Classifications

• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F13/00—Bandages or dressings; Absorbent pads
  • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
  • A61F13/15577—Apparatus or processes for manufacturing
  • A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
  • A61F13/15739—Sealing, e.g. involving cutting

Definitions

• the present invention relates to an apparatus and a process to manufacture disposable absorbent articles. More specifically, it relates to a heat- sealing, packaging device that seals and packages an absorbent core in a cost-effective yet efficient manner to yield disposable absorbent articles.
• Examples of the disposable absorbent articles of the present invention are sanitary napkins and diapers.
• Disposable absorbent articles that absorb and retain discharged bodily fluids like urine, menses, and incontinence matter are known in the art. Typical examples are sanitary napkins and pads, and diapers etc.
• Such disposable absorbent articles typically comprise a three-layered structure, viz., a liquid permeable top-sheet, an absorbent member, and an impervious back sheet.
• the top- and the back-sheet conventionally comprise of nonbiodegradable plastic (polyethylene and/or polypropylene sheet or film) material
• the absorbent member generally comprises a pulp matter, which are fluid absorptive and retentive in nature. This pulp matter has conventionally been derived from cellulose and/or cotton based naturally available or artificially made products. Typical examples are cotton waste, pine wood pulp etc.
• the present invention discloses a cost-effective apparatus to manufacture disposable absorbent articles.
• the apparatus is a unique embossing, sealing, and cutting device that packages an absorbent core with a top- and back-sheet through a uniform sealing and cutting mechanism to yield a cost-effective and efficient disposable absorbent article.
• the apparatus of the present invention comprise a sealing and cutting base and an upper lid, the bottom portion of which further comprise an arrangement to emboss, heat-seal and cut .
• a process to manufacture disposable absorbent articles using the apparatus of the present invention is also disclosed.
• FIG. 1 is a schematic front view of an embodiment of an apparatus of the present invention, to manufacture a sanitary napkin product
• FIG. 2 is a view of an embodiment of a sealing and cutting base of the apparatus of the present invention.
• FIG. 3 is a facing view of an embodiment of bottom portion of lid of the apparatus of the present invention.
• FIG. 1 is a schematic side view of an embodiment of manufacturing equipment of one form of sanitary napkin product of the present invention.
• the apparatus 100 of the present invention comprises side walls 102 and 104, sealing and cutting base 106, a lid with a bottom portion 108 and an upper portion 110, a gas lift 112, and a temperature regulator 114.
• the sealing and cutting base 106 has a standard napkin-shaped mould 1062 at its centre.
• said mould 1062 is a pad- shaped depression area, configured to accept an absorbent core.
• the outer layer of said mould 1062 is made up of a rubber -based polymeric material.
• said mould 1062 is surrounded by another layer so as to form a continuous trough between said outer layer and said surrounding layer. The said trough comprises an area adapted to receive the cutting teeth from the bottom portion 108 of lid (described later).
• said bottom portion 108 of lid of said apparatus 100 comprise a plurality of concentric layers adapted to emboss, seal, and cut an absorbent core placed in said sealing and cutting base 106.
• said bottom portion 108 comprise an innermost embossing layer 1082, a middle sealing layer 1084, and an outermost cutting layer 1086.
• said innermost embossing layer 1082 is an outwardly projecting layer comprising a crest and trough structure designed so as to form an embossed layer on an absorbent core.
• Such embossed layer plays a functional role in forming channels in said absorbent core to guide the menstrual fluid to be distributed evenly in the pad.
• different embossing pattern in the said innermost embossing layer 1082 shall result in specific channels formed in absorbent core.
• said middle sealing layer 1084 is a continuous pad shaped layer, beneath which is an heating element evenly spread out (not seen in the diagrams) that heats and seals the absorbent core with a top- and back-sheet (described later).
• the temperature of said heating element is controlled by said temperature regulator 114.
• the optimum temperature range for the operation of the apparatus 100 of the present invention is between 115 and 120 degree Celsius.
• the temperature regulator 114 and its use is as is commonly known in the art.
• said outermost cutting layer 1086 further comprises teethed structure laid down evenly along the outer periphery of said layer so as to provide a sharp, cutting mechanism when said layer 1086 is pressed against said sealing and cutting base 106 of said apparatus 100.
• the present invention contemplates a spring actuated compression action when the lid of apparatus 100 is brought down towards the sealing and cutting base 106.
• the said spring actuated compression is achieved by a plurality of springs arranged in the space between said bottom portion 108 and said upper portion 110 of the lid.
• an eight-springs arranged is laid out so as to achieve a uniform compression across the cross-section of said sealing and cutting base 106.
• said eight-springs are arranged in a manner that four of them are located at four corners of said outermost cutting layer 1086 and remaining four at four corners in the area between innermost embossing layer 1082, and a middle sealing layer 1084.
• said apparatus 100 is placed in close proximity to an arrangement where rolls of top- and back-sheet of can be spread over said sealing and cutting base 106.
• the materials used for top- and back-sheet are as widely known in the art.
• a disposable absorbent article like sanitary napkin using the apparatus of the present invention, said apparatus 100 is connected to an electricity source and the temperature adjusted to a range of 115 - 120 degree Celsius using said temperature regulator 114.
• a back-sheet material is rolled over to lie above said sealing and cutting base 106 of said apparatus 100.
• An absorbent core prepared from known process in the art is placed in the designated space within said napkin-shaped mould 1062 of said sealing and cutting base 106 of said apparatus 100 in a manner that said back-sheet cover lies beneath said absorbent core in within said napkin-shaped mould 1062.
• a watery-gum material is sprayed over said absorbent core using liquid dispenser/sprayer as commonly known in the art.
• the spraying prepares said absorbent core to attach a top-sheet material in a uniform and consistent manner.
• the top-sheet is rolled over said absorbent cover so as to occupy said sealing and cutting base 106.
• said lid of said apparatus 100 is pulled down. Presence of gas lifts 112 eases the operation of the lid to pull it down and later, to push it up. Pulling down of said lid over said sealing and cutting base 106 effectuates a first level of action, whereby said innermost embossing layer 1082 presses against said absorbent core to form the specific channel design on it.
• said middle sealing layer 1084 heat-seals the top-sheet and back-sheet onto said absorbent core so as to form a compact and sealed disposable absorbent article like sanitary napkin.
• the heat-sealing achieved by the present process ensures an 8-10 mm thickness of sealing that makes the sealing process uniformly thick and tamper-proof.
• the time for which said lid is present against said sealing and cutting base 106 to effect an embossing and sealing process is in the range of 4-8 seconds.
• said lid is pressed further so that said outermost cutting layer 1086 is pressed against said sealing and cutting base 106 of said apparatus 100. Since said outermost cutting layer 1086 further comprises teethed structure laid down evenly along the outer periphery of said layer, such pressing against said sealing and cutting base 106, provides a sharp, cutting mechanism wherein the sealed absorbent core is separated out as a single unit.
• This single unit comprises a back-sheet, an absorbent core with channels forms for fluid movement and retention, and an outer top-sheet, is a functional disposable absorbent articles.
• said absorbent core is prepared using known processes and systems in the art.
• pine wood pulp is used as the absorbing material (90% by weight) and mixed with 10% Super Absorbent Polymer (SAP) material.
• SAP Super Absorbent Polymer
• This mixture is pulverized in a pulverizer to yield a fluff that is suitable to be used as an absorbent core.
• the pulverizer of the present invention are as known in the art and typically break down the mixture of absorbing material and SAP into uniform fluff size, which is ideal to make a uniform sized absorbent core.
• the fluff thus obtained is brought to a weighing unit in small quantities. 7.4 - 7.8 grams of fluff is weighed out.
• a tray with a plurality of standard napkin size mould is taken and the weighed fluff is evenly spread across the mould. Typically, a tray with such 4 moulds is used.
• the next step is to take this tray to a pressing unit, wherein said tray is firmly fixed in the lower portion of said pressing unit.
• a typical pressing unit is known in the art and comprises a manually-operated wheel at the top, clockwise movement of which longitudinally shifts a pressing system that corresponds with the moulds in said tray and presses the latter so as to form a uniformly compresses absorbent core. This process is repeated twice.
• the sanitary napkin prepared thus is taken to a gumming step, where a thin strip of gum material is applied on the back-sheet of the napkin, over which a release paper is then pasted.
• the process of manufacture culminates with UV sterilization of the sanitary napkin.
• a sterilization unit which is as understood in the art, stacks of napkins are arranged so that they do not overlap on each other. UV sterilization is carried out, typically for duration of 20 minutes, after which the napkins are taken out and packed and sealed.
• the disposable absorbent articles prepared by the present apparatus and process meet the BIS standards, is hygienic and effective and as the same cost effective.
• the present invention provides a low cost solution to the manufacture disposable absorbent articles.
• the present invention provides a low-cost apparatus that packs and seals an absorbent core to yield a disposable absorbent article.
• the present invention provides a low-cost apparatus that packs the top- and back-sheet around an absorbent core and heat seals the ends to yield a disposable absorbent article.
• the present invention provides a low-cost apparatus that achieves a minimum of 8- 10mm of sealing.
• the present invention provides a low-cost apparatus that seals uniformly and is tamper-proof.
• the present invention provides a low-cost apparatus that can be operated by a semi skilled person.
• the present invention provides a manufacturing assembly comprising novel apparatus and process to manufacture a low cost disposable absorbent article.
• the present invention provides a hand operated manufacturing assembly line for manufacture of low-cost disposable absorbent articles.
• the present invention provides a disposable absorbent article that is equivalent in quality as those commercially available.
• the present invention provides an absorbent article that meets the BIS standards as laid down by the Government of India.
• the present invention makes absorbent articles like diapers and sanitary napkins widely affordable to a large, unreached section of the society.

Landscapes

• Health & Medical Sciences (AREA)
• Engineering & Computer Science (AREA)
• Heart & Thoracic Surgery (AREA)
• Manufacturing & Machinery (AREA)
• Epidemiology (AREA)
• Biomedical Technology (AREA)
• Mechanical Engineering (AREA)
• Vascular Medicine (AREA)
• Life Sciences & Earth Sciences (AREA)
• Animal Behavior & Ethology (AREA)
• General Health & Medical Sciences (AREA)
• Public Health (AREA)
• Veterinary Medicine (AREA)
• Absorbent Articles And Supports Therefor (AREA)

Applications Claiming Priority (2)

Publications (1)

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Cited By (1)

Citations (4)

• 2014
  • 2014-11-24 WO PCT/IB2014/066290 patent/WO2015079374A1/en active Application Filing
  • 2014-11-24 IN IN3478DE2013 patent/IN2013DE03478A/en unknown

Patent Citations (4)

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