the remaining scrap web material 394 .
- the scrap web material 394 includes remnants of all three layers, with multiple apertures where pads have been cut out.
- FIG. 11 a machine 400 for the in-line automatic manufacture of two-layer pads employing ultrasonic embossing, slitting and bonding equipment is illustrated in schematic representation.
- the machine 400 of FIG. 11 may be employed to make pads having “folded” handles as generally disclosed in Woods et al U.S. Pat. No. 6,493,898.
- FIG. 12 is a corresponding highly schematic representation of in line steps to manufacture pads with “folded” handles employing the machine of FIG. 11 .
- the machine 400 of FIG. 11 includes a single bonding station.
- a web 402 of fusible base pad forming material having a longitudinal axis represented by directional arrow 404 ( FIG. 12 ) and a width 406 ( FIG. 12 )
- a web 410 of fusible handle forming material having a longitudinal axis also represented by the directional arrow 404 , and having a width 416 .
- the width 416 of the handle forming material web 410 is approximately two times the width 406 of the base pad material web 402 .
- FIGS. 11 and 12 it is not absolutely necessary that the web 410 of handle forming material be longitudinally slit or split. However, in some embodiments, depending on the configuration of the downstream handle folding tooling, described hereinbelow, it may be advantageous to provide individual sub webs of handle forming material.
- the embodiment of FIGS. 11 and 12 does not require an intermediate barrier material layer.
- the machine 400 includes a feed roll 420 feeding or supplying the web 402 of fusible base pad forming material, and a feed roll 424 supplying the web 410 of fusible handle forming material.
- the material webs 402 and 410 are of thermoplastic materials, such as polypropylene.
- the web 402 of base pad forming material is an absorbent material, made of non woven fibers such as polypropylene or polyester.
- a blend of fibers for the base pad 402 material may also be employed, for example including cotton (which by itself is non fusible), but with a sufficient percentage of fusible fibers in the blend so that the resultant base pad material web 402 is fusible.
- the machine of FIG. 11 may be employed to manufacture pads in a single line as implied by FIG. 12 .
- pads are manufactured in line in multiple longitudinal lines defining rows with multiple pad precursors extending across the width of the web 402 . Accordingly, it will be appreciated that the single line of pads in FIG. 12 is to illustrate the principles of the invention.
- FIG. 12 two webs are represented.
- the first is the web 410 of handle forming material.
- the second is a representative combined web 430 after a longitudinally extending pleat of handle forming material has been formed, thus effectively reducing the width of the web of handle forming material, and after the webs 402 and 410 are conveyed into adjacency.
- the representative combined web 430 is shown in plan view, including both layers, and including pad precursors or precursor regions 432 , 434 , 436 and 438 representing stages or steps of pad manufacture by the machine 400 of FIG. 11 . It will be appreciated that the actual steps or stages represented by the pad precursors 432 , 434 , 436 and 438 are spaced out along the length of the FIG. 11 machine 400 , and are not actually immediately adjacent as perhaps implied by the representation of FIG. 12 .
- FIG. 12 also shows a finished pad 440 in plan view, which has been cut out from the representative combined web 430 .
- the pad 440 as manufactured has an embossed handle graspable portion 442 which is folded down as manufactured.
- FIG. 12F is an end elevational view of the pad 440 in its in use configuration, with the handle graspable portion 442 pivoted up along fold lines 444 and 445 .
- embossing tooling 446 embosses the handle forming material 410 providing texture to facilitate grasping the resultant pad handles.
- Texture embossing 448 is represented by hatching.
- the embossing 448 is continuous longitudinally along the web 410 of handle forming material, even though the embossing 448 is also represented in FIG. 12 as discontinuous sections corresponding to the pad precursors 432 , 434 , 436 and 438 .
- Mechanical embossing tooling may be employed at 446 or, alternatively, ultrasonic embossing tooling may be employed.
- the two webs 402 and 410 are conveyed into adjacency, between a pair of rollers 450 .
- FIG. 12A represents the condition at point 452 in the machine 400 of FIG. 11 . Both layers are present, but no pleating or bonding has occurred, so the handle forming material web 410 is wider than the base pad material web 402 . Pads have not yet been cut out, existing as precursor regions only.
- the handle layer material web 410 is formed into a longitudinally extending pleat 456 including two facing segments 458 and 459 and a folded edge 460 , the pleat 456 defining a handle graspable portion precursor.
- the pleat 456 there is no particular requirement regarding the height of the pleat 456 .
- a pair of longitudinally extending handle attached portion precursors 462 and 464 are formed, joined to the pleat 456 along the fold lines 444 and 445 .
- the pleat 456 is folded down to one side generally over the handle attached portion precursor 462 .
- the FIG. 12 pad precursor 432 and the corresponding view of FIG. 12B represent the condition at point 468 in the machine 400 of FIG. 11 , immediately downstream of the first handle folding tooling station 454 .
- FIG. 12 pad precursor 434 and the corresponding view of FIG. 12C represent the condition at point 472 in the machine of FIG. 11 , immediately downstream of the second tooling station 470 .
- a characteristic of the machine 400 of FIG. 11 is that there is a single bonding station 474 .
- bond lines are formed parallel to the longitudinal axis, a pair of outer bond lines 476 and 478 near lateral edges of the pad precursor 436 , and a pair of inner bond lines 480 and 482 adjacent the fold lines 444 and 445 .
- the bond lines 476 , 478 , 480 and 482 are shown as solid lines, such is for purposes of illustration only.
- Various interrupted bond line patterns may be employed, resembling stitching, or even a series of points. It is important that a bonding pattern be selected which is sufficient for structural integrity but which, at the same time, does not result in pads which are unduly stiff.
- the FIG. 12 pad precursor 436 and the corresponding view of FIG. 12D show the condition immediately following bonding.
- FIG. 12 pad precursor 438 Immediately downstream with reference to the bonding station 474 is another handle folding tooling station 484 which folds the pleat 456 down, prior to cutting.
- FIG. 12 pad precursor 438 Immediately downstream with reference to the bonding station 474 is another handle folding tooling station 484 which folds the pleat 456 down, prior to cutting.
- FIG. 12 pad precursor 438 Immediately downstream with reference to the bonding station 474 is another handle folding tooling station 484 which folds the pleat 456 down, prior to cutting.
- FIG. 12 pad precursor 438 Located downstream with reference to the bonding station 474 is another handle folding tooling station 484 which folds the pleat 456 down, prior to cutting.
- FIG. 12 pad precursor 438 Located downstream with reference to the bonding station 474 is another handle folding tooling station 484 which folds the pleat 456 down, prior to cutting.
- rotary die cutting tooling for example cuts through both layers of material, creating and freeing multilayer pads 440 at 490 .
- the finished pads 440 are collected and packaged in a conventional manner.
- scrap rewind roll 492 collects the remaining scrap web material 494 .
- the scrap web material 494 includes remnants of both layers, with multiple apertures where pads have been cut out.
- FIGS. 13A, 13B, 13C, 13D and 13E illustrate, for purposes of example, five of the many ultrasonic welding/bonding patterns available.
- the patterns of FIGS. 13A and 13B are employed in the embodiments specifically disclosed herein. However, the patterns of FIGS. 13C, 13D and 13E may as well be employed, depending upon the particular pad configuration. It is important to select an ultrasonic bonding pattern which provides sufficient structural integrity which, at the same time, does not render the resultant pad unduly stiff.
- FIG. 14 illustrates a machine 500 which, in general, is an alternative to the machine 300 of FIG. 7 .
- the machine 500 of FIG. 14 may be employed to make pads having “L”-shaped handles, or pads having handles resembling “wings.”
- the primary difference between the machine 500 of FIG. 14 and the machine 300 of FIG. 7 is that rather than separate layers of base pad material 302 and barrier layer material 308 , the machine 500 employs a single web 505 of co-extruded barrier to base material.
- a web 505 is formed by hot extrusion of material forming an impervious barrier layer over a layer of base pad forming material to form a single fused web prior to further processing.
- a web 510 of handle forming material is essentially identical to the web 310 of handle forming material described hereinabove with reference to FIGS. 7, 8 and 10 .
- the machine 500 includes a feed roll 520 feeding or supplying the web 505 of co-extruded barrier to base material, and a feed roll 524 supplying the web 510 of fusible handle forming material.
- the machine 500 thus includes embossing and slitting tooling 546 , rollers 550 , a single bonding station 560 , a die cutting station 588 and a scrap rewind roll 592 .
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Abstract
In-line methods for manufacturing a plurality of multilayer pads and the resultant pads. Various embodiments of the invention employ one or two thermal bonding stations, such as ultrasonic bonding stations, along with handle folding tooling, to produce two- or three-layer pads in various configurations, without the use of adhesive. Following bonding and handle folding, a cutter, such as a die cutter, is employed to cut through the layers to form individual pads. Pads of various configurations are manufactured, including pads with “L”-shaped handles, handles of “wing” configuration, and “folded” handles.
Description
- This is a continuation of U.S. patent application Ser. No. 14/509,491, filed Oct. 8, 2014, which is a division of U.S. patent application Ser. No. 13/188,855, filed Jul. 22, 2011, now U.S. Pat. No. 9,051,669, which in turn claims the benefit of U.S. provisional patent application Ser. No. 61/366,984, filed Jul. 23, 2010.
- The invention relates generally to multilayer pads and methods of manufacture such as are disclosed in our earlier Woods et al U.S. Pat. No. 5,230,119, titled “Multilayer Laminated Pad;” U.S. Pat. No. 5,507,906 (now US Re. 36,601), titled “Method for Making Multilayer Pad;” U.S. Pat. No. 5,771,524, titled “Disposable Pad;” and U.S. Pat. No. 6,493,898, titled “Laminated pads and methods of manufacture employing mechanically folded handles,” the entire disclosures of which are hereby expressly incorporated by reference; as well as Zygmont U.S. Pat. No. 6,044,515, the entire disclosure of which is hereby expressly incorporated by reference.
- The pads disclosed in our earlier patents generally are manufactured by initially forming a two- or three-layer composite laminated sheet using adhesive or other attachment to combine base pad forming material, impervious barrier layer forming material, and handle forming material. The base pad forming material, barrier layer forming material and handle forming material are provided as respective webs of material from supply rolls, the webs each having a predetermined width (typically the same width for all three webs in the pads disclosed in U.S. Pat. No. 5,230,119; U.S. Pat. No. 5,507,906; US Re. 36,601 and U.S. Pat. No. 5,771,524), with lengths depending on the roll size. U.S. Pat. No. 5,230,119; U.S. Pat. No. 5,507,906 and US Re. 36,601 generally disclose pads which have what may be referred to as “L”-shaped handles. U.S. Pat. No. 5,771,524 generally discloses pads which have handles that may be referred to as “wings”. U.S. Pat. No. 6,493,898 generally discloses pads which have what may be referred to as “folded” handles.
- In the pads disclosed in U.S. Pat. No. 5,230,119; U.S. Pat. No. 5,507,906 and US Re. 36,601 (“L”-shaped handles), and U.S. Pat. No. 5,771,524 (“wings”), the exemplary adhesive attaching the web of base pad forming material and the web of barrier layer forming material to each other is applied as a full coating, such that these two web layers are continuously adhered to each other along their entire widths. However, the adhesive which joins the web of barrier layer forming material to the web of handle forming material is applied in longitudinal strips, which may be referred to as “zone coating.” A cutter is then used to cut through all three layers of the laminated sheets to produce individual multilayer pads. The cutter is aligned with reference to the adhesive strips securing the handle forming material to the barrier forming material, as well as with reference to uncoated areas between the adhesive strips, such that, in each of the resulting pads, a portion of the handle forming material layer is over an adhesive strip resulting in an adhered segment of the handle, and another portion (or portions) of the handle forming material layer within the shape of the cutter is over an uncoated area resulting in a free or graspable portion of the handle. The resultant graspable handle portion lies flat against the barrier layer prior to initial use, and pivots up for use.
- U.S. Pat. No. 6,493,898 (“folded” handles) discloses the manufacture of similar pads, while avoiding the need for zone coating to define adhered handle segments. Rather, the handle forming material is mechanically folded, employing a pleating/folding machine, prior to being adhered to the barrier layer. As alternatives, adhesive is applied to the barrier layer, or to the underside of the handle forming material subsequent to folding, or to the underside of the handle forming material prior to folding.
- Although several prior art patents, for example Woods et al U.S. Pat. No. 5,771,524, include general suggestions that layers may be fused employing an ultrasonic bonding process without the use of adhesive, as a practical matter specific processes and resultant pads are not disclosed. Rather, a characteristic of actual commercial embodiments (for example pads with “L”-shaped handles as disclosed in U.S. Pat. No. 5,230,119) is that the various layers are joined employing adhesives.
- In one aspect, a multilayer pad is provided. The multilayer pad includes an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite the applying/wiping surface, and an outer periphery. The multilayer pad additionally includes a barrier layer having a lower surface attached by fusing to the base pad layer attachment surface, an upper surface and an outer periphery coextensive with the outer periphery of the base pad layer. The multilayer pad further includes a handle with an attached portion fused to a portion of the barrier layer upper surface, and at least one graspable free portion joined to the handle attached portion along a fold line defining an axis of the multilayer pad. The handle attached portion is attached to the barrier layer upper surface along at least one bond line parallel to the pad axis.
- In another aspect, a multilayer pad is provided. The multilayer pad includes an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite the applying/wiping surface, and an outer periphery. The multilayer pad additionally includes a barrier layer having a lower surface attached by fusing to the base pad layer attachment surface, an upper surface, and an outer periphery coextensive with the outer periphery of the base pad layer. The multilayer pad further include a handle with an attached portion fused to a portion of the barrier layer upper surface, and at least one graspable free portion joined to the handle attached portion along a fold line defining an axis of the multilayer pad. The handle attached portion is attached to the barrier layer upper surface, and the barrier layer lower surface is attached to the base pad layer attachment surface along bond lines parallel to the pad axis.
- In yet another aspect, a multilayer pad is provided. The multilayer pad includes an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite the applying/wiping surface, and an outer periphery. The multilayer pad additionally includes a barrier layer having a lower surface attached by fusing to the base pad layer attachment surface, an upper surface, and an outer periphery coextensive with the outer periphery of the base pad layer. The multilayer pad further include a handle with an attached portion fused to a portion of the barrier layer upper surface, and at least one graspable free portion joined to the handle attached portion along a fold line defining an axis of the multilayer pad. The barrier layer is continuously fused to the base pad layer, and the handle attached portion is attached to the barrier layer upper surface along at least one bond line parallel to the pad axis.
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FIG. 1 is a schematic representation of a machine for the in-line automatic manufacture of three-layer pads, which have what may be referred to as “L”-shaped handles, the machine ofFIG. 1 including ultrasonic bonding equipment and automatic folding tooling; -
FIG. 2 is a three-dimensional view of a web of handle forming material embossed and slit into sub webs, a web of intermediate barrier layer material, and a web of base pad material adjacent to each other as processed in the machine ofFIG. 1 , in a condition prior to fusing; -
FIG. 3 is a highly schematic representation of in-line steps to manufacture pads with “L”-shaped handles employing the machine ofFIG. 1 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors; -
FIGS. 3A, 3B, 3C and 3D are views taken onlines 3A-3A, 3B-3B, 3C-3C and 3D-3D ofFIG. 3 , representing pad precursors in end elevational view at various stages of manufacture prior to individual pads being cut out of a moving web; -
FIG. 3E is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence ofFIG. 3 , except with the pad handle pivoted up; -
FIG. 3F is a side elevational view of the pad ofFIG. 3E , taken online 3F-3F ofFIG. 3E ; -
FIG. 4 is a schematic representation of a machine for the in-line automatic manufacture of two-layer pads, which have what may be referred to as “folded” handles, the machine ofFIG. 3 including ultrasonic bonding equipment and automatic folding tooling; -
FIG. 5 is a highly schematic representation of in-line steps to manufacture pads with “folded” handles employing the machine ofFIG. 4 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors; -
FIGS. 5A, 5B, 5C and 5D are views taken on lines 5A-5A, 5B-5B, 5C-5C and 5D-5D ofFIG. 5 , representing pad precursors in end elevational view at various stages of manufacture prior to individual pads being cut out of a moving web; -
FIG. 5E is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence ofFIG. 5 , except with the pad handle pivoted up; -
FIG. 5F is a side elevational view of the pad ofFIG. 5E , taken online 5F-5F ofFIG. 5E ; -
FIG. 6A is a representation of a single ultrasonic horn and anvil, which may be tooled to emboss, weld and slit various materials; -
FIG. 6B is a representation of an array of across-the-web ultrasonic horns and anvils, which may be tooled to perform various in-line processes; -
FIG. 7 is a schematic representation of a machine for the in-line automatic manufacture of three-layer pads, which pads either have “L”-shaped handles (as described hereinbelow with reference toFIG. 8 ), or have handles configured as “wings” (as described hereinbelow with reference toFIG. 10 ), the machine ofFIG. 7 requiring only a single ultrasonic bonding station; -
FIG. 8 is a highly schematic representation of in-line steps to manufacture pads with “L”-shaped handles employing the machine ofFIG. 7 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors; -
FIGS. 8A and 8B are views taken onlines 8A-8A and 8B-8B ofFIG. 8 , representing pad precursors in end elevational view at two stages of manufacture prior to individual pads being cut out of a moving web; -
FIG. 8C is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence ofFIG. 8 , except with the pad handle pivoted up; -
FIG. 8D is a side elevational view of the pad ofFIG. 8C , taken online 8D-8D ofFIG. 8C ; -
FIG. 9A is an end elevational view of an “L”-shaped handle in isolation similar to handle of the pad ofFIGS. 8, 8C and 8D , but with the horizontal leg of the handle being significantly shorter than the upright portion, -
FIG. 9B is an end elevational view of a pad having the “L”-shaped handle ofFIG. 9A , the handle being folded down in the configuration ofFIG. 9B ; -
FIG. 9C is a plan view of the pad ofFIG. 9C ; -
FIG. 9D is an end elevational view of the pad ofFIGS. 9B and 9C , in the same orientation asFIG. 9B , but with the handle being folded up in the configuration ofFIG. 9D ; -
FIG. 10 is a highly schematic representation of in-line steps to manufacture pads with “wing” handles employing the machine ofFIG. 7 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors; -
FIGS. 10A and 10B are views taken onlines 10A-10A and 10B-10B ofFIG. 10 , representing pad precursors in end elevational view at two stages of manufacture prior to individual pads being cut out of a moving web; -
FIG. 10C is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence ofFIG. 10 , except with the wings of the pad handle pivoted up; -
FIG. 10D is a side elevational view of the pad ofFIG. 10C , taken online 10D-10D ofFIG. 10C ; -
FIG. 11 is a schematic representation of a machine for the in-line automatic manufacture of two-layer pads, which pads have what may be referred to as “folded” handles, similar to the handles ofFIGS. 5, 5E and 5F made by the machine ofFIG. 4 , the machine ofFIG. 11 , like the machine ofFIG. 7 , requiring only a single ultrasonic bonding station; -
FIG. 12 is a highly schematic representation of in-line steps to manufacture pads with “folded” handles employing the machine ofFIG. 12 , illustrating pads in top plan view at various stages of manufacture, with dash lines representing future cut lines and representing pad precursors; -
FIGS. 12A, 12B, 12C, 12D and 12E are views taken onlines 12A-12A, 12B-12B, 12C-12C, 12D-12D and 12E-12E ofFIG. 12 , representing pad precursors in end elevational view at various stages of manufacture prior to individual pads being cut out of a moving web; -
FIG. 12F is an end elevational view of an individual pad in its in-use configuration, generally corresponding to the right-most pad in the sequence ofFIG. 12 , except with the pad handle pivoted up; -
FIG. 12G is a side elevational view of the pad ofFIG. 12F , taken on line 12G-12G ofFIG. 12F ; -
FIGS. 13A, 13B, 13C, 13D and 13E illustrate, for purposes of example, five of the many ultrasonic welding/bonding patterns available; and -
FIG. 14 is a schematic representation of a machine for the in-line automatic manufacture of two-layer pads using a co-extruded barrier-to-base layer material ultrasonically bonded to a layer of handle forming material, which pads either have “L”-shaped handles or have handles configured as “wings,” the machine ofFIG. 14 , like the machine ofFIG. 7 , requiring only a single ultrasonic bonding station. - In overview, a thermal bonding, thermal fusion or heat fusion process is employed in embodiments of the invention to bond one or two layers of impervious film to a layer of non-woven base pad forming material, without the use of an adhesive of any kind. A cutter, such as a die cutter, is then employed to cut through the layers to form individual pads. An embosser may be employed to emboss film used for the handle, making the handle easier to see, as well as providing a better grip).
- The presently-preferred thermal bonding, thermal fusion or heat fusion process is ultrasonic bonding (also known as ultrasonic laminating or ultrasonic welding). Accordingly, the embodiments of the invention described hereinbelow employ ultrasonic bonding or welding, by way of example and not limitation. When ultrasonic welding or bonding is employed, vibratory energy is converted to heat, which softens and may even melt the materials. Other potential sources of heat for thermal bonding include hot irons, hot air or other gas, a source of infrared energy, or other electromagnetic energy source such as a laser, all by way of example and not limitation. Fundamentally, any technique which provides localized heat in predetermined patterns for bonding, welding or fusion may be employed.
- In addition to thermal bonding, thermal processes may be employed in the die cutter, as well as in the embosser. Thus individual pads may be cut out using, as examples, ultrasonic tooling or a laser. Thermal or heat-producing equipment may be employed to emboss film used for the handle
- Ultrasonic bonding or welding (also known as ultrasonic laminating or ultrasonic welding) is a joining technique that uses high-frequency ultrasonic acoustic vibrations to effect solid state welding of materials that have either the same or different melting point temperatures. An ultrasonic solid-state bond is as strong as the bonded materials themselves.
- Suitable ultrasonic bonding or welding equipment (i.e., ultrasonic tooling) is available, as an example, from Dukane Corporation, 2900 Dukane Drive, St. Charles, Ill. 60174 (http://www.dukane.com/us/). Another source is Herrmann Ultrasonics Inc., 1261 Hardt Circle, Bartlett, Ill. 60103 (www.herrmannultrasonics.com). Information regarding ultrasonic bonding or welding is available from TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, United Kingdom, and ultrasonic welding is described on their webpage http://www.twi.co.uk/content/pjkultrason.html. In addition, information regarding ultrasonic welding is available on the webpage http://www.plastemart.com/upload/Literature/Frequency-in-ultrasonic-plastic-welding-machines-applications-limitations.asp?LiteratureID=1292 or http://www.plastemart.com/PrintFile.asp?REF=/webtech/upload/Literature/Frequency-in-ultrasonic-plastic-welding-machines-applications-limitations.asp&LiteratureID=1292.
- Ultrasonic equipment may be tooled for a variety of specific operations, including in-line welding, embossing, slitting and sealing, either in single modules or arranged in an array across the web.
- Illustrated herein are examples of two- and three-layer multilayer pads manufactured employing ultrasonic bonding or welding, without the use of adhesives of any kind. Various standard ultrasonic tooling is readily available and may be employed in the embossing, welding and slitting of a variety of materials employed in the manufacture of multilayer pads.
- Referring now to
FIG. 1 , amachine 100 for the in-line automatic manufacture of three-layer pads employing ultrasonic embossing, slitting and bonding equipment is illustrated in schematic representation. Themachine 100 ofFIG. 1 may be employed to make pads having “L”-shaped handles as generally disclosed in Woods et al U.S. Pat. No. 5,230,119 and US Re. 36,601. -
FIG. 2 is a three-dimensional representation of three webs of material as processed in themachine 100 ofFIG. 1 , aweb 102 of fusible base pad forming material having a longitudinal axis represented bydirectional arrow 104 and awidth 106, aweb 108 of fusible intermediate barrier layer forming material having a longitudinal axis also represented by thedirectional arrow 104 and thesame width 106, and aweb 110 of fusible handle forming material having a longitudinal axis also represented by thedirectional arrow 104. Theweb 110 is longitudinally split or slit into a plurality of narrower sub webs of handle forming material, for example twosub webs FIG. 2 there is a lateral gap between thesub webs sub webs -
FIG. 3 is a corresponding highly schematic representation of in-line steps to manufacture pads with “L”-shaped handles employing the machine ofFIG. 1 . - The
machine 100 includes afeed roll 120 feeding or supplying theweb 102 of fusible base pad forming material, afeed roll 122 supplying theweb 108 of fusible intermediate barrier layer forming material having a longitudinal axis and a width, and afeed roll 124 supplying theweb 110 of fusible handle forming material. To facilitate thermal fusion, thematerial webs web 102 of base pad forming material is an absorbent material, made of non-woven fibers such as polypropylene or polyester. A blend of fibers for thebase pad 102 material may also be employed, for example including cotton (which by itself is non-fusible), but with a sufficient percentage of fusible fibers in the blend so that the resultant basepad material web 102 is fusible. - The machine of
FIG. 1 may be employed to manufacture pads in a single line as implied byFIG. 3 . However, in practical commercial embodiments pads are manufactured in-line in multiple longitudinal lines defining rows withmultiple pad precursors 126 shown in dash lines extending across the width of thewebs arrow 104. Although two rows of pad precursors 126 (and twocorresponding sub webs FIG. 2 , more rows are processed in a typical commercial embodiment. Examples are disclosed in U.S. Pat. No. Re. 36,601; U.S. Pat. No. 5,771,524 and U.S. Pat. No. 6,493,898. Accordingly, it will be appreciated that the single line of pads inFIG. 3 is to illustrate the principles of the invention. - In
FIG. 3 , a representative combined web 130 is shown in plan view, including all three layers, and including pad precursors orprecursor regions machine 100 ofFIG. 1 . It will be appreciated that the actual steps or stages represented by thepad precursors FIG. 1 machine 100, and are not actually immediately adjacent as perhaps implied by the representation ofFIG. 3 . -
FIG. 3 also shows afinished pad 140 in plan view, which has been cut out from the representative combined web 130. Thepad 140 as manufactured has an embossed handlegraspable portion 142 which is folded down as manufactured.FIG. 3E is an end elevational view of thepad 140 in its in-use configuration, with the handlegraspable portion 142 pivoted up along a fold line 144. - Considering the manufacturing method disclosed in
FIGS. 1, 2 and 3 in greater detail, inFIG. 1 , embossing and slittingtooling 146 optionally embosses thehandle forming material 110 providing texture to facilitate grasping the resultant pad handles, as well as slitting theinitial web 110 of handle forming material into thesub webs FIGS. 2 and 3 ,texture embossing 148 is represented by hatching. Theembossing 148 is represented inFIG. 3 as discontinuous sections corresponding to pad precursors. However, as shown inFIG. 2 theembossing 148 is actually continuous longitudinally along theweb 110 of handle forming material, or, more particularly, along thesub webs - Mechanical embossing and slitting tooling may be employed at 146 or, alternatively, ultrasonic embossing and slitting tooling may be employed.
- Downstream of the embossing and slitting
tooling 146, the threewebs rollers 150. -
FIG. 3 pad precursor 132 and the corresponding view ofFIG. 3A , represent the condition atpoint 152 in themachine 100 ofFIG. 1 . All three layers are present, but no bonding has occurred. Pads have not yet been cut out, existing as precursor regions only. - At a
first bonding station 154, aportion 156 of thehandle forming material 110 is fused to the barrierlayer forming material 108, leaving afree portion 158 of the handle forming material. Thefree portion 158 includes theembossing 148, and ultimately becomes the handlegraspable portion 142. Correspondingly, thebarrier layer material 108 is fused to thebase pad material 102. TheFIG. 3 pad precursor 134 and the corresponding view ofFIG. 3B represent the condition atpoint 160 in themachine 100 ofFIG. 1 , immediately downstream of thefirst bonding station 154. - More particularly, in the illustrated embodiment, at the
first bonding station 154, two bond lines are formed parallel to the longitudinal axis, afirst bond line 162 near a lateral edge of thepad precursor 134, and asecond bond line 164 near the middle of thepad precursor 134. Although thebond lines - The next stage in the
machine 100 ofFIG. 1 , downstream with reference to thefirst bonding station 154, is ahandle folding station 166 which folds over thefree portion 158 of the handle forming material to uncover aportion 168 of thebarrier layer material 108 previously covered by thefree portion 158. TheFIG. 3 pad precursor 136 and the corresponding view ofFIG. 3C represent the condition atpoint 170 in themachine 100 ofFIG. 1 , immediately downstream of thehandle folding station 166. - At a
second bonding station 172 the now uncoveredportion 168 of thebarrier layer material 108 is fused to the basepad forming material 102, along abond line 174, which is similar to the first andsecond bond lines FIG. 3 pad precursor 138 and the corresponding view ofFIG. 3D , which represent the condition ofpoint 176 in themachine 100 ofFIG. 1 , immediately downstream of thesecond bonding station 172. - Next, at a
die cutting station 178 rotary die cutting tooling for example cuts through all three layers of material, creating and freeingmultilayer pads 140 at 180. Although not illustrated, thefinished pads 140 are collected and packaged in a conventional manner. As one example, a die cutter and collection mechanism is disclosed in greater detail in the above-referenced Woods et al U.S. Pat. No. 6,493,898. - Finally, a
scrap rewind roll 182 collects the remainingscrap web material 184. Thescrap web material 184 includes remnants of all three layers, with multiple apertures where pads have been cut out. - Referring next to
FIG. 4 , amachine 200 for the in-line automatic manufacture of two-layer pads employing ultrasonic embossing, slitting and bonding equipment is illustrated in schematic representation. Themachine 200 ofFIG. 4 may be employed to make pads having “folded” handles as generally disclosed in Woods et al U.S. Pat. No. 6,493,898.FIG. 5 is a corresponding highly schematic representation of in-line steps to manufacture pads with “folded” handles employing the machine ofFIG. 4 . - Two webs of fusible material are processed in the
machine 200 ofFIG. 4 , aweb 202 of fusible base pad forming material having a longitudinal axis represented by directional arrow 204 (FIG. 5 ) and a width 206 (FIG. 5 ), and aweb 210 of fusible handle forming material having a longitudinal axis also represented by thedirectional arrow 204, and having awidth 216. In order to provide additional material to form the longitudinally extending pleat of a “folded” handle, thewidth 216 of the handle formingmaterial web 210 is approximately two times thewidth 206 of the basepad material web 202. In the embodiment ofFIGS. 4 and 5 it is not absolutely necessary that theweb 210 of handle forming material be longitudinally slit or split. However, in some embodiments, depending on the configuration of the downstream handle folding tooling, described hereinbelow, it may be advantageous to provide individual sub webs of handle forming material. The embodiment ofFIGS. 4 and 5 does not require an intermediate barrier material layer. - The
machine 200 includes afeed roll 220 feeding or supplying theweb 202 of fusible base pad forming material, and afeed roll 224 supplying theweb 210 of fusible handle forming material. To facilitate thermal fusion, thematerial webs web 202 of base pad forming material is an absorbent material, made of non-woven fibers such as polypropylene or polyester. A blend of fibers for thebase pad 202 material may also be employed, for example including cotton (which by itself is non-fusible), but with a sufficient percentage of fusible fibers in the blend so that the resultant basepad material web 202 is fusible. - The machine of
FIG. 4 may be employed to manufacture pads in a single line as implied byFIG. 5 . However, in practical commercial embodiments pads are manufactured in-line in multiple longitudinal lines defining rows with multiple pad precursors extending across the width of theweb 202 as disclosed in U.S. Pat. No. 6,493,898. Accordingly, it will be appreciated that the single line of pads inFIG. 5 is to illustrate the principles of the invention. - In
FIG. 5 , two webs are represented. The first is theweb 210 of handle forming material. The second is a representative combinedweb 230 after a longitudinally extending pleat of handle forming material has been formed, thus effectively reducing the width of the web of handle forming material, and after thewebs web 230 is shown in plan view, including both layers, and including pad precursors orprecursor regions machine 200 ofFIG. 4 . It will be appreciated that the actual steps or stages represented by thepad precursors FIG. 4 machine 200, and are not actually immediately adjacent as perhaps implied by the representation ofFIG. 5 . -
FIG. 5 also shows afinished pad 240 in plan view, which has been cut out from the representative combinedweb 230. Thepad 240 as manufactured has an embossed handlegraspable portion 242 which is folded down as manufactured.FIG. 5E is an end elevational view of thepad 240 in its in-use configuration, with the handlegraspable portion 242 pivoted up alongfold lines - Considering the manufacturing method disclosed in
FIGS. 4 and 5 in greater detail, inFIG. 4 , optional embossing tooling 246 embosses thehandle forming material 210 providing texture to facilitate grasping the resultant pad handles.Texture embossing 248 is represented by hatching. As shown on theFIG. 5 web segment 210, theembossing 248 is continuous longitudinally along theweb 210 of handle forming material, even though theembossing 248 is also represented inFIG. 5 as discontinuous sections corresponding to thepad precursors - Mechanical embossing tooling may be employed at 246 or, alternatively, ultrasonic embossing tooling may be employed.
- Downstream of the embossing tooling 246, the two
webs rollers 250. - The corresponding view of
FIG. 5A represents the condition atpoint 252 in themachine 200 ofFIG. 4 . Both layers are present, but no pleating or bonding has occurred, so the handle formingmaterial web 210 is wider than the basepad material web 202. Pads have not yet been cut out, existing as precursor regions only. - At a first handle
folding tooling station 254, the handlelayer material web 210 is formed into alongitudinally extending pleat 256 including two facingsegments edge 260, thepleat 256 defining a handle graspable portion precursor. To subsequently provide clearance for ultrasonic bonding tooling, the height of thepleat 256 is less than one-half of the width of thepad 240 being manufactured. In addition, a pair of longitudinally extending handle attachedportion precursors pleat 256 along thefold lines pleat 256 is folded down to one side generally over the handle attachedportion precursor 262, while leaving aportion 266 of theprecursor 262 exposed near a lateral edge (since the height of thepleat 256 is less than one-half the width of thepad 240 being manufactured.) The other handle attachedportion precursor 264 is fully exposed. TheFIG. 5 pad precursor 234 and the corresponding view ofFIG. 5B represent the condition atpoint 268 in themachine 200 ofFIG. 4 , immediately downstream of the first handlefolding tooling station 254. - At a
first bonding station 270, the other handle attachedportion precursor 264 is fused to the base pad formingmaterial layer 202, at least immediately adjacent thefold line 245, and preferably in additional bonding regions. In addition, the exposedportion 266 of the handle attachedportion precursor 262 is fused to the base pad formingmaterial layer 202. TheFIG. 5 pad precursor 236 and the corresponding view ofFIG. 5C represent the condition atpoint 272 in the machine ofFIG. 4 , immediately downstream of thefirst bonding station 270. - More particularly, in the illustrated embodiment, at the
first bonding station 270, three bond lines are formed parallel to the longitudinal axis, a pair ofouter bond lines pad precursor 236, and a firstinner bond line 278 adjacent thefold line 245. Although thebond lines - The next stage in the
machine 200 ofFIG. 4 , downstream with reference to thefirst bonding station 270 is a second handle foldingtooling station 280 which folds thepleat 256 over to the other side to fully expose the one handle attachedportion precursor 262. - Then, at a
second bonding station 282, the one handle attachedportion precursor 262 is fused to the base pad formingmaterial layer 202 at least immediately adjacent thefold line 244, along a secondinner bond line 284, which is similar to thebond lines FIG. 5 pad precursor 238 and the corresponding view ofFIG. 5D , which represent the condition ofpoint 286 in themachine 200 ofFIG. 4 , immediately downstream of thesecond bonding station 282. - Next, at a
die cutting station 288 rotary die cutting tooling for example cuts through both layers of material, creating and freeingmultilayer pads 240 at 290. Although not illustrated, thefinished pads 240 are collected and packaged in a conventional manner. As one example, a die cutter and collection mechanism is disclosed in greater detail in the above-referenced Woods et al U.S. Pat. No. 6,493,898. - Finally, a
scrap rewind roll 292 collects the remainingscrap web material 294. Thescrap web material 294 includes remnants of both layers, with multiple apertures where pads have been cut out. -
FIG. 6A schematically represents a single ultrasonic horn and anvil set 296 for use when pads are manufactured in a single line. Theset 296 may be tooled to emboss, weld and slit materials. -
FIG. 6B schematically represents anarray 298 of across-the-web ultrasonic horns and anvils for use when pads are manufactured in multiple longitudinal lines. - Referring next to
FIG. 7 , amachine 300 for the in-line automatic manufacture of three-layer pads employing ultrasonic embossing, slitting and bonding equipment is illustrated in schematic representation. Themachine 300 ofFIG. 7 may be employed to make pads having “L”-shaped handles as generally disclosed in Woods et al U.S. Pat. No. 5,230,119 and US Re. 36,601, or handles resembling “wings” as disclosed in Woods et al U.S. Pat. No. 5,771,524.FIG. 8 is a corresponding highly schematic representation of in-line steps to manufacture pads with “L”-shaped handles employing themachine 300 ofFIG. 7 .FIG. 10 is a corresponding highly schematic representation of in-line steps to manufacture pads with “wing” handles employing themachine 300 ofFIG. 7 . - Three webs of fusible material are processed in the
machine 300 ofFIG. 7 , aweb 302 of fusible base pad forming material having a longitudinal axis represented bydirectional arrow 304 and awidth 306, aweb 308 of fusible intermediate barrier layer forming material having a longitudinal axis also represented by thedirectional arrow 304 and thesame width 306, and aweb 310 of fusible handle forming material having a longitudinal axis also represented by thedirectional arrow 304. - For use in the
machine 300 ofFIG. 7 , it is necessary that theweb 310 of handle forming material be trimmed in width so that the handle material does not extend all the way across the width of a pad being manufactured. More particularly, for making pads with “L”-shaped handles as inFIG. 8 , theweb 310 of handle forming material is trimmed on one side, resulting in theFIG. 8 web 312. For making pads with “wing” handles as inFIG. 10 , theweb 310 of handle forming material is trimmed on both sides, resulting in theFIG. 10 web 314. - The
machine 300 includes afeed roll 320 feeding or supplying theweb 302 of fusible base pad forming material, afeed roll 322 supplying theweb 308 of fusible intermediate barrier layer forming material having a longitudinal axis and a width, and afeed roll 324 supplying theweb 310 of fusible handle forming material. To facilitate thermal fusion, thematerial webs web 302 of base pad forming material is an absorbent material, made of non-woven fibers such as polypropylene or polyester. A blend of fibers for thebase pad 302 material may also be employed, for example including cotton (which by itself is non-fusible), but with a sufficient percentage of fusible fibers in the blend so that the resultant basepad material web 302 is fusible. - The machine of
FIG. 7 may be employed to manufacture pads in a single line as implied byFIGS. 8 and 10 . However, in practical commercial embodiments pads are manufactured in-line in multiple longitudinal lines defining rows with multiple pad precursors extending across the width of thewebs FIGS. 8 and 10 are to illustrate the principles of the invention. - In
FIG. 8 , a representative combinedweb 330 is shown in plan view, including all three layers, and including pad precursors orprecursor regions 332 and 334 representing stages or steps of pad manufacture by themachine 300 ofFIG. 7 . InFIG. 10 , a similar representative combinedweb 335 is shown in plan view, including all three layers, and including pad precursors orprecursor regions machine 300 ofFIG. 7 . It will be appreciated that the actual steps or stages represented by thepad precursors 332 and 334 (FIG. 8 ) and 336 and 338 (FIG. 10 ) are spaced out along the length of theFIG. 7 machine 300, and are not actually immediately adjacent as perhaps implied by the representations ofFIGS. 8 and 10 . -
FIG. 8 also shows afinished pad 340 with an “L”-shaped handle in plan view, which has been cut out from the representative combinedweb 330. Thepad 340 as manufactured has an embossed handlegraspable portion 341 which is folded down as manufactured.FIG. 8C is an end elevational view of thepad 340 in its in-use configuration, with the handlegraspable portion 341 pivoted up along afold line 342. - Similarly,
FIG. 10 also shows afinished pad 343 with a “wings” configuration handle in plan view, which has been cut out from the representative combinedweb 335. Thepad 343 as manufactured has a pair of embossed handlegraspable portions FIG. 10C is an end elevational view of thepad 343 in its in-use configuration, with the handlegraspable portions - Considering the manufacturing method disclosed in
FIGS. 7, 8 and 10 in greater detail, inFIG. 7 , embossing and slittingtooling 346 optionally embosses thehandle forming material 310 providing texture to facilitate grasping the resultant pad handles, as well as slitting or trimming theinitial web 310 of handle forming material to form thenarrower web 312 ofFIG. 8 or thenarrower web 314 ofFIG. 10 . InFIGS. 8 and 10 ,texture embossing 348 is represented by hatching. As shown on theFIG. 8 web segment 312 and on theFIG. 10 web segment 314, theembossing 348 is continuous longitudinally along theweb 310 of handle forming material, even though theembossing 348 is also represented inFIGS. 8 and 10 as discontinuous sections corresponding to thepad precursors - Mechanical embossing and slitting tooling may be employed at 346 or, alternatively, ultrasonic embossing and slitting tooling may be employed.
- Downstream of the embossing and slitting
tooling 346, the threewebs rollers 350. As described in greater detail below, at least one side edge portion of the intermediate barrierlayer material web 308 is exposed near a pad precursor lateral edge, made possible because thehandle material web 310 is trimmed in width. - Thus,
FIG. 8 pad precursor 332 and the corresponding view ofFIG. 8A , represent the condition atpoint 352 in themachine 300 ofFIG. 7 when pads with “L”-shaped handles are being manufactured. All three layers are present, but no bonding has occurred. Pads have not yet been cut out, existing as precursor regions only. Significantly aside edge portion 354 of the barrierlayer material web 308 is exposed. - Similarly,
FIG. 10 pad precursor 336 and the corresponding view ofFIG. 10A , represent the condition atpoint 352 in themachine 300 ofFIG. 7 when pads having “wing” configuration handles are being manufactured. All three layers are present, but no bonding has occurred. Pads have not yet been cut out, existing as precursor regions only. Significantly two oppositeside edge portions layer material web 308 is exposed. - An advantageous characteristic of the
machine 300 ofFIG. 7 is that there is asingle bonding station 360. This is made possible by the exposed side edge portions 354 (FIG. 8 ) or 356 and 358 (FIG. 10 ), which in turn results from theweb 310 of handle forming material being trimmed in width. - Thus, at the bonding station 360 a portion of the
handle forming material 310 is fused to the barrierlayer forming material 308, leaving at least one other portion of thehandle forming material 310 free to define a graspable portion precursor. - More particularly, in the in-line steps of
FIG. 8 to make pads having “L”-shaped handles, aportion 362 of thehandle forming material 310 is fused to the intermediatebarrier layer material 308, leaving afree portion 364 of the handle forming material as a graspable portion precursor. At the same time, thebarrier layer material 308 is fused to thebase pad material 302. TheFIG. 8 pad precursor 334 and the corresponding view ofFIG. 8B represent the condition atpoint 366 in themachine 300 ofFIG. 7 , immediately downstream of thebonding station 360. - When making pads with “L”-shaped handles as in
FIG. 8 , at thebonding station 360, three bond lines are formed parallel to the longitudinal axis. A pair ofouter bond lines bond line 372 near the middle of the pad precursor 334. Theouter bond line 368 and themiddle bond line 372 bond all three layers, including theportion 362 of handle forming material. Theouter bond line 370 fuses only thebarrier layer 308 and thebase pad layer 302. Although thebond lines - In the in-line steps of
FIG. 10 to make pads having “wing” handles, aportion 374 of thehandle forming material 310 is fused to the intermediatebarrier layer material 308, leaving a pair offree portions barrier layer material 308 is fused to thebase pad material 302. TheFIG. 10 pad precursor 338 and the corresponding view ofFIG. 10B represent the condition atpoint 366 in themachine 300 ofFIG. 7 , immediately downstream of thebonding station 360. - When making pads having “wing” handles as in
FIG. 10 , at thebonding station 360, three bond lines are formed parallel to the longitudinal axis. A pair ofouter bond lines pad precursor 338, and anotherbond line 384 near the middle of thepad precursor 338. Theouter bond lines barrier layer 308 and thebase pad layer 302. Themiddle bond line 384 bonds all three layers, including theportion 374 of handle forming material. The resultant “wing” handle may be viewed as having a “V” configuration, with thebonding line 384 in the center of the “V”. Although thebond lines -
FIGS. 9A, 9B, 9C and 9D illustrate a hybrid form ofpad 386 which may be made by themachine 300 ofFIG. 7 . The handle ofpad 368 generally is of “L” configuration, but with the horizontal portion of the handle significantly shorter than the upright portion. Alternatively, thepad 386 may be viewed as a “wing” handle pad where one of the two “wings” is missing. Accordingly, it will be appreciated that thepad 386 ofFIGS. 9A, 9B, 9C and 9D is manufactured in essentially the same manner as thepad 343 ofFIG. 10 . - Next, at a
die cutting station 388 rotary die cutting tooling for example cuts through all three layers of material, creating and freeingmultilayer pads finished pads - Finally, a
scrap rewind roll 392 collects the remainingscrap web material 394. Thescrap web material 394 includes remnants of all three layers, with multiple apertures where pads have been cut out. - Referring next to
FIG. 11 , amachine 400 for the in-line automatic manufacture of two-layer pads employing ultrasonic embossing, slitting and bonding equipment is illustrated in schematic representation. Themachine 400 ofFIG. 11 may be employed to make pads having “folded” handles as generally disclosed in Woods et al U.S. Pat. No. 6,493,898.FIG. 12 is a corresponding highly schematic representation of in line steps to manufacture pads with “folded” handles employing the machine ofFIG. 11 . Like themachine 300 ofFIG. 7 , themachine 400 ofFIG. 11 includes a single bonding station. - Two webs of fusible material are processed in the
machine 400 ofFIG. 11 , aweb 402 of fusible base pad forming material having a longitudinal axis represented by directional arrow 404 (FIG. 12 ) and a width 406 (FIG. 12 ), and aweb 410 of fusible handle forming material having a longitudinal axis also represented by thedirectional arrow 404, and having awidth 416. In order to provide additional material to form the longitudinally extending pleat of a “folded” handle, thewidth 416 of the handle formingmaterial web 410 is approximately two times thewidth 406 of the basepad material web 402. In the embodiment ofFIGS. 11 and 12 it is not absolutely necessary that theweb 410 of handle forming material be longitudinally slit or split. However, in some embodiments, depending on the configuration of the downstream handle folding tooling, described hereinbelow, it may be advantageous to provide individual sub webs of handle forming material. The embodiment ofFIGS. 11 and 12 does not require an intermediate barrier material layer. - The
machine 400 includes afeed roll 420 feeding or supplying theweb 402 of fusible base pad forming material, and afeed roll 424 supplying theweb 410 of fusible handle forming material. To facilitate thermal fusion, thematerial webs web 402 of base pad forming material is an absorbent material, made of non woven fibers such as polypropylene or polyester. A blend of fibers for thebase pad 402 material may also be employed, for example including cotton (which by itself is non fusible), but with a sufficient percentage of fusible fibers in the blend so that the resultant basepad material web 402 is fusible. - The machine of
FIG. 11 may be employed to manufacture pads in a single line as implied byFIG. 12 . However, in practical commercial embodiments pads are manufactured in line in multiple longitudinal lines defining rows with multiple pad precursors extending across the width of theweb 402. Accordingly, it will be appreciated that the single line of pads inFIG. 12 is to illustrate the principles of the invention. - In
FIG. 12 , two webs are represented. The first is theweb 410 of handle forming material. The second is a representative combinedweb 430 after a longitudinally extending pleat of handle forming material has been formed, thus effectively reducing the width of the web of handle forming material, and after thewebs web 430 is shown in plan view, including both layers, and including pad precursors orprecursor regions machine 400 ofFIG. 11 . It will be appreciated that the actual steps or stages represented by thepad precursors FIG. 11 machine 400, and are not actually immediately adjacent as perhaps implied by the representation ofFIG. 12 . -
FIG. 12 also shows afinished pad 440 in plan view, which has been cut out from the representative combinedweb 430. Thepad 440 as manufactured has an embossed handlegraspable portion 442 which is folded down as manufactured.FIG. 12F is an end elevational view of thepad 440 in its in use configuration, with the handlegraspable portion 442 pivoted up alongfold lines - Considering the manufacturing method disclosed in
FIGS. 11 and 12 in greater detail, inFIG. 11 ,optional embossing tooling 446 embosses thehandle forming material 410 providing texture to facilitate grasping the resultant pad handles.Texture embossing 448 is represented by hatching. As shown on theFIG. 12 web segment 410, theembossing 448 is continuous longitudinally along theweb 410 of handle forming material, even though theembossing 448 is also represented inFIG. 12 as discontinuous sections corresponding to thepad precursors - Mechanical embossing tooling may be employed at 446 or, alternatively, ultrasonic embossing tooling may be employed.
- Downstream of the
embossing tooling 446, the twowebs rollers 450. - The corresponding view of
FIG. 12A represents the condition atpoint 452 in themachine 400 ofFIG. 11 . Both layers are present, but no pleating or bonding has occurred, so the handle formingmaterial web 410 is wider than the basepad material web 402. Pads have not yet been cut out, existing as precursor regions only. - At a first handle
folding tooling station 454, the handlelayer material web 410 is formed into alongitudinally extending pleat 456 including two facingsegments edge 460, thepleat 456 defining a handle graspable portion precursor. In this particular embodiment, there is no particular requirement regarding the height of thepleat 456. In addition, a pair of longitudinally extending handle attachedportion precursors pleat 456 along thefold lines pleat 456 is folded down to one side generally over the handle attachedportion precursor 462. TheFIG. 12 pad precursor 432 and the corresponding view ofFIG. 12B represent the condition atpoint 468 in themachine 400 ofFIG. 11 , immediately downstream of the first handlefolding tooling station 454. - Next, at a
second tooling station 470 thepleat 456 is pivoted so as to stand in an upright position perpendicularly to the handle attachedportion precursors pad forming material 402. TheFIG. 12 pad precursor 434 and the corresponding view ofFIG. 12C represent the condition atpoint 472 in the machine ofFIG. 11 , immediately downstream of thesecond tooling station 470. - With the
pleat 456 upright, all required bonding points are accessible. A characteristic of themachine 400 ofFIG. 11 is that there is asingle bonding station 474. - At the
bonding station 474, four bond lines are formed parallel to the longitudinal axis, a pair ofouter bond lines pad precursor 436, and a pair ofinner bond lines fold lines bond lines FIG. 12 pad precursor 436 and the corresponding view ofFIG. 12D show the condition immediately following bonding. - Immediately downstream with reference to the
bonding station 474 is another handlefolding tooling station 484 which folds thepleat 456 down, prior to cutting. The result is represented byFIG. 12 pad precursor 438 and the corresponding view ofFIG. 12E , which represent the condition ofpoint 486 in themachine 400 ofFIG. 11 . - Next, at a
die cutting station 488 rotary die cutting tooling for example cuts through both layers of material, creating and freeingmultilayer pads 440 at 490. Although not illustrated, thefinished pads 440 are collected and packaged in a conventional manner. - Finally, a
scrap rewind roll 492 collects the remainingscrap web material 494. Thescrap web material 494 includes remnants of both layers, with multiple apertures where pads have been cut out. -
FIGS. 13A, 13B, 13C, 13D and 13E illustrate, for purposes of example, five of the many ultrasonic welding/bonding patterns available. The patterns ofFIGS. 13A and 13B are employed in the embodiments specifically disclosed herein. However, the patterns ofFIGS. 13C, 13D and 13E may as well be employed, depending upon the particular pad configuration. It is important to select an ultrasonic bonding pattern which provides sufficient structural integrity which, at the same time, does not render the resultant pad unduly stiff. - Finally,
FIG. 14 illustrates amachine 500 which, in general, is an alternative to themachine 300 ofFIG. 7 . Themachine 500 ofFIG. 14 may be employed to make pads having “L”-shaped handles, or pads having handles resembling “wings.” - The primary difference between the
machine 500 ofFIG. 14 and themachine 300 ofFIG. 7 is that rather than separate layers ofbase pad material 302 andbarrier layer material 308, themachine 500 employs asingle web 505 of co-extruded barrier to base material. Such aweb 505 is formed by hot extrusion of material forming an impervious barrier layer over a layer of base pad forming material to form a single fused web prior to further processing. - Otherwise, the elements and functioning of the
FIG. 14 machine 500 are similar. - A
web 510 of handle forming material is essentially identical to theweb 310 of handle forming material described hereinabove with reference toFIGS. 7, 8 and 10 . - Briefly, the
machine 500 includes afeed roll 520 feeding or supplying theweb 505 of co-extruded barrier to base material, and afeed roll 524 supplying theweb 510 of fusible handle forming material. - The
machine 500 thus includes embossing and slittingtooling 546,rollers 550, asingle bonding station 560, adie cutting station 588 and ascrap rewind roll 592. - In view of the foregoing, it will be appreciated that embodiments of the invention, wherein layers forming multi-layer pads are laminated ultrasonically, without the use of any form of adhesive, provide a number of potential advantages, including:
-
- Environmental. No chemicals such as those contained in solvent, water-based and hot melt adhesives are released into the atmosphere.
- Reduced health hazards. The elimination of any residual chemical binders, released during the application of adhesives, that equipment operators may inhale or otherwise come into contact with.
- Scrap from like substrate materials, polypropylene film to polypropylene non-woven for example, employed in the manufacture of pads may be recycled without concern for contamination by various adhesives. Scrap generated from similar materials that include adhesives is generally not recyclable.
- No adhesive costs, as well as a significant reduction in the total cost of the pads produced.
- Adhesives equipment and tooling requires substantial set-up, as well as ongoing and end-of-shift cleaning and adjusting. Substantial time and labor cost savings can be effected by eliminating the ongoing and end-of-shift adhesive tooling clean up.
- The elimination of adhesive equipment also means there is no down-time for the start-up, pre-heating and repeated refilling of adhesive reservoirs.
- Ultrasonic bonding or welding can reduce or eliminate potential adverse effects of heating the materials used to manufacture the pads. The materials used to manufacture the pads are temperature sensitive. This means that in order to create a bond the hot melt adhesive may reach a temperature such that the substrates can, and sometimes do, become warped.
- Hot melt adhesive applicators are highly sensitive to line speed. Thus, the dwell time may increase (decrease in line speed) such that the hot adhesive sits too long at one spot and also causes warping. This can result in down time, clean up costs, materials loss and quality control issues. On the other hand ultrasonic tooling may be stopped and started almost instantaneously, similar to the way a sewing machine can stop and start. With ultrasonic tooling, there is no warping, loss of time, wasted material, nor related quality control issues.
- When adhesives are employed to join substrates there is the possibility of undesirable overspray or adhesive misplacement, which can result in surface “tack” and resultant pick up and transfer of particles and soil to the finished product. When such occurs, the production line must be shut down, all of the contaminated substrate and product discarded, and all equipment thoroughly cleaned, all at a significant cost in time and money.
- While specific embodiments of the invention have been illustrated and described herein, it is realized that numerous modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention.
Claims (9)
1. A multilayer pad comprising:
an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite said applying/wiping surface, and an outer periphery;
a barrier layer having a lower surface attached by fusing to said base pad layer attachment surface, an upper surface, and an outer periphery coextensive with said outer periphery of said base pad layer;
a handle including an attached portion fused to a portion of said barrier layer upper surface, and including at least one graspable free portion joined to said handle attached portion along a fold line defining an axis of said multilayer pad; and
said handle attached portion being attached to said barrier layer upper surface along bond lines parallel to the pad axis, a major portion of said handle attached portion not being attached to said barrier layer.
2. The multilayer pad of claim 1 , wherein said handle attached portion is attached to said barrier layer upper surface at least by a bond line adjacent the fold line.
3. The multilayer pad of claim 1 , wherein
said handle has a pair of attached portions, including said handle attached portion, and an intermediate graspable portion in the form of a fold; and wherein
each of said handle attached portions is attached to said barrier layer upper surface at least by a bond line adjacent the fold line.
4. A multilayer pad comprising:
an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite said applying/wiping surface, and an outer periphery;
a barrier layer having a lower surface attached by fusing to said base pad layer attachment surface, an upper surface, and an outer periphery coextensive with said outer periphery of said base pad layer;
a handle including an attached portion fused to a portion of said barrier layer upper surface, and including at least one graspable free portion joined to said handle attached portion along a fold line defining an axis of said multilayer pad; and
said handle attached portion being attached to said barrier layer upper surface and said barrier layer lower surface being attached to said base pad layer attachment surface along bond lines parallel to the pad axis, a major portion of said handle attached portion not being attached to said barrier layer.
5. The multilayer pad of claim 4 , wherein said handle attached portion is attached to said barrier layer upper surface at least by a bond line adjacent the fold line.
6. The multilayer pad of claim 4 , wherein
said handle has a pair of attached portions, including said handle attached portion, and an intermediate graspable portion in the form of a fold; and wherein
each of said handle attached portions is attached to said barrier layer upper surface at least by a bond line adjacent the fold line.
7. A multilayer pad comprising:
an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite said applying/wiping surface, and an outer periphery;
a barrier layer having a lower surface attached by fusing to said base pad layer attachment surface, an upper surface, and an outer periphery coextensive with said outer periphery of said base pad layer;
a handle including at least one attached portion fused to a portion of said barrier layer upper surface, and including at least one graspable free portion joined to said handle attached portion along a fold line defining an axis of said multilayer pad;
said barrier layer being continuously fused to said base pad layer; and
said handle attached portion being attached to said barrier layer upper surface along a bond line parallel to the pad axis, a major portion of said handle attached portion not being attached to said barrier layer.
8. The multilayer pad of claim 7 , wherein said handle attached portion is attached to said barrier layer upper surface at least by a bond line adjacent the fold line.
9. The multilayer pad of claim 7 , wherein
said handle has a pair of attached portions, including said at least one handle attached portion, and an intermediate graspable portion in the form of a fold; and wherein
each of said handle attached portions is attached to said barrier layer upper surface at least by a bond line adjacent the fold line.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/000,247 US20160128541A1 (en) | 2010-07-23 | 2016-01-19 | Multilayer pads and methods of manufacture employing thermal bonding |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US36698410P | 2010-07-23 | 2010-07-23 | |
US13/188,855 US9051669B2 (en) | 2010-07-23 | 2011-07-22 | Multilayer pads and methods of manufacture employing thermal bonding |
US14/509,491 US20150089760A1 (en) | 2010-07-23 | 2014-10-08 | Multilayer pads and methods of manufacture employing thermal bonding |
US15/000,247 US20160128541A1 (en) | 2010-07-23 | 2016-01-19 | Multilayer pads and methods of manufacture employing thermal bonding |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/509,491 Continuation US20150089760A1 (en) | 2010-07-23 | 2014-10-08 | Multilayer pads and methods of manufacture employing thermal bonding |
Publications (1)
Publication Number | Publication Date |
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US20160128541A1 true US20160128541A1 (en) | 2016-05-12 |
Family
ID=45493859
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/188,855 Active 2032-02-09 US9051669B2 (en) | 2010-07-23 | 2011-07-22 | Multilayer pads and methods of manufacture employing thermal bonding |
US14/509,491 Abandoned US20150089760A1 (en) | 2010-07-23 | 2014-10-08 | Multilayer pads and methods of manufacture employing thermal bonding |
US15/000,247 Abandoned US20160128541A1 (en) | 2010-07-23 | 2016-01-19 | Multilayer pads and methods of manufacture employing thermal bonding |
Family Applications Before (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/188,855 Active 2032-02-09 US9051669B2 (en) | 2010-07-23 | 2011-07-22 | Multilayer pads and methods of manufacture employing thermal bonding |
US14/509,491 Abandoned US20150089760A1 (en) | 2010-07-23 | 2014-10-08 | Multilayer pads and methods of manufacture employing thermal bonding |
Country Status (4)
Country | Link |
---|---|
US (3) | US9051669B2 (en) |
EP (1) | EP2603627A1 (en) |
CA (1) | CA2806300C (en) |
WO (1) | WO2012012730A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10363727B1 (en) | 2017-07-10 | 2019-07-30 | James M. Woods | Thermally-bonded multilayer pads formed from wide webs |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10060059B2 (en) * | 2012-01-19 | 2018-08-28 | Illinois Tool Works, Inc. | Cross-contamination prevention wipe |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5230119A (en) * | 1990-04-13 | 1993-07-27 | M. J. Woods, Inc. | Multilayer laminated pad |
US20020026678A1 (en) * | 2000-09-04 | 2002-03-07 | Anders Gustafsson | Wipe |
US6493898B1 (en) * | 1998-12-09 | 2002-12-17 | M. J. Woods, Inc. | Laminated pads and methods of manufacture employing mechanically folded handles |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5507906A (en) | 1990-04-13 | 1996-04-16 | M. J. Woods, Inc. | Method for making multilayer pad |
US5771524A (en) | 1996-12-31 | 1998-06-30 | M.J. Woods, Inc. | Disposable pad |
US6044515A (en) | 1998-04-13 | 2000-04-04 | Unilever Home And Personal Care Usa | Applicator pad with handle |
-
2011
- 2011-07-22 CA CA2806300A patent/CA2806300C/en active Active
- 2011-07-22 US US13/188,855 patent/US9051669B2/en active Active
- 2011-07-22 WO PCT/US2011/045028 patent/WO2012012730A1/en active Application Filing
- 2011-07-22 EP EP11744140.2A patent/EP2603627A1/en not_active Withdrawn
-
2014
- 2014-10-08 US US14/509,491 patent/US20150089760A1/en not_active Abandoned
-
2016
- 2016-01-19 US US15/000,247 patent/US20160128541A1/en not_active Abandoned
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5230119A (en) * | 1990-04-13 | 1993-07-27 | M. J. Woods, Inc. | Multilayer laminated pad |
US6493898B1 (en) * | 1998-12-09 | 2002-12-17 | M. J. Woods, Inc. | Laminated pads and methods of manufacture employing mechanically folded handles |
US20020026678A1 (en) * | 2000-09-04 | 2002-03-07 | Anders Gustafsson | Wipe |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10363727B1 (en) | 2017-07-10 | 2019-07-30 | James M. Woods | Thermally-bonded multilayer pads formed from wide webs |
Also Published As
Publication number | Publication date |
---|---|
CA2806300A1 (en) | 2012-01-26 |
US20150089760A1 (en) | 2015-04-02 |
US20120021187A1 (en) | 2012-01-26 |
EP2603627A1 (en) | 2013-06-19 |
WO2012012730A1 (en) | 2012-01-26 |
CA2806300C (en) | 2020-02-04 |
US9051669B2 (en) | 2015-06-09 |
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