U.S. patent application number 10/858318 was filed with the patent office on 2004-12-02 for multipurpose disposable applicator.
Invention is credited to Kane, James P. JR., Moore, Shanna La'Vonne, Visioli, Donna Lynn.
Application Number | 20040237235 10/858318 |
Document ID | / |
Family ID | 33511710 |
Filed Date | 2004-12-02 |
United States Patent
Application |
20040237235 |
Kind Code |
A1 |
Visioli, Donna Lynn ; et
al. |
December 2, 2004 |
Multipurpose disposable applicator
Abstract
A disposable multi-purpose applicator or wipe designed to desorb
and distribute a liquid while protecting persons using the
applicator from contact with the liquid is disclosed. The wipe
comprises (a) a first top layer of an absorbent material comprising
at least one layer of non-woven material; (b) a second layer of
liquid impermeable material underlying the first top layer, wherein
the first top layer and second layer are joined together at their
margins, or portions thereof, to form a peripheral seal, and (c) at
least one liquid absorbed into the top layer. The applicator or
wipe can be folded and the edges adhered in a peelable seal to
enclose the absorbent layer(s) and the absorbed liquid in a liquid
impermeable package comprised of the second layer of liquid
impermeable material and the peelable seal. Also described are
methods for preparing and using the applicator.
Inventors: |
Visioli, Donna Lynn; (Lower
Gwynedd, PA) ; Kane, James P. JR.; (Wilmington,
DE) ; Moore, Shanna La'Vonne; (Wilmington,
DE) |
Correspondence
Address: |
E I DU PONT DE NEMOURS AND COMPANY
LEGAL PATENT RECORDS CENTER
BARLEY MILL PLAZA 25/1128
4417 LANCASTER PIKE
WILMINGTON
DE
19805
US
|
Family ID: |
33511710 |
Appl. No.: |
10/858318 |
Filed: |
June 1, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60475725 |
Jun 2, 2003 |
|
|
|
Current U.S.
Class: |
15/104.94 ;
15/104.93; 15/209.1; 15/227 |
Current CPC
Class: |
A45D 37/00 20130101;
A61F 13/02 20130101; A61F 2013/00182 20130101; A45D 2200/1018
20130101; A61F 2013/00536 20130101; A61F 2013/00851 20130101; A45D
2200/1036 20130101; A47K 7/02 20130101; A47L 13/18 20130101; A61F
2013/00297 20130101; A47L 13/16 20130101; A61F 2013/0057
20130101 |
Class at
Publication: |
015/104.94 ;
015/104.93; 015/209.1; 015/227 |
International
Class: |
A47L 013/17; A47L
013/19 |
Claims
We claim:
1. An applicator or wipe characterized by the ability to desorb and
distribute a liquid while protecting persons using the applicator
from contact with said liquid comprising: (a) a first top layer of
an absorbent material comprising at least one layer of non-woven
material; (b) a second layer of liquid impermeable material
underlying said first top layer, wherein said first top layer and
said second layer are joined together at their margins, or portions
thereof, to form a peripheral seal, and (c) at least one liquid
absorbed into said first top layer.
2. The applicator or wipe according to claim 1 wherein said first
top layer and said second layer are joined together along the
entire perimeter of the top layer to form a peripheral seal, said
peripheral seal defining a closed area within the margins of said
second layer.
3. The applicator or wipe according to claim 2 having a center axis
dividing the surface of said absorbent first top layer into two
equal faces and dividing the margins of said second layer of liquid
impermeable material into two opposite portions, wherein said
applicator is folded along said center axis such that said faces
are contacted and said opposite portions are contacted; and said
opposite portions are adhered in a peelable seal to enclose said
first top layer and said absorbed liquid in a liquid impermeable
package comprised of said second layer of liquid impermeable
material and said peelable seal.
4. The applicator or wipe according to claim 1 wherein said first
top absorbent layer and said second impermeable layer are joined
together along a portion of the margin of said first top layer to
form a peripheral seal, such that a portion of said first top layer
is adhered to said second layer and the remainder of said first top
layer is not adhered.
5. The applicator or wipe according to claim 4 having a center axis
dividing the area of said second impermeable layer into two equal
faces and dividing the margins of said second layer into two
opposite portions, wherein said applicator or wipe is folded along
said center axis such that said opposite portions are contacted;
and said opposite portions are adhered in a peelable seal to
enclose said first top absorbent layer and said absorbed liquid in
a liquid impermeable package comprised of said equal faces of said
second layer and said peelable seal to contain and preserve the
said absorbed liquid until it is used.
6. The applicator or wipe according to claim 1 wherein said
non-woven material of said first top layer is selected from the
group consisting of thermoplastic polymeric fiber, cellulosic
fiber, and combinations thereof.
7. The applicator or wipe according to claim 6 wherein said
thermoplastic polymeric fiber is selected from the group consisting
of polyolefins, polyamides, and polyesters.
8. The applicator or wipe according to claim 1 wherein said second
layer of liquid impermeable material comprises at least one layer
of polymer selected from the group consisting of polyamides;
polyolefins; polyesters; polyethylene vinyl alcohol; polyvinylidene
chloride, anhydride-modified ethylene homopolymer,
anhydride-modified ethylene copolymer, and combinations
thereof.
9. The applicator or wipe according to claim 8 wherein said second
layer of liquid impermeable material comprises a polyolefin
film.
10. The applicator or wipe according to any of claims 1 through 5
further comprising a handle means providing a grasping portion by
which the applicator or wipe may be grasped and used.
11. The applicator according to claim 10 wherein said handle means
is formed integral with said second layer of liquid impermeable
material.
12. The applicator according to claim 11 wherein said handle means
comprises a pleat or gusset defining a folded flap formed in said
second layer of liquid impermeable material.
13. The applicator according to claim 6 wherein said handle means
comprises an elongated strip attached to said second layer of
liquid impermeable material at opposite end portions of said
elongated strip with the medial portion thereof being unattached so
that the medial portion of said strip forms a loop.
14. A method of preparing the applicator or wipe comprising the
steps of: providing an absorbent layer; providing a web of liquid
impermeable material; joining said absorbent layer to said web at
their margins, or portions thereof, to form a peripheral seal;
applying liquid to said absorbent layer; and separating said web
into individual applicators or wipes.
15. The method of claim 14 further comprising the steps of folding
the web along a center axis; and sealing the web in a peelable seal
in the dimensions of an individual applicator or wipe.
16. The method of claim 14 or claim 15 further comprising the step
of providing a handle means for said applicator or wipe.
17. The method of claim 16 wherein providing said handle means
comprises forming a folded flap in said layer of liquid impermeable
material and adhering the ends of the flap to the edges of said
applicator or wipe.
18. The method of claim 16 wherein providing said handle means
comprises attaching an elongated strip to said layer of liquid
impermeable material at opposite end portions of said strip with
the medial portion thereof being unattached so that the medial
portion of said strip forms a loop.
19. An apparatus for preparing the applicator or wipe of claim 1
comprising: a means for joining an absorbent layer to a web of
liquid impermeable material at their margins, or portions thereof;
a means for applying a liquid to the absorbent layer; and a means
for separating said web into individual applicators or wipes.
20. The apparatus of claim 19 further comprising a means for
folding the web along a center axis; and a means for sealing the
web in a peelable seal in the dimensions of an individual
applicator or wipe.
21. The apparatus of claim 19 or claim 20 further comprising a
means for providing a handle means for said applicator or wipe.
22. The apparatus of claim 21 wherein the means for providing a
handle means comprises a means for forming a pleat or gusset
defining a folded flap in said layer of liquid impermeable material
and a means for adhering the ends of the flap to the edges of said
applicator or wipe.
23. The apparatus of claim 21 wherein the means for providing a
handle means comprises a means for attaching an elongated strip to
said layer of liquid impermeable material at opposite end portions
of said strip with the medial portion thereof being unattached so
that the medial portion of said strip forms a loop.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Applicant claims the benefit of priority to provisional
application 60/475,725 filed Jun. 2, 2003; herein incorporated by
reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to disposable applicators or wipes
that are designed to desorb and distribute a liquid while
protecting persons using the applicator from contact with the
liquid in a wide variety of applications, including in the medical,
personal care, cosmetic, household and industrial fields, as well
as methods and apparatus for making such applicators.
[0004] 2. Description of the Related Art
[0005] Applicators or wipes comprising absorbent and/or absorbent
material have been known for some time. Typically, these wipes have
been used to absorb liquids (for example, to clean up spilled
liquids, or to absorb bodily fluids during medical treatment). They
have also been used to transfer liquids from a source to a surface
by absorbing the liquid and wiping the surface with the
applicator.
[0006] Typical wipes comprise a single layer of absorbent material
that allows contact between the absorbed liquid and the user. For
example, conventional wipes have included an air laid web of
fibers, which are uniformly mixed or distributed throughout the
web. The wipes have included polymeric fibers such as polyester,
polyethylene and polypropylene and natural or synthetic fibers such
as cellulosic fibers. Other conventional wet wipes have included a
coformed web of polypropylene and cellulosic fibers wherein the
fibers are uniformly mixed throughout the web.
[0007] However, it is desirable to minimize contact between a
user's skin and the liquid absorbed into the wipes.
[0008] U.S. Pat. Nos. 4,813,944 and 4,925,453 describe absorbent
pads that comprise liquid impermeable layers attached to absorbent
layers for absorbing liquids such as bodily fluids. U.S. Pat. No.
5,771,524 discloses an applicator pad comprising an absorbent base
layer and a barrier layer.
[0009] Wipes have also been packaged with liquid preabsorbed into
the wipe. For example, disinfectant solutions have been absorbed
into disposable wipes and packaged individually in liquid
impermeable packages to provide a sterile, disinfectant wipe. More
recently, wipes have been prepared preabsorbed with a variety of
cleansing solutions, solvents, waxes, polishes and the like for
household and cosmetic uses. Wet wipes have become well known
commercial consumer products, which have been available in many
forms. The wet wipes have been made from a variety of materials,
which have been moistened with a variety of suitable wiping
solutions. Such wet wipes have been used for baby wipes, hand
wipes, household cleaning wipes, industrial wipes and the like. For
example, see U.S. Pat. No. 6,028,018 for a multilayer wet wipe
comprising layers of different nonwoven materials. Typically, in
these applications, a number of wipes are enclosed in a liquid
impermeable package, such as a tub, a canister with a fitment to
dispense the wipes, or a flexible pouch, from which the consumer
removes the wipes as needed. Multi-wipe packages, however, have
certain disadvantages. For example, once the customer unseals the
package, the liquid absorbed into the wipes can evaporate on
storage and the wipes dry out, rendering them ineffective for their
intended purpose. In some cases, excess liquid is provided in the
package to extend the shelf life of the wipes after the package is
opened, which results in waste and added cost of the product.
[0010] It can also be problematic to dispense wipes from such
packages, particularly if contact between the preabsorbed liquid
and the user's skin is to be avoided.
[0011] Therefore, it is desirable to develop a wipe in which
contact between the preabsorbed liquid and the user's skin is
avoided. It is also desirable to provide such a wipe in a form that
will contain and preserve the preabsorbed liquid until the consumer
is ready to use the wipe.
BRIEF SUMMARY OF THE INVENTION
[0012] Accordingly, it is an object of the present invention to
provide an applicator or wipe designed to desorb and distribute a
liquid while protecting persons using the applicator from contact
with the liquid. Additionally, it is an object of this invention to
provide the applicator or wipe in a form that contains and
preserves a preabsorbed liquid until it is used. It is another
object of the present invention to provide methods and apparatus
for making such applicators in substantial quantities and at low
cost.
[0013] In one aspect of the invention, this invention provides an
applicator or wipe characterized by the ability to desorb and
distribute a liquid while protecting persons using the applicator
from contact with the liquid comprising:
[0014] (a) a first top layer of an absorbent layer comprising at
least one layer of non-woven material;
[0015] (b) a second layer of liquid impermeable material underlying
the first top layer, wherein the first top layer and second layer
are joined together at their margins, or portions thereof, to form
a peripheral seal, and
[0016] (c) at least one liquid absorbed into the first top
layer.
[0017] In one embodiment, the top and second layers are joined
together along the entire perimeter of the first top layer to form
a peripheral seal, the peripheral seal defining a closed area
within the second layer.
[0018] In a preferred embodiment, this invention provides the
applicator described above, having a center axis dividing the
surface of the absorbent top layer into two equal faces and
dividing the margins of the second layer of liquid impermeable
material into two opposite portions, wherein the applicator or wipe
is folded along the center axis such that the faces are contacted
and the opposite portions are contacted; and the opposite portions
are adhered in a peelable seal to enclose the first top layer and
the absorbed liquid in a liquid impermeable package comprised of
the second layer of liquid impermeable material and the peelable
seal to contain and preserve the preabsorbed liquid until it is
used.
[0019] In an alternate embodiment, the first top absorbent layer
and the second impermeable layer are joined together along a
portion of the margin of said first top layer to form a peripheral
seal, such that a portion of the first top layer is adhered to the
second layer and the remainder of the first top layer is not
adhered.
[0020] In a preferred embodiment, this invention provides the
applicator described above, having a center axis dividing the area
of the second impermeable layer into two equal faces and dividing
the margins of the second layer into two opposite portions, wherein
the applicator or wipe is folded along the center axis such that
the opposite portions are contacted; and the opposite portions are
adhered in a peelable seal to enclose the first top absorbent layer
and the absorbed liquid in a liquid impermeable package comprised
of the equal faces of the second layer and the peelable seal to
contain and preserve the preabsorbed liquid until it is used.
[0021] In additional preferred embodiments, this invention provides
the applicators described above, further comprising a handle means
providing a grasping portion by which the applicator may be grasped
and used.
[0022] The present invention also provides a method of preparing
the aforementioned applicator or wipe comprising the steps of
providing an absorbent layer; providing a web of liquid impermeable
material; joining said absorbent layer to said web at their
margins, or portions thereof, to form a peripheral seal; applying
liquid to said absorbent layer; and separating said web into
individual applicators or wipes. In a preferred embodiment, this
invention also provides the method of preparing the aforementioned
applicator or wipe further comprising folding the web along a
center axis; and sealing the web in a peelable seal in the
dimensions of an individual applicator or wipe. This invention also
provides said methods further comprising providing a handle means
for said applicator or wipe.
[0023] The present invention also provides an apparatus for
preparing the aforementioned applicator or wipe comprising a means
for joining an absorbent layer to a web of liquid impermeable
material at their margins, or portions thereof; a means for
applying a liquid to the absorbent layer; and a means for
separating said web into individual applicators or wipes.
[0024] In a preferred embodiment, the present invention also
provides the apparatus for preparing the aforementioned applicator
or wipe further comprising a means for folding the web along a
center axis; and a means for sealing the web in a peelable seal in
the dimensions of an individual applicator or wipe.
[0025] This invention also provides said apparatus further
comprising means providing a handle means for said applicator or
wipe.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0026] FIG. 1 is a cross-sectional side view of an applicator
embodying the principles of the present invention.
[0027] FIG. 2 is a top perspective view of the applicator shown in
FIG. 1.
[0028] FIG. 3 is a cross-sectional side view of a preferred
embodiment of the applicator wherein the applicator is folded along
a center axis and sealed at the edges to form a liquid impermeable
package.
[0029] FIG. 4 is a top perspective view of a preferred embodiment
of the applicator wherein the applicator is folded along a center
axis and sealed at the edges to form a liquid impermeable
package.
[0030] FIG. 5 is a top perspective view of an applicator similar to
FIG. 1 and having a center axis for folding, but illustrating an
embodiment of the handle means.
[0031] FIG. 6 is a top perspective view of an applicator similar to
FIG. 1 and having a center axis for folding, but illustrating an
alternative embodiment of the handle means.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The terms "applicator" and "wipe" and the like as used
herein to describe the same implement and can be used
interchangeably.
[0033] One embodiment of this invention provides an applicator or
wipe characterized by the ability to desorb and distribute a liquid
while protecting persons using the applicator from contact with
said liquid comprising (a) a top layer of an absorbent layer
comprising at least one layer of non-woven material; (b) a second
layer of liquid impermeable material underlying said top layer, the
top and second layers being joined together at their margins along
the entire perimeter of the top layer to form a peripheral seal,
said peripheral seal defining a closed area on the inside of said
second layer; and (c) said liquid absorbed into the top layer.
[0034] This embodiment of this invention can be understood by
referring to FIGS. 1 and 2, which illustrate the construction of an
applicator of this invention.
[0035] FIG. 1 shows a cross section of an applicator or wipe (1) of
this invention that comprises a top layer (2) of an absorptive
layer comprising at least one layer of non-woven material. One
embodiment of the absorptive layer comprises a single layer of
non-woven material. As illustrated in FIG. 1, an alternate
embodiment of the absorptive layer comprises two layers (3) and
(4). A second layer (5), in contact with the underside of the top
layer, comprises a sheet of moisture impermeable material. In the
schematic drawings depicted in FIG. 1 and FIG. 3 (described below),
the thickness of the various layers is exaggerated in comparison to
the overall dimensions of the applicator. Depending upon its
projected use, the applicator is cut or formed to the desired shape
and the edges of the absorbent layer (2) are sealed to the liquid
impermeable layer into a peripheral seal (6) that defines a closed
area on the inside of said second layer to prevent the escape of
liquid contained within the absorbent layer. The peripheral seal
(6) is sealed by, for example, heat welding and/or compression. In
a preferred embodiment, the margins (8) of the moisture impermeable
layer (5) extend beyond the peripheral seal (6). A liquid is
absorbed into the absorbent layer during preparation of the
applicator. FIG. 1 also shows a vertical line A-A' that bisects the
applicator into two equal portions.
[0036] FIG. 2 shows a top perspective of the applicator or wipe (1)
of this invention that comprises a top layer (2) of an absorptive
layer comprising at least one layer of non-woven material. In this
top perspective, any optional layer(s) of absorbent material
underneath the top layer of absorbent material are not shown. A
second layer (5), in contact with the underside of the top layer,
comprises a sheet of moisture impermeable material. As indicated
above, the applicator is cut or formed to the desired shape and the
edges of the absorbent layer (2) are sealed to the liquid
impermeable layer into a peripheral seal (6) that defines a closed
area on the inside of said second layer to prevent the escape of
liquid contained within the absorbent layer. In a preferred
embodiment, the margin (8) of the moisture impermeable layer (5)
extends beyond the peripheral seal (6). FIG. 2 also shows the
vertical line A-A' and a horizontal line B-B' that define a plane
that bisects the applicator into two equal portions.
[0037] In a preferred embodiment, this invention provides the
applicator described above, having a center axis dividing the
surface of said top layer into two equal faces and dividing said
peripheral seal into two opposite edges wherein said applicator or
wipe is folded along said center axis such that said faces are
contacted and said opposite edges are contacted; and said opposite
edges are adhered in a peelable seal to enclose said top layer and
said absorbed liquid in a liquid impermeable package comprised of
said second layer of liquid impermeable material and said peelable
seal to contain and preserve the preabsorbed liquid until it is
used.
[0038] This embodiment of the invention can be understood by
referring to FIGS. 3 and 4.
[0039] FIG. 3 depicts a cross section of a preferred embodiment of
the applicator wherein the applicator, which comprises an
absorptive layer (12) comprising two layers of non-woven material
(13) and (14) and a layer of moisture impermeable material (15) in
contact with the underside of the absorptive layer (12), forms a
liquid impermeable package (11). To form the liquid impermeable
package (11), the applicator is folded along an axis that passes
through line A-A' such that the surface of said absorptive layer
(12) is divided into two equal faces and that said faces are
contacted. The axis B-B' that passes through line A-A' divides the
peripheral seal described in FIG. 1 into two equal portions (16)
and (17) and also divides the margin of the impermeable surface
layer extending beyond the peripheral seal into two equal portions
(18) and (19). When the applicator is folded along said axis B-B',
the two equal portions of the peripheral seal (16) and (17) and the
two equal portions of the margins (18) and (19) are respectively
aligned and contacted in a face-to-face manner. The portions of the
margins (18) and (19) adjacent to the peripheral seal are adhered
in a peelable seal (20) such that the applicator forms the liquid
impermeable package (11). The edges (21) and (22) of the margins
(18) and (19) are not sealed to provide a grasping area (23) to
facilitate opening the peelable seal (20). Optionally, the edges
(21) and (22) may be of different dimensions to facilitate
separation of said edges forming the grasping area (23). The
absorptive layers (13) and (14) and the liquid absorbed therein are
fully contained within the package (11). The margins (18) and (19)
may optionally include features such as notches or tear regions to
facilitate opening the package.
[0040] FIG. 4 shows a top perspective view of the preferred
embodiment of the applicator wherein the applicator has been folded
across an axis defined by the vertical line A-A' and a horizontal
line B-B', along the line B-B' to form the liquid impermeable
package (11) described above. The cover sheet formed by the layer
of moisture impermeable material (15) has a margin (5). A portion
(18) of said margin (5) is sealed to a corresponding underlying
portion (not shown) in a peelable seal (20) to form a liquid
impermeable package (11). The edge (24) of the margin (5) is not
sealed to a corresponding underlying edge (not shown) to provide
grasping areas to facilitate opening the peelable seal. The fold
(24) along the line B-B' is not sealed, so that after severing of
the peelable seal, the package may be unfolded.
[0041] In this preferred embodiment, the user will open the liquid
impermeable package (11) by severing the peelable seal (20),
opening the applicator by unfolding fold (24) along the center axis
B-B', thereby exposing the top face of the absorbent layer and the
liquid contained therein. The user can then hold the applicator
with the liquid impermeable cover sheet adjacent to the user's skin
and apply and/or distribute the liquid by wiping with the absorbent
layer to desorb the liquid.
[0042] In an alternate embodiment, the top and second layers of the
applicator are joined together along a portion of the margin of
said top layer to form a peripheral seal, such that a portion of
said absorbent top layer is adhered to the second impermeable layer
and the remainder of said top layer is not adhered. In this
embodiment, the top absorbent layer may optionally have an area
larger than the area of the second impermeable layer. When the area
of the top absorbent layer is larger, the top layer may be folded
such that it lies within the area of the second impermeable
layer.
[0043] In a preferred embodiment, this invention provides the
applicator described above, having a center axis dividing the area
of said second layer of liquid impermeable material into two equal
faces and dividing the margins of said second layer into two
opposite portions, wherein said applicator is folded along said
center axis such that said opposite portions are contacted; and
said opposite portions are adhered in a peelable seal to enclose
said top layer and said absorbed liquid in a liquid impermeable
package comprised of said equal faces of said second layer and said
peelable seal to contain and preserve the preabsorbed liquid until
it is used.
[0044] In this embodiment, the user will open the liquid
impermeable package by severing the peelable seal, opening the
applicator by unfolding along the center axis, thereby exposing the
top absorbent layer and the liquid contained therein. The user can
then hold the applicator with the liquid impermeable cover sheet
adjacent to the user's skin and apply and/or distribute the liquid
by wiping with the absorbent layer to desorb the liquid. When the
top layer is folded as described above, it may be unfolded to
expose the entire area of the top layer.
[0045] The top absorbent layer (2) can be made from a variety of
materials including meltblown materials, coform materials, air-laid
materials, bonded-carded web materials, hydroentangled materials,
spunbonded materials, spunlaced materials, and the like; and can
comprise synthetic and/or natural fibers. Desirably, the absorbent
layer includes fibrous materials that provide an improved
appearance and feel to the wipe. Preferably, the absorbent layer
comprises thermoplastic polymeric fibers and optionally cellulosic
fibers.
[0046] Examples of thermoplastic polymeric fibers suitable for use
with the present invention include fibers comprising polymers
selected from the group consisting of polyolefins such as
polypropylene and polyethylene, polyamides, and polyesters such as
polyethyleneteraphthalat- e. Preferred are polyolefins such as
polypropylene and polyethylene and polyesters such as
polyethyleneteraphthalate. Alternative synthetic fibers that may be
suitable include staple nylon and rayon fibers. Examples of natural
fibers suitable for use in the present invention include cellulosic
fibers such as wood pulp fibers, cotton fibers, flax fibers, jute
fibers, silk fibers and the like.
[0047] Depending on the application, the absorbent layer (2) of the
wipe may include more than one layer, as illustrated in FIG. 1. For
example, the absorbent layer may comprise at least one soft and
flexible layer (3) and/or at least one strong, resilient layer (4).
Soft and flexible layers are desirable when the wipe is used to
apply a liquid to a person's skin. Strong and resilient layers may
be desirable to provide tensile strength and/or durability for
other applications such as scrubbing a hard or rough surface. The
soft and flexible layer may include soft polymeric fibers, such as
linear low density polyethylene fibers and/or other polymeric
fibers having similar properties. The soft polymeric fibers may or
may not be combined with natural fibers such as cellulosic fibers.
The strong, resilient layer may include resilient polymeric fibers
with relatively high tensile strength, such as polypropylene fibers
and/or other polymeric fibers having similar properties. Such
strong polymeric fibers may or may not be combined with natural
fibers such as cellulosic fibers. Desirably, at least one of the
layers contains natural fibers such as cellulosic fibers to provide
improved thickness and wettability to the basesheet. The natural
fibers may also provide void volume within the basesheet that
allows for improved moisture retention.
[0048] If the absorbent layer of the layered basesheet is a
combination of polymeric and natural fibers, such as polypropylene
and cellulosic fibers, the relative percentages of the polymeric
fibers and natural fibers in the layer can vary over a wide range
depending on the desired characteristics of the wet wipes. For
example, the layer may comprise from about 20 to about 95 weight
percent, desirably from about 20 to about 60 weight percent, and
more desirably from about 30 to about 40 weight percent of
polymeric fibers based on the dry weight of the layer. Such a layer
of polymeric and natural fibers may be manufactured by any method
known to those skilled in the art.
[0049] Generally, it is desirable that such a layer be formed by a
coform process for a more uniform distribution of the polymeric and
natural fibers within the layer. Such coform layers are
manufactured generally as described in U.S. Pat. Nos. 4,100,324;
4,604,313 and 5,350,624; which are herein incorporated by reference
to the extent they are consistent herewith. Typically, such coform
layers comprise a gas-formed matrix of thermoplastic polymeric
meltblown microfibers, such as, for example, polypropylene
microfibers, and cellulosic fibers, such as, for example, wood pulp
fibers. A coform layer is formed by initially forming at least one
primary air stream containing the synthetic or polymeric fibers and
merging the primary stream with at least one secondary stream of
natural or cellulosic fibers. The primary and secondary streams are
merged under turbulent conditions to form an integrated stream
containing a thorough, homogeneous distribution of the different
fibers. The integrated air stream is directed onto a forming
surface to air form the layer of material. A multiplicity of these
coform layers can then be formed in succession to provide a web of
multiple coform layers.
[0050] In a particular embodiment, the absorbent layer of the wipe
of the present invention comprises an outermost soft and flexible
layer. The outer soft layer may comprise a coformed layer of
meltblown linear low density polyethylene microfibers and wood pulp
fibers wherein the pulp to polymer weight ratio is from about 50/50
to about 75/25 and desirably about 65/35. A suitable polyethylene
is available from Dow under the trade designation DOW 6831A.
[0051] As noted above, the absorbent layer may also comprise a
strong resilient layer. The absorbent layer may comprise a single
strong resilient layer, or it may comprise an inner strong
resilient layer underlying a soft and flexible layer. The strong,
resilient layer can comprise a coformed layer of meltblown
polypropylene microfibers and wood pulp fibers wherein the pulp to
polymer weight ratio is from about 50/50 to about 75/25 and
desirably about 65/35. A suitable polypropylene is available from
Montel under the trade designation MONTEL PF015.
[0052] A family of polyesters suitable for the absorbent layer of
this invention is available from DuPont under the tradename
Sontara.RTM.. These polyesters comprise spunlaced
polyethyleneteraphthalate and optionally other fibers such as, for
example, wood fibers and rayon.
[0053] The different fibers in the different layers of the layered
absorbent layer of the present invention, such as the
polypropylene, polyethylene or polyester microfibers set forth
above, typically may not be compatible with and may not bond to
each other. However, the different fibers may entangle with each
other resulting in suitable securement between the layers. For
example, in a layered basesheet containing a coform layer of
polyethylene and cellulosic fibers and a coform layer of
polypropylene and cellulosic fibers, the polyethylene and
polypropylene fibers may entangle with each other and the
cellulosic fibers and may at least partially bond to the cellulosic
fibers which results in securement between the layers.
[0054] The absorbent layer may be optionally further processed by
quilting, embossing and/or needle-punching by mechanical means or
other means such as water jets.
[0055] Interlayer bonding and entanglement may be enhanced by a
thermo-mechanical process wherein the layered basesheet is passed
between a heated smooth anvil roll and a heated pattern roll. The
pattern roll may have any raised pattern, which provides the
desired entanglement and interlayer bonding. Desirably, the pattern
roll defines a raised pattern, which defines a plurality of bond
locations, which define a bond area of between about 4 and about 30
percent of the total area of the roll for improved interlayer
attachment.
[0056] The pressure between the rolls and the temperature of the
rolls must be balanced to produce a basesheet having adequate
strength and integrity while maintaining the softness of the outer
layers. The temperature and pressure may vary depending upon the
types of fibers being used to provide the desired wipe. In a
particular embodiment wherein the layers comprise at least one
layer of polyethylene fibers and at least one other layer of
polypropylene fibers, the pressure between the rolls may be between
about 5 and about 90 kilograms per lineal centimeter and the
temperature of at least one of the rolls may be between about 65
and about 95.degree. C. for improved entanglement and bonding.
Under such conditions of temperature and pressure, the polyethylene
fibers deform to provide mechanical entanglement with and possible
bonding to the polypropylene fibers. As a result, the layers become
entangled and bonded in discrete areas arranged in a pattern, which
corresponds to the raised pattern on the pattern roll.
[0057] The layered basesheet for the absorbent layer may have a
total basis weight of from about 25 to about 120 grams per square
meter and desirably from about 40 to about 90 grams per square
meter. Such basis weight of the layered basesheet may also vary
depending upon the desired end use of the wipe. For example, a
suitable basesheet for wiping the skin may define a basis weight of
from about 60 to about 80 grams per square meter and desirably
about 75 grams per square meter. In a particular embodiment wherein
the layered basesheet includes coform layers of polypropylene and
cellulosic fibers and polyethylene and cellulosic fibers, the
layered basesheet defines a basis weight of from about 60 to about
90 grams per square meter and desirably about 80 grams per square
meter for improved softness and adequate strength.
[0058] Each layer may or may not have a different basis weight
depending upon the desired properties such as strength and softness
of the wipe. For example, in a two-layer absorbent layer which
includes an inner layer of polypropylene and wood pulp fibers and
an outer layer of polyethylene and wood pulp fibers, the basis
weight of the layers may define an inner/outer layer weight ratio
of from about 80/10 to about 20/40, desirably about 50/25 to about
33/33 and more desirably about 40/30 based on a total weight of the
basesheet for improved performance.
[0059] The overall thickness of the absorbent layer may be varied
as desired depending upon the amount of absorbency required and is
typically between about 1 mm to about 15 mm thick.
[0060] Underlying the absorbent layer (2) is a layer of liquid
impermeable material (5) that forms a liquid impermeable cover
sheet that prevents passage of liquid within the absorbent layer to
the exterior of the wipe. The liquid impermeable cover sheet covers
the face of the absorbent layer and forms an effective barrier
between the person using the applicator and the liquid absorbed
into the pad. In that regard, the face of the liquid impermeable
cover sheet that contacts the nonwoven must be nonabsorbent and
impervious to any liquid and must be chemically inert to the
liquid.
[0061] The impermeable layer suitable for use in the present
invention comprises at least one layer of a polymer selected from
polymers in the group consisting of polyamides; polyolefins;
polyesters; polyethylene vinyl alcohol; polyvinylidene chloride and
anhydride-modified ethylene homo- and co-polymers. In a preferred
embodiment, the liquid impermeable cover sheet is formed from a
polyolefin, such as polyethylene or polypropylene or a polyester
such as polyethyleneteraphthalate.
[0062] Polyamides suitable for use herein include aliphatic
polyamides, amorphous polyamides, or a mixture thereof. "Aliphatic
polyamides" as the term is used herein can refer to aliphatic
polyamides, aliphatic copolyamides, and blends or mixtures of
these. Preferred aliphatic polyamides for use in the invention are
polyamide 6, polyamide 6.66, blends and mixtures thereof.
Polyamides 6.66 are commercially available under the tradenames
"Ultramid C4" and "Ultramid C35" from BASF, or under the tradename
"Ube5033FXD27" from Ube Industries Ltd. Polyamide 6 is commercially
available under the tradename Nylon 4.12 from E.I. du Pont de
Nemours and Company, for example.
[0063] The impermeable layer may further comprise other polyamides
such as those described in U.S. Pat. Nos. 5,408,000; 4,174,358;
3,393,210; 2,512,606; 2,312,966 and 2,241,322, which are
incorporated herein by reference. The film may also comprise
partially aromatic polyamides. A suitable partially aromatic
polyamide is the amorphous copolyamide 6-I/6-T of the following
formula: 1
[0064] Some suitable partially aromatic copolyamides for use in the
present invention are the amorphous nylon resins 6-I/6-T
commercially available under the tradename Selar.RTM. PA from E.I.
du Pont de Nemours and Company or commercially available under the
tradename Grivory.RTM. G 21 from EMS-Chemie AG, for example.
[0065] Polyolefins suitable for use in the present invention are
selected from polypropylenes, polyethylene polymers and copolymers.
Polyethylenes useful for use herein can be prepared by a variety of
methods, including well-known Ziegler-Natta catalyst polymerization
(see U.S. Pat. No. 4,076,698 and U.S. Pat. No. 3,645,992 for
examples), metallocene catalyst polymerization (see U.S. Pat. No.
5,198,401 and U.S. Pat. No. 5,405,922 for examples) and by free
radical polymerization. Polyethylene polymers useful herein can
include linear polyethylenes such as high density polyethylene
(HDPE), linear low density polyethylene (LLDPE), very low or
ultralow density polyethylenes (VLDPE or ULDPE) and branched
polyethylenes such as low density polyethylene (LDPE). The
densities of polyethylenes suitable for use in the present
invention range from 0.865 g/cc to 0.970 g/cc. Linear polyethylenes
for use herein can incorporate alpha-olefin comonomers such as
butene, hexene or octene to decrease their density within the
density range so described. The impermeable layer of the present
invention can comprise ethylene copolymers such as ethylene vinyl
acetate and ethylene methyl acrylate and ethylene (meth)acrylic
acid polymers. Polypropylene polymers useful in the practice of the
present invention include propylene homopolymers, impact modified
polypropylene and copolymers of propylene and alpha-olefins.
[0066] Polyethylene vinyl alcohol ("EVOH") having from about 20 to
about 50 mole % ethylene can be suitable for use herein. Suitable
polyethylene vinyl alcohol polymers are commercially available
under the tradename Evalca.RTM. from Kuraray or commercially
available under the tradename Soarnol.RTM. from Nippon Goshei, for
example.
[0067] Polyvinylidene chloride (PVDC) suitable for use herein can
be obtained commercially from Dow Chemical under the tradename
Saran.RTM., for example.
[0068] Examples of coated film include the Mylar RL and Mylar OL
films produced by DuPont Teijin Films.
[0069] It may be desirable to match the composition of the
impermeable layer and the absorbent layer to provide good
layer-to-layer adhesion. For example, if the absorbent layer
comprises polyethylene fibers, it may be desirable for the
impermeable layer to comprise polyethylene. Alternatively,
anhydride or acid-modified ethylene and propylene homo- and
co-polymers can be used as extrudable adhesive layers (also known
as "tie" layers) to improve bonding of layers of polymers together
when the polymers do not adhere well to each other, thus improving
the layer-to-layer adhesion in a multilayer structure. Depending on
the nature of the innermost layer of the impermeable structure, an
additional inner tie layer can optionally be included to provide a
desirable level of adhesion to the absorbent layer. The
compositions of the tie layers will be determined according to the
compositions of the adjoining layers that need to be bonded in a
multilayer structure. One skilled in the polymer art can select the
appropriate tie layer based on the other materials used in the
structure. Various tie layer compositions are commercially
available under the tradenames Bynel.RTM. or Appeel.RTM. from E.I.
du Pont de Nemours and Company, for example.
[0070] To form the peelable seal, the impermeable layer can be
sealed to itself by any means known in the art, such as laser
welding, induction sealing, or preferably heat sealing. The
impermeable layer may alternatively be sealed by application of a
solvent such as tetrahydrofuran to soften the layers prior to
adhering. If heat sealing is used to form the peelable seal, the
impermeable layer preferably consists of a bilayer or multilayer
coated or coextruded film so that the applied heat does not deform
the outermost part of the impermeable layer. Such multilayer
structures produced by coating or coextrusion are well known in the
flexible packaging art.
[0071] Impermeable films useful in the present invention can
additionally comprise optional materials, such as the conventional
additives used in polymer films including: plasticizers,
stabilizers, antioxidants, ultraviolet ray absorbers, hydrolytic
stabilizers, anti-static agents, dyes or pigments, fillers,
fire-retardants, lubricants, reinforcing agents such as glass fiber
and flakes, processing aids, antiblock agents, release agents,
and/or mixtures thereof.
[0072] The wipe may be optionally quilted or embossed by heat and
pressure. The wipe may be optionally quilted or embossed in any of
a number of ways, such as a pattern of parallel lines or of dots
formed by heat and pressure sufficient to deform the layers and
compress them together. As noted above, the basic wipe structure
may be formed in large sheets and then cut to the desired shape and
size. The margins, or portions thereof, of the top layer and the
second layer are secured together by any suitable means, such as by
heat sealing, application of a solvent such as tetrahydrofuran, or
hot melt adhesive, forming a peripheral seal. Sealing the edges of
the layers maintains the absorbent layer and any fluids absorbed
therein within the boundary of the impermeable cover sheet and
prevents migration of such fluids to the outside surface which is
an important safety and protection feature of the instant
applicator.
[0073] The applicators or wipes of the present invention comprise a
liquid that can be absorbed into the wipe basesheet (consisting of
the absorbent layer and the impermeable layer as described above)
and may include any suitable components which provide the desired
wiping properties. For example, the components may include water,
solvents, emollients, surfactants, fragrances, preservatives,
chelating agents, pH buffers, waxes, polishes or combinations
thereof as are well known to those skilled in the art. The liquid
may also contain lotions, sunscreen agents, insect repellents
and/or medicaments. The desired amount of liquid is applied to the
top face of the absorbent layer. The liquid incident upon the
surface of the absorbent layer is retained in the interstices or
pores until it is desorbed by wiping a surface. During use, the
applicator will desorb and distribute the liquid while protecting
persons using the applicator from contact with the liquid.
[0074] The amount of liquid contained within each wet wipe may vary
depending upon the type of material being used to provide the wet
wipe, the type of liquid being used and the desired end use of the
wet wipe. Generally, each wet wipe can contain from about 150 to
about 600 weight percent and desirably from about 250 to about 450
weight percent liquid based on the dry weight of the wipe for
improved wiping. In a particular aspect, the amount of liquid
contained within the wet wipe is from about 300 to about 400 weight
percent and desirably about 330 weight percent based on the dry
weight of the wet wipe.
[0075] Each wet wipe can be generally rectangular in shape and may
have any unfolded width and length suitable for its intended
application. For example, the wet wipe may have an unfolded length
of from about 2.0 to about 40.0 centimeters, alternatively from
about 5.0 to about 25.0 centimeters, alternatively from about 10.0
to about 20.0 centimeters; and unfolded width of from about 2.0 to
about 40.0 centimeters, alternatively from about 5.0 to about 25.0
centimeters, alternatively from about 10.0 to about 20.0
centimeters. Of note are wipes with an unfolded length of from
about 5.0 to about 10.0 centimeters and an unfolded width of from
about 5.0 to about 10.0 centimeters. Also of note are wipes with an
unfolded length of from about 10.0 to about 20.0 centimeters and an
unfolded width of from about 10.0 to about 20.0 centimeters.
[0076] Although the applicator is depicted in the Figures and
described as generally rectangular in shape, other shapes can be
embodied in the present invention. For example, an applicator
having a square shape can be folded along a center axis running
diagonally from opposite corners into a package having a generally
triangular shape. Alternatively, an applicator having a circular
shape can be folded along a center axis running through the
diameter of the applicator into a package having a generally
semicircular shape. Other shapes may also be envisioned, provided
that the shape is symmetrical about a center axis so that, by
folding, the areas of the two halves are coequal and coextensive
and the margins can be adhered together in a peelable seal.
[0077] In another preferred embodiment, the applicator of this
invention is provided with a handle means providing a grasping
portion by which the applicator may be grasped and used. The
optional handle means is positioned on the outside surface of the
liquid impermeable cover sheet so that the grasping portion is
isolated from the layer of absorbent material by the liquid
impermeable cover sheet. This makes more effective use of the
liquid impermeable cover sheet by effectively putting the hand,
particularly the fingers and thumb, of the user centrally behind
the impermeable sheet. In this manner, the hand of a person using
the applicator is effectively shielded from contact with the liquid
contained within the applicator.
[0078] The handle means may take many different forms. FIGS. 5 and
6 depict applicators of this invention that are provided with
handle means.
[0079] In one embodiment of the present invention the applicator is
similar to that described above, except that a handle means is
formed integral with the liquid impermeable material forming the
cover sheet. FIG. 5 shows an applicator (25) wherein the cover
sheet (26) is folded longitudinally along line C-C' to form a
gusset or pleat (27) defining a folded flap portion (28) by which
the applicator (25) may be grasped by insertion of one or more
fingers into the flap opening (29). The ends of the flap portion
(30) are secured with the edges of the cover sheets so that the
fold lies flat when not in use. Optionally, the fold (31) along
line C-C' is adhered to the cover sheet (26) when the peripheral
seals are made. FIG. 5 also illustrates a line D-D' that defines an
axis dividing the applicator (25) into two portions of equal area,
one portion (32) comprising the handle means (i.e. the gusset
(27)). The other portion (33) of the applicator (25) can be folded
along line D-D' to a position underlying and in contact with
portion (33). The two portions (32) and (33) can be adhered at the
margins (34) and (35) with a peelable seal as previously described
to form a liquid impermeable package.
[0080] In an alternative embodiment of the present invention the
applicator (33) is similar to that described above, except that a
handle means is formed of an elongate strip. FIG. 6 shows an
applicator (40) wherein the handle means is formed of an elongate
strip (41) that is adhesively secured to the liquid impermeable
cover sheet (42) at opposite end portions (43) and (44) of the
strip. The unsecured middle portion of the strip (45) forms an open
loop (46) defining the grasping portion by which the applicator may
be handled, but which lays flat when not in use. FIG. 6 also
illustrates a line E-E' that defines an axis dividing the
applicator (40) into two portions of equal area, one portion (47)
comprising the handle means (i.e. the strip (41)). The other
portion (48) of the applicator (40) can be folded along line E-E'
to a position underlying and in contact with portion (47). The two
portions (47) and (48) can be adhered at the margins (49) and (50)
with a peelable seal as previously described to form a liquid
impermeable package.
[0081] The layered basesheet for the wipe of the different aspects
of the present invention may be provided on a single manufacturing
line which includes multiple individual forming banks. Each forming
bank is configured to provide an individual layer having the
desired properties. For example, a forming bank may be configured
to provide the outer, soft layer of the absorbent layer. The
mechanical entanglement between the fibers of each layer during the
process provides attachment between the layers and may form bonds
between the adjacent layers to provide the layered basesheet.
Subsequent thermomechanical bonding may also be used on the layered
basesheet to improve the attachment between the layers.
[0082] Each forming bank may include the appropriate equipment to
provide the desired type of web. For example, if each layer
comprises a coform layer of meltblown microfibers and natural
fibers such as wood pulp fibers, each forming bank may include a
plurality of meltblowing dies as are well known to those skilled in
the art. In general, meltblowing processes include meltblowing dies
which are configured to extrude a molten polymeric material into
fine streams. The fine streams are then attenuated by converging
flows of high velocity gas to break the polymer streams into
discrete microfibers of small diameter. The stream or streams of
natural fibers which are converged with the streams of meltblown
microfibers may be provided by a conventional pulp picker roll
process as is well known to those skilled in the art.
[0083] Alternatively, one or more layers of the wipe of the
different aspects of the present invention can be made from a
different type of material such as a meltblown sheet of polymeric
microfibers. For example, a strong and resilient layer may include
a layer of meltblown polypropylene fibers while a soft layer may
include a coform layer of polyethylene and wood pulp fibers as
described above. The outer soft and flexible layers may otherwise
be provided by different types of materials such as airlaid, carded
web, or meltblown materials as are set forth above and which are
manufactured by processes well known to those skilled in the
art.
[0084] The impermeable layer of the present invention can be
prepared by (co)extrusion as follows: granulates of the various
components are melted in extruder(s). The molten polymers are
passed through a die or set of dies to form layer(s) of molten
polymers that are processed as a laminar flow. The molten polymers
are cooled to form a layered structure. Molten extruded polymers
can be converted into a film using a suitable converting technique.
For example, the basesheet for a wipe of the present invention can
be made by (co)extrusion of the impermeable layer followed by
lamination onto one or more other layers comprising the absorbent
layer. Other suitable converting techniques are, for example, blown
film extrusion, cast film extrusion, cast sheet extrusion,
extrusion coating, dispersion coating and solution coating. A web
of basesheet may be prepared wider than the desired width of the
finished wipe and can be slit longitudinally into strips of the
desired width.
[0085] As indicated above, the present invention also provides a
method of preparing the aforementioned applicator or wipe
comprising preparing an absorbent layer; preparing a web of liquid
impermeable material; joining said absorbent layer to said web at
their margins, or portions thereof, to form a peripheral seal;
applying liquid to said absorbent layer; and separating said web
into individual wipes. In a preferred embodiment, this invention
also provides a method of preparing the aforementioned applicator
or wipe further comprising folding the web along a center axis; and
sealing the web in a peelable seal in the dimensions of an
individual wipe.
[0086] For example, a web of absorbent material prepared as
described above is cut to length into individual pads by a
transverse cutter. The individual pads are advanced away from the
strips by a pair of rollers to form a space between successive rows
of absorbent pads.
[0087] A web of liquid impermeable film is provided, either
withdrawn from a supply roll or from a film fabrication machine,
and brought onto the advancing absorbent pads by a pair of rollers.
Heated rotating disks press the longitudinal edges and longitudinal
land areas of the absorbent web and impervious web together so that
such areas of the webs are adhesively secured together with a good
seal.
[0088] This invention also provides said methods further comprising
providing a handle means for said wipes. In one aspect of this
embodiment, strips of handle material may be withdrawn from supply
rolls and brought onto the advancing impermeable film to form
handle means on the outside surface of the film. In the alternative
case of an integrally formed handle, the web of impermeable film is
folded longitudinally by conventional folding means to form a
gusset or pleat therein defining a folded flap as a handle means.
Alternatively, the web may be prefolded and supplied with the
gusset or pleat already therein. Transverse bars seal the
impermeable web, the absorbent web and the handle means together in
the desired lengths for the finished wipe. The seal is applied in a
manner to securely attach the ends of the strip or gusset to the
film while allowing a free portion to lift away from the film for
easy handling of the wipe. Liquid, in an amount desired for the
finished wipe, is applied to each area of the absorbent layer
corresponding to the area of the finished wipe.
[0089] In a preferred embodiment, the wipe is prepared by folding
along a center axis and sealing at the margins to form a liquid
impermeable package to contain and preserve the preabsorbed liquid
until the consumer is ready to use the wipe. In a preferred
embodiment of a method of this invention, the web with liquid
applied is folded longitudinally along a central axis so that the
longitudinal edges are brought into contact. The longitudinal edges
are sealed with a peelable seal. The folded web then passes through
a transverse sealer/cutter which seals the transverse edges of the
wipes and simultaneously cuts the web into individual wipes.
Alternatively, the cutter perforates the web at the seal. This
allows the web to be maintained as a strip or roll of attached
wipes. Individual wipes can then be dispensed by severing the web
at the perforations.
[0090] In this embodiment, the liquid can be applied to the
absorbent layer prior to the formation of the peelable seal.
Alternatively, portion(s) of the peelable seal may be formed such
that there is an opening in the folded applicator, the liquid
applied to the absorbent layer through the opening, and the
remainder of the peelable seal formed to completely enclose the
absorbent layer and the absorbed liquid. For example, the wipe may
be folded and sealed on two sides of the package, liquid applied
through the open third side opposite the fold, and then the third
side is sealed.
[0091] The present invention also provides an apparatus for
preparing the aforementioned applicator or wipe comprising a means
for joining an absorbent layer to a web of liquid impermeable
material at their margins, or portions thereof; means for applying
a liquid to the absorbent layer; and a means for separating said
web into individual wipes.
[0092] In this embodiment, means for joining an absorbent layer to
a web of liquid impermeable material at their margins, or portions
thereof, include, for example, means for heat sealing, means for
application of a solvent such as tetrahydrofuran, or means for
applying hot melt adhesive. Heat sealing means include heated
rollers or bars.
[0093] Means for applying a liquid to the absorbent layer include,
for example, a liquid reservoir with at least one orifice to
dispense the liquid. Additional components may include valves,
tubing, measuring devices, and the like, that allow for application
of a specific portion of liquid to the absorbent layer.
[0094] Means for separating said web into individual wipes include
cutter bars or wheels as described above.
[0095] In a preferred embodiment, the present invention also
provides an apparatus for preparing the aforementioned applicator
or wipe further comprising a means for folding the web along a
center axis; and means for sealing the web in a peelable seal in
the dimensions of an individual wipe. Means for folding the web
along a center axis include, for example, a forming device to bring
the longitudinal margins of the impermeable wipe together in a
facing orientation. Means for sealing the web in a peelable seal in
the dimensions of an individual wipe include, for example, means
for heat sealing, means for application of a solvent such as
tetrahydrofuran, or means for applying hot melt adhesive.
[0096] This invention also provides said apparatus further
comprising means providing a handle means for said wipes. This
means includes, for example, means for supplying a handle means
comprising an elongate strip and adhering it to the web of
impermeable material. Means for adhering the strip to the web
include means for heat sealing, means for application of a solvent
such as tetrahydrofuran, or means for applying hot melt adhesive.
Typically, these means will adhere the handle means concurrently
with other aspects of assembling the wipe such as forming the
peripheral seal or the peelable seal. Means for forming an integral
handle comprising a pleat or gusset defining a folded flap include,
for example, a forming device to bring a portion of the web of
impermeable material into an overlying orientation with the
remainder of the web.
[0097] In the specification there have been set forth preferred
embodiments of the invention, and although specific terms are
employed, they are used in a generic and descriptive sense only and
not for purposes of limitation. The foregoing has been illustrative
of the principles of the present invention as embodied in a
preferred form thereof. Various modifications or alternative forms
may occur to workers in the art without departing from the spirit
and scope of the invention.
* * * * *