U.S. patent application number 10/674174 was filed with the patent office on 2005-03-31 for closure system and method of manufacture.
This patent application is currently assigned to 3M Innovative Properties Company. Invention is credited to Jackson, Byron M., Wood, Leigh E..
Application Number | 20050066486 10/674174 |
Document ID | / |
Family ID | 34376816 |
Filed Date | 2005-03-31 |
United States Patent
Application |
20050066486 |
Kind Code |
A1 |
Wood, Leigh E. ; et
al. |
March 31, 2005 |
Closure system and method of manufacture
Abstract
A closure system that combines a base tab with a stable carrier
tab for supporting a fastening component and methods of
manufacturing the closure system are disclosed. The carrier tab
overlaps only one side of the base tab and is connected to the base
tab by a bonding tape. The bonding tape is located over the inner
edge of the carrier tab with a portion of the bonding tape being
attached to the base tab and another portion of the bonding tape
being attached to the carrier tab. As a result, a portion of the
carrier tab is located between the bonding tape and the base
tab.
Inventors: |
Wood, Leigh E.; (Woodbury,
MN) ; Jackson, Byron M.; (Forest Lake, MN) |
Correspondence
Address: |
3M INNOVATIVE PROPERTIES COMPANY
PO BOX 33427
ST. PAUL
MN
55133-3427
US
|
Assignee: |
3M Innovative Properties
Company
|
Family ID: |
34376816 |
Appl. No.: |
10/674174 |
Filed: |
September 29, 2003 |
Current U.S.
Class: |
24/442 |
Current CPC
Class: |
Y10T 24/27 20150115;
A61F 13/58 20130101; A61F 13/15756 20130101 |
Class at
Publication: |
024/442 |
International
Class: |
A44B 001/04 |
Claims
1. A closure system comprising: a base tab comprising an outer edge
and first and second major surfaces; a carrier tab comprising first
and second major surfaces, an inner edge, and an opposing outer
edge, the inner edge and the outer edge defining a length of the
carrier tab; a fastener component attached to at least one of the
first and second major surfaces of the carrier tab; an overlap
region in which a portion of the first major surface of the carrier
tab faces the second major surface of the base tab such that the
outer edge of the base tab is located between the inner and outer
edges of the carrier tab; and bonding tape attached to the second
major surface of the base tab adjacent the overlap region, the
bonding tape further attached to the first major surface of the
carrier tab within the overlap region, wherein the inner edge of
the carrier tab is located between the bonding tape and the second
major surface of the base tab.
2. A closure system according to claim 1, wherein no adhesive is
located between the first major surface of the carrier tab and the
second major surface of the base tab within the overlap region.
3. A closure system according to claim 1, wherein at least a
portion of the base tab exhibits elasticity.
4. A closure system according to claim 1, wherein the bonding tape
is adhesively attached to the base tab and the carrier tab.
5. A closure system according to claim 1, wherein the bonding tape
is welded to the base tab and the carrier tab.
6. A closure system according to claim 1, wherein the bonding tape
is adhesively attached and welded to the base tab and the carrier
tab.
7. A closure system according to claim 1, wherein the bonding tape
comprises a layer of pressure sensitive adhesive facing the base
tab and the carrier tab.
8. A closure system according to claim 1, wherein the carrier tab
is inelastic.
9. A closure system according to claim 1, wherein the bonding tape
is inelastic.
10. A closure system according to claim 1, wherein the base tab
comprises an integral portion of a disposable garment.
11. A closure system according to claim 1, wherein the fastener
component is adhesively attached to the carrier tab.
12. A closure system according to claim 1, wherein the fastener
component comprises a mechanical fastener component.
13. A closure system according to claim 1, wherein the bonding tape
is coextensive with a width of the carrier tab as measured
transverse to the length of the carrier tab.
14. A closure system according to claim 1, wherein the fastener
component is coextensive with a width of the carrier tab as
measured transverse to the length of the carrier tab.
15. A closure system comprising: an elastic base tab comprising an
outer edge and first and second major surfaces; a carrier tab
comprising first and second major surfaces, an inner edge, and an
opposing outer edge, the inner edge and the outer edge defining a
length of the carrier tab, wherein the carrier tab is inelastic; a
fastener component attached to at least one of the first and second
major surfaces of the carrier tab; an overlap region in which a
portion of the first major surface of the carrier tab faces the
second major surface of the elastic base tab such that the outer
edge of the elastic base tab is located between the inner and outer
edges of the carrier tab; and a bonding tape adhesively attached
and welded to the second major surface of the elastic base tab
adjacent the overlap region, the bonding tape further adhesively
attached and welded to the first major surface of the carrier tab
within the overlap region, wherein the inner edge of the carrier
tab is located between the bonding tape and the second major
surface of the elastic base tab, and further wherein the bonding
tape is inelastic.
16. A method of manufacturing a composite web for closure systems,
the method comprising: providing a base tab web comprising an outer
edge and first and second major surfaces; providing a carrier tab
web comprising first and second major surfaces, an inner edge, and
an opposing outer edge; aligning the base tab web and the carrier
tab web to form an overlap region in which a portion of the first
major surface of the carrier tab web faces the second major surface
of the base tab web such that the outer edge of the base tab web is
located between the inner and outer edges of the carrier tab web;
aligning a bonding tape over the inner edge of the carrier tab web,
wherein the inner edge of the carrier tab web is located between
the bonding tape and the second major surface of the base tab web;
attaching the bonding tape to the second major surface of the base
tab web adjacent the overlap region; attaching the bonding tape to
the first major surface of the carrier tab web within the overlap
region; and attaching a fastener component web to at least one of
the first and second major surfaces of the carrier tab web.
17. A method according to claim 16, wherein no adhesive is located
between the first major surface of the carrier tab web and the
second major surface of the base tab web within the overlap
region.
18. A method according to claim 16, wherein at least a portion of
the base tab web comprises elastic sheet material.
19. A method according to claim 16, wherein attaching the bonding
tape to the base tab web and the carrier tab web comprises
adhesively attaching the bonding tape to the base tab web and the
carrier tab web.
20. A method according to claim 16, wherein attaching the bonding
tape to the base tab web and the carrier tab web comprises welding
the bonding tape to the base tab web and the carrier tab web.
21. A method according to claim 16, wherein attaching the bonding
tape to the base tab web and the carrier tab web comprises
adhesively attaching the bonding tape to the base tab web and the
carrier tab web and welding the bonding tape to the base tab web
and the carrier tab web.
22. A method according to claim 16, wherein the bonding tape
comprises a layer of pressure sensitive adhesive facing the base
tab web and the carrier tab web.
23. A method according to claim 16, wherein the carrier tab web is
inelastic.
24. A method according to claim 16, wherein the bonding tape is
inelastic.
25. A method according to claim 16, wherein attaching the fastener
component web to the carrier tab web comprises adhesively attaching
the fastener component web to the carrier tab web.
26. A method according to claim 16, wherein the fastener component
web comprises a mechanical fastener component web.
27. A method according to claim 16, further comprising separating
the composite web into a plurality of discrete closure systems
after attaching the bonding tape web to the base tab web and the
carrier tab web and attaching the fastener component web to the
carrier tab web, wherein each discrete closure system of the
plurality of discrete closure systems comprises a base tab, carrier
tab, a bonding tape, and a fastener component.
28. A method of manufacturing a composite web for closure systems,
the method comprising: providing an elastic base tab web comprising
an outer edge and first and second major surfaces; providing a
carrier tab web comprising first and second major surfaces, an
inner edge, and an opposing outer edge, wherein the carrier tab web
is inelastic; aligning the elastic base tab web and the carrier tab
web to form an overlap region in which a portion of the first major
surface of the carrier tab web faces the second major surface of
the elastic base tab web such that the outer edge of the elastic
base tab web is located between the inner and outer edges of the
carrier tab web; aligning a bonding tape over the inner edge of the
carrier tab web, wherein the inner edge of the carrier tab web is
located between the bonding tape and the second major surface of
the elastic base tab web, and wherein the bonding tape is
inelastic, and further wherein the bonding tape comprises a layer
of pressure sensitive adhesive facing the elastic base tab web and
the carrier tab web; adhesively attaching and welding the bonding
tape to the second major surface of the elastic base tab web
adjacent the overlap region; adhesively attaching and welding the
bonding tape to the first major surface of the carrier tab web
within the overlap region; and attaching a fastener component web
to at least one of the first and second major surfaces of the
carrier tab web.
Description
[0001] The manufacture of closure systems for use in articles such
as, e.g., disposable diapers, may often involve adhesive attachment
of the different components in the closure systems. Application of
adhesives to the various components can, however raise issues with
respect to control over delivery and placement of the adhesive.
Problems with accurate adhesive delivery and placement can limit
throughput in production lines. Adhesive control and placement can
also adversely affect product quality if, e.g., the adhesive is
misapplied or migrates to unwanted locations after application.
[0002] Many closure systems incorporate elastic materials to
provide elasticity to the articles into which they are
incorporated. If, e.g., the articles are garments designed to be
worn, the elasticity of a closure system may be useful for
providing dynamic fit or comfort as the wearer moves. In articles
that are not designed to be worn by an individual, the elasticity
may provide improved robustness to the closure system in response
to forces that could otherwise cause the closure system to release
undesirably.
[0003] Although elasticity may be a desirable characteristic, it
can be difficult to incorporate elastic components into a closure
system while still retaining the ability of the closure system to
function properly. For example, it is generally difficult to
provide mechanical fasteners, e.g., hook and loop closures,
hermaphroditic closures, etc. on elastic substrates.
SUMMARY OF THE INVENTION
[0004] The present invention provides a closure system that
combines a base tab with a stable carrier tab for supporting a
fastening component. The carrier tab overlaps only one side of the
base tab and is connected to the base tab by a bonding tape. The
bonding tape is located over the inner edge of the carrier tab with
a portion of the bonding tape being attached to the base tab and
another portion of the bonding tape being attached to the carrier
tab. As a result, a portion of the carrier tab is located between
the bonding tape and the base tab.
[0005] Potential advantages of this construction are numerous. For
example, the bonding tape may include a layer of adhesive facing
the base tab and the carrier tab. As a result, adhesive attachment
of the carrier tab to the base tab during manufacturing can be
accomplished without applying adhesive alone to either the base tab
or the carrier tab.
[0006] Another potential advantage of using an adhesive bonding
tape is that, if the closure is to be used in a garment such as,
e.g., a diaper, the potential for exposure of any adhesive to the
skin of a wearer can be reduced or eliminated. The adhesive is
located only on the bonding tape which is attached to the other
components of the closure, thus eliminating exposed adhesive on the
closure (unless that adhesive is used in the controlled environment
of the fastener component as discussed herein).
[0007] In one aspect, the present invention provides a closure
system including a base tab with an outer edge and first and second
major surfaces; a carrier tab having first and second major
surfaces, an inner edge, and an opposing outer edge, the inner edge
and the outer edge defining a length of the carrier tab; a fastener
component attached to at least one of the first and second major
surfaces of the carrier tab; an overlap region in which a portion
of the first major surface of the carrier tab faces the second
major surface of the base tab such that the outer edge of the base
tab is located between the inner and outer edges of the carrier
tab; and bonding tape attached to the second major surface of the
base tab adjacent the overlap region, the bonding tape further
attached to the first major surface of the carrier tab within the
overlap region, wherein the inner edge of the carrier tab is
located between the bonding tape and the second major surface of
the base tab.
[0008] In another aspect, the present invention provides a closure
system including an elastic base tab with an outer edge and first
and second major surfaces; a carrier tab with first and second
major surfaces, an inner edge, and an opposing outer edge, the
inner edge and the outer edge defining a length of the carrier tab,
wherein the carrier tab is inelastic; a fastener component attached
to at least one of the first and second major surfaces of the
carrier tab; an overlap region in which a portion of the first
major surface of the carrier tab faces the second major surface of
the elastic base tab such that the outer edge of the elastic base
tab is located between the inner and outer edges of the carrier
tab; and a bonding tape adhesively attached and welded to the
second major surface of the elastic base tab adjacent the overlap
region, the bonding tape further adhesively attached and welded to
the first major surface of the carrier tab within the overlap
region, wherein the inner edge of the carrier tab is located
between the bonding tape and the second major surface of the
elastic base tab, and further wherein the bonding tape is
inelastic.
[0009] In another aspect, the present invention provides a method
of manufacturing a composite web for closure systems by providing a
base tab web having an outer edge and first and second major
surfaces; providing a carrier tab web having first and second major
surfaces, an inner edge, and an opposing outer edge; aligning the
base tab web and the carrier tab web to form an overlap region in
which a portion of the first major surface of the carrier tab web
faces the second major surface of the base tab web such that the
outer edge of the base tab web is located between the inner and
outer edges of the carrier tab web; aligning a bonding tape over
the inner edge of the carrier tab web, wherein the inner edge of
the carrier tab web is located between the bonding tape and the
second major surface of the base tab web; attaching the bonding
tape to the second major surface of the base tab web adjacent the
overlap region; attaching the bonding tape to the first major
surface of the carrier tab web within the overlap region; and
attaching a fastener component web to at least one of the first and
second major surfaces of the carrier tab web.
[0010] In another aspect, the present invention provides a method
of manufacturing a composite web for closure systems by providing
an elastic base tab web having an outer edge and first and second
major surfaces; providing a carrier tab web having first and second
major surfaces, an inner edge, and an opposing outer edge, wherein
the carrier tab web is inelastic; aligning the elastic base tab web
and the carrier tab web to form an overlap region in which a
portion of the first major surface of the carrier tab web faces the
second major surface of the elastic base tab web such that the
outer edge of the elastic base tab web is located between the inner
and outer edges of the carrier tab web; aligning a bonding tape
over the inner edge of the carrier tab web, wherein the inner edge
of the carrier tab web is located between the bonding tape and the
second major surface of the elastic base tab web, and wherein the
bonding tape is inelastic, and further wherein the bonding tape
includes a layer of pressure sensitive adhesive facing the elastic
base tab web and the carrier tab web; adhesively attaching and
welding the bonding tape to the second major surface of the elastic
base tab web adjacent the overlap region; adhesively attaching and
welding the bonding tape to the first major surface of the carrier
tab web within the overlap region; and attaching a fastener
component web to at least one of the first and second major
surfaces of the carrier tab web.
[0011] These and other features and advantages of the present
invention may be described in more detail below with respect to
various illustrative embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an edge view of one closure system according to
the present invention.
[0013] FIG. 2 is a plan view of the closure system of FIG. 1 taken
from below the closure system as seen in FIG. 1.
[0014] FIG. 3 is a diagram of one process of manufacturing a
closure system according to the present invention.
[0015] FIG. 4 is a view of two closure systems of the present
invention attached to an article.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS OF THE
INVENTION
[0016] In the following detailed description of illustrative
embodiments, reference is made to the accompanying figures of the
drawing which form a part hereof, and in which are shown by way of
illustration specific embodiments in which the invention may be
practiced. It is to be understood that other embodiments may be
utilized and structural changes may be made without departing from
the scope of the present invention.
[0017] FIG. 1 is an edge view and FIG. 2 is a plan view of one
illustrative embodiment of a closure system according to the
present invention. The closure system includes a base tab 10, a
carrier tab 20, a bonding tape 30 and a fastener component 40
located on the carrier tab 20. The view of FIG. 2 is taken from
below the edge view depicted in FIG. 1, i.e., from the side on
which the bonding tape 30 is located.
[0018] The base tab 10 includes first and second major surfaces 11
and 12 (respectively). The base tab 10 also includes an inner edge
13 and an outer edge 14. It may be preferred that the base tab 10
be flexible such that it can be processed using conventional web
processing equipment.
[0019] The base tab 10 may exhibit elasticity in primarily the
directions indicated by double-headed arrow 15 in FIG. 2, or it may
exhibit elasticity in any or all directions. Elasticity in all
directions is not, however required for an elastic base tab 10. As
used herein "elastic" and "elasticity" (and variations thereof)
refer to the ability of the base tab 10 or at least a portion of
the tab, if elongated in response to a load, to recover to a state
that is at or near it's original state (i.e., before elongation)
after removal of the load causing the elongation. The recovery
preferably occurs within a relatively short period of time (e.g.,
one minute or less).
[0020] Suitable sheet materials for the base tab 10 may be unitary,
homogeneous materials (e.g., polymeric films, nonwovens, woven
fabrics, knitted fabrics, paper, etc.). Alternatively, they may be
laminated or composite sheet materials. If the base tab 10 is to be
elastic or include portions that are elastic, laminated sheet
materials used for the base tab 10 may include only one or more
components that exhibits elasticity, but in which the laminated
sheet material as a whole exhibits desired elastic
characteristics.
[0021] Examples of some potentially suitable elastic sheet
materials for the base tab 10 may be described in, e.g., U.S. Pat.
Nos. 5,653,704 (Buell et al.); 5,807,368 (Helmer); 5,840,412 (Wood
et al.); 5,885,908 (Jaeger et al.); 6,159,584 (Eaton et al.); and
6,270,910 (Jaeger et al.).
[0022] Elastic sheet materials suitable for the base tab 10 may or
may not be activated (i.e., stretched to activate the elastic
properties of the sheet material as is known in the art). The sheet
materials used for the base tabs 10 may include portions or zones
that do not exhibit elasticity (either because they are incapable
of exhibiting elasticity or they have not been activated). Also,
the sheet materials used for the base tab 10 may include one or
more nonwoven fibrous outer layers (as described in, e.g., U.S.
Pat. No. 5,807,368 to Helmer).
[0023] Although the base tab 10 is depicted as having an inner edge
13, it should be understood that in some instances, the base tab 10
will be an integral extension or portion of a larger article (e.g.,
a diaper, adult incontinence device, gown, etc) and, as such, may
not have a defined inner edge 13 as depicted in connection with the
illustrative closure system of FIGS. 1 & 2.
[0024] The outer edge 14 of the base tab 10 is the edge from which
the carrier tab 20 extends when attached to the closure system.
Although the outer edge 14 is depicted as a straight edge, it will
be understood that outer edge 14 could take any suitable shape,
e.g., curvilinear, sinusoidal, sawtooth, etc.
[0025] The carrier tab 20 includes first and second major surfaces
21 and 22 along with an inner edge 23 and an outer edge 24. The
carrier tab 20 may be manufactured of any suitable sheet material,
but may preferably be inelastic. As used herein, "inelastic" means
that the carrier tab 20 will not exhibit significant recovery after
elongation in response to a load, i.e., substantially all of the
elongation will be permanent. It may be preferred that, in addition
to preferably being inelastic, the carrier tab 20 be substantially
inextensible when used as intended in an article (e.g., a
disposable garment, diaper, incontinence device, etc.).
[0026] Suitable materials for the carrier tab 20 may be any sheet
material that provides the desired inelastic and inextensible
characteristics. It may be preferred that the carrier tab 20 be
flexible such that it can be processed using conventional web
processing equipment. Examples of suitable materials may include
unitary, homogeneous materials (e.g., films, nonwovens, woven
fabrics, etc.). Alternatively, the suitable materials may be
laminated or composite sheet structures that, as a whole, exhibit
the desired characteristics, e.g., inelasticity, inextensibility,
etc. Regardless of the specific constructions of the materials for
the carrier tab 20, the materials preferably provide at least an
area of at least one surface suitable for attachment of a fastener
component as discussed herein.
[0027] Examples of some potentially suitable sheet materials for
the carrier tab are cloth (woven, knitted, etc.), paper, cellophane
film, polymeric films (e.g., polyolefin, poly (ethylene
terephthalate), poly(vinyl chloride), etc.), nonwoven materials
(such as, e.g., meltblown or spunbond webs), etc. Laminates may
also be used as sheet materials for the carrier tab, e.g.,
polymeric film/nonwoven laminates, etc. Suitable polymeric sheet
materials for the carrier tab 20 may be described in, e.g., U.S.
Pat. Nos. 4,237,889 (Gobran); 4,769,283 (Sipinen et al.); and
4,808,474 (Sipinen).
[0028] The base tab 10 and the carrier tab 20 are attached to each
other using the bonding tape 30. Bonding tape 30 is attached to
major surface 12 of the base tab 10 and major surface 22 of the
carrier tab 20. As such, the inner edge 23 of the carrier tape 20
is located between major surface 12 of base tab 10 and the bonding
tape 30. Bonding tape 30 includes an inner edge 32 and an outer
edge 34, with the inner edge 32 being located on major surface 12
of the base tab 10 between inner edge 13 and outer edge 14 of the
base tab 10. The outer edge 34 of the bonding tape 30 is located on
second major surface 22 of the carrier tab 20 between the inner
edge 23 and the outer edge 24 of the carrier tab 20.
[0029] Bonding tape 30 is preferably inelastic. As a result, the
elasticity of the portion of the base tab 10 attached to the
bonding tape 30 is restrained, i.e., it does not operate
elastically because it is constrained by the inelastic nature of
the bonding tape 30.
[0030] Bonding tape 30 may preferably, but not necessarily, include
a layer of adhesive 36 on its surface facing the base tab 10 and
the carrier tab 20. The adhesive 36 may preferably be a
pressure-sensitive adhesive such as the pressure-sensitive
adhesives described in, e.g., U.S. Pat. Nos. 3,932,328 (Korpman)
and 5,019,071 (Bany et al.). Other attachment or bonding techniques
may be used in place of pressure sensitive adhesives, e.g.,
heat-activated bonding (as described in, e.g., U.S. Pat. No.
4,973,326 (Wood et al.)) or the construction adhesives described in
connection with disposable diaper manufacturing in U.S. Pat. Nos.
5,149,741 (Alper et al.) and 6,184,285 B1 (Hatfield et al.).
[0031] In some instances, the only attachment between the bonding
tape 30 and the base tab 10 and carrier tab 20 may be an adhesive
attachment using the adhesive 36 on the bonding tape 30.
Alternatively, it may be preferred to supplement the adhesive
attachment provided by the adhesive 36 by welding the bonding tape
30 to the base tab 10 and/or the carrier tab 20. The welding may be
performed by any suitable technique, e.g., chemical welds (using,
e.g., solvents), ultrasonic welds, heat sealing, heat welding, etc.
Another welding technique that may be used is dynamic mechanical
welding as described in, e.g., U.S. Pat. Nos. 4,854,984 and
4,919,738 (both to Ball et al.).
[0032] If welding is to be used as a supplement to adhesive
attachment, the adhesive 36 should be compatible with the welding
technique to be employed, both in the composition of the adhesive
36 and in how it is provided on the bonding tape 30. For example,
it may be desirable to provide a thinner layer of adhesive 36 on
the bonding tape 30 if welding is to be used to supplement the
adhesive. The thinner layer of adhesive may preferably provide a
positioning bond to position the base tab 10, carrier tab 20 and
bonding tape 30 in the manufacturing process until the bonding tape
30 can be welded into place. Other alternatives to a thinner layer
of adhesive may include pattern coating the bonding tape 30 such
that areas to be welded may be free of or include thinner layers of
adhesive 36 than the surrounding areas on the bonding tape.
[0033] Also, if welding is to be used to attach the bonding tape 30
to the base tab 10 and the carrier tab 20, the materials present on
the surfaces facing each other are preferably compatible with the
welding technique to be used. For example, the bonding tape 30 may
preferably have a film backing amenable to welding or be a
composite that includes a film layer that is amenable to welding.
Similarly, the second major surface 12 of the base tab 10 and the
second major surface 22 of the carrier tab 20 to which the bonding
tape 30 is welded are also preferably of a composition that is
amenable to welding.
[0034] Although the bonding tape 30 is depicted with adhesive 36,
the use of an adhesive to attach the bonding tape 30 to the base
tab 10 and the carrier tab 20 is optional. In some instances the
bonding tape 30 may be attached to the base tab 10 and/or carrier
tab solely by welding. The welding may be performed by any suitable
technique, e.g., chemical welds (using, e.g., solvents), ultrasonic
welds, heat sealing, heat welding, etc. Another welding technique
that may be used is dynamic mechanical welding as described in,
e.g., U.S. Pat. Nos. 4,854,984 and 4,919,738 (both to Ball et
al.).
[0035] In the arrangement of the base tab 10 and the carrier tab
20, it may be preferred that the two tabs overlap each other such
that an overlap region 18 be created. The boundaries of the overlap
region 18 are defined by the outer edge 14 of the base tab 10 and
the inner edge 23 of the carrier tab 20 (along with the sides of
the base tab 10 and the carrier tab 20). As a result, the outer
edge 14 of the base tab 10 is located between the inner edge 23 and
the outer edge 24 of the carrier tab 20. The boundaries of the
overlap region 18 are seen in FIG. 2 where the outer edge 14 of the
base tab 10 and the inner edge 23 of the carrier tab 20 are
depicted as hidden (broken) lines because they are located on the
opposite side of the bonding tape 30.
[0036] Within the overlap region 18, the major surface 21 of the
carrier tab 20 faces the major surface 12 of the base tab 10. In
the depicted embodiment, no adhesive is provided between the major
surface 21 of the carrier tab 20 and the major surface 12 of the
base tab 10, i.e., the surface 21 of the carrier tab 20 is not
adhered to the surface 12 of the base tab 10. Rather, the
attachment of the base tab 10 and the carrier tab 20 is
accomplished through the bonding tape 30 which is attached to the
second major surface 12 of the base tab 10 and the second major
surface 22 of the carrier tab 20.
[0037] The overlap region 18 may preferably be located within the
boundaries of the bonding tape 30. By overlapping the base tab 10
and the carrier tab 20, any adhesive 36 that is on the side of the
bonding tape 30 facing the base tab 10 and the carrier tab 20 is
covered by either or both of the base tab 10 and the carrier tab
20. Alternatively, the overlap region 18 may extend outside of the
boundaries of the boding tape 30. For example, the outer edge 14 of
the base tab 10 may be located between the outer edge 34 of the
bonding tape 30 and the outer edge 24 of the carrier tab 20. In the
depicted embodiment, however, the outer edge 14 of the base tab 10
is located between the inner edge 32 and the outer edge 34 of the
bonding tape 30, i.e., within the boundaries of the bonding tape
30.
[0038] The bonding tape 30 in the illustrative embodiment of FIGS.
1 & 2 also depicts another optional feature, i.e., that the
bonding tape 30 is coextensive with the width of the carrier tab
20, where the width of the carrier tab 20 is measured transverse to
the direction defined by double-headed arrow 15 in FIG. 2. Although
the bonding tape 30 is also coextensive with the width of the base
tab 10, the bonding tape 30 may not always be coextensive with the
base tab 10 (when, e.g., the carrier tab 20 has a narrower width
than the base tab 10).
[0039] The closure system of FIGS. 1 & 2 also includes a
fastener component 40 located on the carrier tab 20. The fastener
component 40 may be attached to the carrier tab 20 by any suitable
technique or combination of techniques. Some suitable techniques
may include one or more adhesives, welding (thermal, ultrasonic,
dynamic mechanical bonding, chemical, etc.), clips, staples,
sewing, etc.
[0040] Although the depicted fastener component 40 is attached to
the second major surface 22 of the carrier tab 20, it could
alternatively be attached to the first major surface 21. In still
another alternative, fastener components could be attached to both
the first and second major surfaces 21 and 22 of the carrier tab
20.
[0041] The depicted fastener component 40 is a hook mechanical
fastener that includes stems 46 (e.g., hooks, mushroom-shaped
structures, etc.) to fasten articles together. Such fastening
systems are well known in the art and some suitable examples may be
described in U.S. Pat. Nos. 4,894,060 (Nestegard) and 5,077,870
(Melbye et al.). The fastener component 40 may alternatively be the
loop component of a hook-and-loop closure system. Some loop
components are described in, e.g., U.S. Pat. Nos. 5,616,394
(Gorman) and 5,605,729 (Mody). In place of hook-and-loop closures,
the fastener component 40 may rely on any known fastening
technology, e.g., pressure-sensitive adhesive, hermaphroditic
closures, cohesive materials, non-tacky adhesive, etc.
[0042] Turning to FIG. 3, a diagram of one method of manufacturing
closure systems is depicted. The manufacturing method involves the
use of webs for each of the components in the closure system such
that high speed and/or economical manufacturing can be provided.
The webs provided to manufacture the closure systems include a base
tab web 110, a carrier tab web 120, a bonding tape 130, and a
fastener web 140 which, taken together, form a composite web 100.
The webs and resulting composite web 100 preferably progress along
a machine direction as indicated by arrow 102 through web
processing equipment during the manufacturing process.
[0043] The base tab web 110 may be an elastic sheet material of
which all of the web 110 is elastic. Alternatively, the sheet
materials used for the base tab web 110 may include one or more
portions or zones that do not exhibit elasticity (either because
they are incapable of exhibiting elasticity or they have not been
activated).
[0044] As seen in FIG. 3, the base tab web 110 and the carrier tab
web 120 are aligned such that they form an overlap region 118 in
which a portion of the major surface 121 of the carrier tab web 120
faces the major surface 112 of the base tab web 110. Because of the
overlap region 118, the outer edge 114 of the base tab web 110 is
located between the inner edge 123 and the outer edge 124 of the
carrier tab web 120. It is preferred that no adhesive be located
between the major surface 121 of the carrier tab web 120 and the
major surface 112 of the base tab web 110 within the overlap region
118.
[0045] The depicted method also includes aligning the bonding tape
130 over the inner edge 123 of the carrier tab web 120 such that
the inner edge 123 of the carrier tab web 120 is located between
the bonding tape 130 and major surface 112 of the base tab web
110.
[0046] The bonding tape 130 is attached to the major surface 112 of
the base tab web 110 adjacent the overlap region 118, i.e., between
the edge 132 of the bonding tape 130 and the inner edge 123 of the
carrier tab web 120. The bonding tape 130 is also attached to major
surface 122 of the carrier tab web 120, i.e., between the inner
edge 123 of the carrier tab web 120 and edge 134 of the bonding
tape 130.
[0047] The bonding tape 130 may be attached to the base tab web 110
and the carrier tab web 120 by any suitable technique or
combination of techniques. Various approaches to attaching the
bonding tape 130 to the base tabs and carrier tabs are described
above in connection with FIGS. 1 & 2 and that discussion will
not be repeated here except to note that the attachment of the
various webs may occur in any desired order. For example, the
bonding tape 130 may be attached to the carrier tab web 120 before
or after the base tab web 110 is aligned with the carrier tab web
120 to define the overlap region 118. Alternatively, alignment of
the base tab web 110 and the carrier tab web 120 may occur before
the bonding tape is attached to either web.
[0048] If an adhesive 136 is provided on the bonding tape 130 as
seen in FIG. 3, the adhesive 136 may preferably be applied to the
bonding tape 130 in an off-line operation. For example, the
adhesive 136 may preferably be coated on or transferred to the
bonding tape 130 before the bonding tape 130 separately, followed
by winding of the bonding tape 130 with the adhesive 136. When used
in the depicted method, the bonding tape 130 with adhesive 136 is
unwound and directed into the process. Those skilled in the art of
web processing will, however, understand that the adhesive 136
could alternatively be coated with adhesive in-line with the
manufacturing process depicted in FIG. 3.
[0049] Another portion of the method depicted in FIG. 3 is the
alignment and attachment of the fastener component web 140 to the
carrier tab web 120. In the depicted method, the fastener component
web 140 includes an adhesive layer 148 that may be used to attach
the fastener component web 140 to major surface 122 of the carrier
tab web 120, although any suitable technique or combination of
techniques could be used to attach the fastener component web 140
to the carrier tab web 120.
[0050] Also, although the fastener component web 140 is depicted as
being attached to the major surface 122 of carrier tab web 120, it
will be understood that the fastener component web 140 could be
attached to the opposite major surface 121 of the carrier tab web
120. In another alternative, fastener component webs could be
attached to both major surfaces 121 and 122 of carrier tab web 120.
It is also contemplated that the fastener components, if attached
to both major surfaces 121 and 122, may not be the same. As one
example, the fastener component on one major surface may be a hook
fastener while the fastener component on the opposite major surface
may the complementary loop fastener. Also, more than one fastener
component web could be attached to any one of the major surfaces
121 and 122 of the carrier tab web 120.
[0051] After the various webs have been aligned and attached,
closure systems (such as those depicted in FIGS. 1 & 2) can be
produced by separating the composite web 100 along a direction
generally transverse to the machine direction as indicated by arrow
102. Furthermore, although the composite web 100 depicted in FIG. 3
can be sheeted into a single or "one-up" row of closure systems, it
will be understood that carrier tab web 120 could be widened and an
additional base tab web, bonding tape 130 and fastener component
web 140 could be attached to form a "two-up" composite web that
could be sheeted into two rows of closure systems. Example of
sheeting patterns that may be used to separate "two-up" composite
webs are depicted in, e.g., FIG. 4 of U.S. Pat. No. 5,399,219
(Roessler et al.) and FIG. 9B of U.S. Pat. No. 6,406,467 B1 (Dilnik
et al.).
[0052] FIG. 4 is a plan view of an article that includes a pair of
closure systems manufactured in accordance with the present
invention. The depicted article 250 is an absorbent garment, e.g.,
a diaper or adult incontinence device. As discussed above, however,
the closure systems of the present invention may be used on any
garment (e.g., a gown, robe, vest, etc.) or any other article
requiring a fastening element (e.g., cable ties, bedding, etc.)
[0053] The article 250 includes a pair of closure systems 200
attached to a chassis 252. The base tabs 210 of each closure system
200 are preferably elastic as discussed above and may be attached
to the chassis by any suitable technique or combination of
techniques. Suitable techniques may include one or more adhesives,
welding (thermal, ultrasonic, dynamic mechanical bonding, chemical,
etc.), clips, staples, sewing, etc.
[0054] The closure systems 200 each include a pair of fastener
components 240 on a carrier tab 220 that is attached to the base
tab 210 by a bonding tape 230. Each fastener component 240 includes
an exposed pressure-sensitive adhesive 248 that, when attached to
the backside of the chassis 252, retains the article in place on a
wearer (where the backside of the chassis is the side facing away
from a viewer of FIG. 4). It should be understood that a
complementary fastener component may preferably be provided on the
backside of the chassis 252 to provide for secure attachment of the
fastener component 240 as described in, e.g., U.S. Pat. Nos.
5,300,057 (Miller et al.) and 5,660,666 (Dilnik et al.).
[0055] In the depicted embodiment, the adhesive fastener components
240 are provided in the form of patches that do not extend over the
width (along axis 241) of the closure systems 200. Alternatively,
the fastener components may extend over the width of the closures
systems 200 as seen in, e.g., FIG. 2.
[0056] All references and publications cited herein are expressly
incorporated herein by reference in their entirety into this
disclosure. Illustrative embodiments of this invention are
discussed and reference has been made to possible variations within
the scope of this invention. These and other variations and
modifications in the invention will be apparent to those skilled in
the art without departing from the scope of the invention, and it
should be understood that this invention is not limited to the
illustrative embodiments set forth herein. Accordingly, the
invention is to be limited only by the claims provided below and
equivalents thereof.
* * * * *