U.S. patent application number 13/525465 was filed with the patent office on 2012-10-04 for method for manufacturing a three dimensionally shaped article comprising hip/thigh panels and a hoop from a plus-shaped blank, and such an article.
Invention is credited to Christoph Schmitz.
Application Number | 20120253311 13/525465 |
Document ID | / |
Family ID | 38038720 |
Filed Date | 2012-10-04 |
United States Patent
Application |
20120253311 |
Kind Code |
A1 |
Schmitz; Christoph |
October 4, 2012 |
METHOD FOR MANUFACTURING A THREE DIMENSIONALLY SHAPED ARTICLE
COMPRISING HIP/THIGH PANELS AND A HOOP FROM A PLUS-SHAPED BLANK,
AND SUCH AN ARTICLE
Abstract
The present invention relates to an article for being worn on
the lower torso of a wearer. The article having leg hoops for
encircling a part of the upper thigh regions, a waist hoop for
encircling the waist of a wearer during use, a centre piece, two
hip/thigh panels, and a further web material for being positioned
on the inner thigh region of the wearer. The centre piece having a
web material including a front region for being positioned in the
front abdominal region of the wearer, a rear region for being
positioned in the lower back region of the wearer, and a centre
region for being positioned in the crotch region of the wearer. The
two hip/thigh panels have web materials for being positioned on the
hips of the wearer and extending downwardly into at least the upper
thigh region of the wearer, being rectangularly or trapzoidally
shaped.
Inventors: |
Schmitz; Christoph;
(Euskirchen Stotzheim, DE) |
Family ID: |
38038720 |
Appl. No.: |
13/525465 |
Filed: |
June 18, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12442636 |
Mar 24, 2009 |
8221380 |
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13525465 |
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Current U.S.
Class: |
604/385.201 ;
2/400; 28/100 |
Current CPC
Class: |
A61F 13/493 20130101;
Y10T 156/1052 20150115; A61F 13/15699 20130101; A61F 13/15
20130101; A61F 13/49413 20130101; A61F 13/496 20130101; Y10T
156/1075 20150115; Y10T 156/1062 20150115; Y10T 156/1074 20150115;
Y10T 156/1077 20150115 |
Class at
Publication: |
604/385.201 ;
2/400; 28/100 |
International
Class: |
A61F 13/493 20060101
A61F013/493; D04H 3/00 20120101 D04H003/00; A41B 9/00 20060101
A41B009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 28, 2006 |
EP |
PCT/EP2006/009430 |
Claims
1. An article for being worn on a lower torso of a wearer, said
article comprising: leg hoops for encircling a part of an upper
thigh region respectively; a waist hoop for encircling a waist of
the wearer during use; a centre piece comprising a web material
comprising a front region for being positioned in a front abdominal
region of the wearer, a rear region for being positioned in a lower
back region of the wearer, and a centre region for being positioned
in a crotch region of the wearer; at least two hip/thigh panels
comprising web materials for being positioned on hips of the wearer
and extending downwardly into at least the upper thigh region of
the wearer, said hip/thigh panels being at one of rectangularly and
trapzoidally shaped; and a further web material for being
positioned on an inner thigh region of the wearer; wherein said
hip/thigh panels are connected to said centre region of said centre
piece essentially only adjacently to a front respectively rear
region to form said leg hoops during use; wherein said hip/thigh
panels are connected to said front and rear regions of said centre
piece to form said waist hoop; wherein said centre region has a
three-dimensional (3D) cup shape sustained by curve-linear fold
lines in a lateral outward position of said centre region, said
fold lines forming at least one connecting line.
2. The article according to claim 1, further comprising a further
material comprised in said waist hoop, which is essentially unitary
within hip regions, and which is one of closed by being connected
in a region corresponding to said front region of said centre
piece, said rear region of said centre piece, said front and rear
region of said centre piece, and which forms a gap positioned in
one of a front region of said article, a rear region of said
article, and said front and rear region of said article.
3. The article according to claim 1, wherein at least one of said
waist and said leg hoops further comprising at least one draw
string, wherein a first end of said drawstring is connected to said
hip/thigh panels in a proximity to a connection of said hip/thigh
panels to said rear region of said centre piece, and a second end
of said drawstring comprises means for being releasably connected
to one of said front region of said centre piece, and to said first
end of said drawstring, wherein said drawstring is positioned in a
tube like envelope, formed by folding over said hip/thigh
panels.
4. The article according to claim 1, wherein at least said centre
piece further comprising liquid absorbent material and a topsheet
overlaying said liquid absorbent material oriented towards the
wearer during use.
5. The article according to claim 4, further comprising a secondary
topsheet positioned essentially between said topsheet and the
wearer during use.
6. The article according to claim 5, wherein said secondary
topsheet is positioned at least in said centre region of said
centre piece, overlaying at least partially said topsheet, and is
connected to said topsheet in a region of said centre piece, and is
connected to leg cuff forming materials in a region laterally
outwardly/upwardly positioned relative to one of said fold lines,
and said connecting line.
7. The article according to claim 6, wherein said secondary
topsheet defining an opening for being positioned in a region of an
anal opening of the wearer during use, said opening having an MD
and an CD extension and a respective perimeter at least during use,
and wherein said article further comprising at least two elastic
elements each connected to at least a point of a perimeter of said
opening or in proximity of said perimeter of said opening, whereby
each two connection points are in a opposing position relative to a
centre of said opening, and at least to a connection point of one
of said topsheet and said secondary topsheet, said connection point
being positioned outwardly away relative to said centre of said
opening creating a force to sustain said opening.
8. The article according to claim 7, wherein said secondary
topsheet further comprising a cut line to form said opening
positioned in the region of the anal opening of the wearer during
use, wherein said elastic elements being one of elastic threads and
bands are positioned essentially aligned with a longitudinal centre
line of said article, wherein said elastic elements are connected
to a point on a perimeter of said cut line or to a point in the
proximity of said cut line and to a point longitudinally away from
said cut line being in a waist region of said article, and
tensioning of said elastic elements being configured to sustain
said opening formed by said cut line.
9. The article according to claim 1, wherein each of said hip/thigh
panels including a side portion material having a curve-linearly
shaped perimeter.
10. The article according to claim 1, wherein each of said
hip/thigh panels including a side portion material comprising one
of defined openings arranged in a predetermined pattern, and
discontinuous cut lines in MD orientation arranged in a
predetermined pattern.
11. The article according to claim 1, further comprising a tear
line for allowing tearing at a predetermined location, and a
re-closeable connecting means arranged to re-connect parts after
being separated along said tear line.
12. The article according to claim 1, wherein each of said
hip/thigh panels comprises at least two zones differing in one of
composition and properties.
13. The article according to claim 1, wherein said article being
one of a disposable absorbent article, a baby incontinence article,
an adult incontinence article, a training pant, a feminine care
article, a menstrual pant, and pant shaped underwear.
14. An article for being worn on a lower torso of a wearer, said
article comprising: leg hoops for encircling a part of an upper
thigh region respectively; a waist hoop for encircling a waist of
the wearer during use; a centre piece comprising a web material
comprising a front region for being positioned in a front abdominal
region of the wearer, a rear region for being positioned in a lower
back region of the wearer, and a centre region for being positioned
in a crotch region of the wearer; at least two hip/thigh panels
comprising web materials for being positioned on hips of the wearer
and extending downwardly into at least the upper thigh region of
the wearer, said hip/thigh panels being at one of rectangularly and
trapzoidally shaped; a further web material for being positioned on
an inner thigh region of the wearer; and a further material
comprised in said waist hoop, which is essentially unitary within
hip regions, and which is one of closed by being connected in a
region corresponding to said front region of said centre piece,
said rear region of said centre piece, said front and rear region
of said centre piece, and which forms a gap positioned in one of a
front region of said article, a rear region of said article, and
said front and rear region of said article; wherein said hip/thigh
panels are connected to said centre region of said centre piece
essentially only adjacently to a front respectively rear region to
form said leg hoops during use; wherein said hip/thigh panels are
connected to said front and rear regions of said centre piece to
form said waist hoop; wherein said centre region has a
three-dimensional (3D) cup shape sustained by curve-linear fold
lines in a lateral outward position of said centre region, said
fold lines forming a perimeter of a connecting region between said
centre region and said further web material.
15. The article according to claim 14, wherein at least one of said
waist and said leg hoops comprises at least one draw string,
wherein a first end of said drawstring is connected to said
hip/thigh panels in a proximity to a connection of said hip/thigh
panels to said rear region of said centre piece, and a second end
of said drawstring comprises means for being releasably connected
to one of said front region of said centre piece, and to said first
end of said drawstring, wherein said drawstring is positioned in a
tube like envelope, formed by folding over said hip/thigh
panels.
16. The article according to claim 14, wherein at least said centre
piece further comprising liquid absorbent material and a topsheet
overlaying said liquid absorbent material oriented towards the
wearer during use.
17. The article according to claim 16, further comprising a
secondary topsheet positioned essentially between said topsheet and
the wearer during use, said secondary topsheet being positioned at
least in said centre region of said centre piece, overlaying at
least partially said topsheet, and is connected to said topsheet in
a region of said centre piece, and is connected to leg cuff forming
materials in a region laterally outwardly/upwardly positioned
relative to one of said fold lines, and said perimeter of said
connecting region.
18. The article according to claim 17, wherein said secondary
topsheet defining an opening for being positioned in a region of an
anal opening of the wearer during use, said opening having an MD
and an CD extension and a respective perimeter at least during use,
and wherein said article further comprising at least two elastic
elements each connected to at least a point of a perimeter of said
opening or in proximity of said perimeter of said opening, whereby
each two connection points are in a opposing position relative to a
centre of said opening, and at least to a connection point of one
of said topsheet and said secondary topsheet, said connection point
being positioned outwardly away relative to said centre of said
opening creating a force to sustain said opening.
19. The article according to claim 18, wherein said secondary
topsheet further comprising a cut line to form said opening
positioned in the region of the anal opening of the wearer during
use, wherein said elastic elements being one of elastic threads and
bands are positioned essentially aligned with a longitudinal centre
line of said article, wherein said elastic elements are connected
to a point on a perimeter of said cut line or to a point in the
proximity of said cut line and to a point longitudinally away from
said cut line being in a waist region of the article, and
tensioning of said elastic elements being configured to sustain
said opening formed by said cut line.
20. The article according to claim 14, further comprising a tear
line for allowing tearing at a predetermined location, and a
re-closeable connecting means arranged to re-connect parts after
being separated along said tear line.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application under 35 U.S.C.
.sctn.121 and 37 CFR 1.53(b) based upon co-pending U.S. application
Ser. No. 12/442,636 filed Mar. 24, 2009. Additionally, this
divisional application claims the benefit of priority of co-pending
U.S. application Ser. No. 12/442,636 filed Sep. 24, 2009, and
International Application No. PCT/EP2006/009430 filed Sep. 28,
2006. The entire disclosures of the prior applications are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the manufacturing of an
article made from web materials, such as textiles, non-wovens,
films, or composites made there from. The articles have a three
dimensional shape when in use and comprise a belt or a hoop
structure. In particular, it can be applied to the production of
wearing apparel or garments to be worn on the lower torso of the
wearer, or of absorbent hygiene articles, such as disposable
diapers. The present invention also relates to the equipment for
making such an article, and such articles.
[0004] 2. Description of the Prior Art
[0005] The industrial manufacturing of articles such as garments
having a three-dimensional (3D) shape and/or comprising a closed
structure, such as a belt or a hoop, conventionally employs little
automation, e.g. automatic sewing of the components. The rarely
used automated methods are typically limited by complex equipment
designs and/or low production speeds. Such sewn articles are
disclosed in EP-A-0988803, relating to a panty girdle, or
US-A-2004/0098784, relating to a net pant, or WO-A-01/061093,
relating to boxer shorts, however the manufacturing is not on
production lines employing a continuous process.
[0006] JP01284284A2 discloses a machine for continuous sewing of an
annular resilient belt-form material. The machine inserts or sews a
tubular elastic belt shape body, e.g. rubber ring, to tubular
cloth, e.g. trousers or a skirt, continuously. The machine sews the
cloth by guiding the rubber ring by a guide device having a guide
plate, bending ends of tubular cloth to make a bent part, and
placing endless rubber ring in the space made by the bent part and
retreats to the open end side of the bent part. In US application
US-A-2002/0084017, a process is described for the manufacturing of
a 3D article, wherein waist elastic, an insert and a 3D skirt or
trunk are combined by using an expandable/retractable fixture,
which is run through a process loop such as a loop conveyor system
This process and equipment however, is complex in design, and
whilst the process may run automated, there are also severe
limitations in the production speed.
[0007] Considering conventional pant like articles or articles to
be worn on the lower torso of the wearer, such as diapers or so
called training pants, and which are manufactured on high speed
production lines, these are typically based on relatively simple
structures. In particular the art of making disposable absorbent
articles is an area where a lot of effort has been spent against
efficient manufacturing of body conforming articles, and a first
generation of articles was based on essentially rectangular
composites, which later were improved by narrowing the composite in
the crotch region when being worn, thus in the longitudinal centre
region of the article. Such articles are commonly referred to as
hourglass shaped articles (refer to FIG. 3E). A variant of this
design, sometimes referred to as T-shaped, is an asymmetric design,
where the rear waist region of the article on the wearer is
significantly wider than the front region, such that the lateral
extensions of the rear regions (also referred to as "back ears")
are wrapping the waist of the wearer and are connected to
themselves and/or to the front region of the article.
[0008] Typically, such articles are essentially two-dimensional,
i.e. made from flat panels, such as web materials, and they can be
folded flat such that all connecting lines connecting various parts
of the article to each other are also flat on a flat surface. Some
of the designs are articles, which are pre-combined by the
manufacturer, such as in a pant style, to be used e.g. as a so
called training pant. Such designs comprise a waist opening and two
leg openings, the leg openings separated by the crotch region of
the article, and the laterally outer regions of the article
corresponding to the hip region of the wearer comprise permanently
or releasably connected side panels. Upon use, the side panels may
be opened and re-closed e.g. for inspection of the article, or may
be torn open, e.g. for removal of a loaded article.
[0009] Typically, such articles are primarily folded along a
fold-line extending cross-directionally, e.g. placing front and
rear ends onto each other. Additional secondary folds, such as to
fold lateral extensions such as ear regions inwardly, may be folded
along a longitudinal fold line.
[0010] Some of the designs as described in the above, attempt to
improve the body conforming fit by introducing a three-dimensional
design, whereby the article as made from essentially flat webs or
panels cannot be laid flat on a flat surface with all connecting
lines lying flat, too.
[0011] All such designs still have in common, that the shape is
such, that, when the article is cut open along a line extending
longitudinally through the side portions of the article and laid on
a flat surface, the article is hourglass-shaped, i.e. narrower in
the crotch region of the article than in the waist region(s).
[0012] A first approach to arrive at a fundamentally different
design is described in co-pending patent applications
PCT/IB05/000845, PCT/EP06/002165, or PCT/EP06/002166. Such designs
comprise side portions, which are positioned--when the article is
cut open or before it is assembled into its final shape--outwardly
of the crotch region. Such a design may be referred to as a Plus
(or +) design, as the blank for manufacturing such an article is
not narrower in the crotch region but rather wider in this region,
because the side-panels are arranged in this area, such that they
can wrap around the outer part of the leg of the wearer. The side
panel may be connected to the side crotch region of the product,
i.e. to the laterally outward regions of the centre crotch region,
so as to form a leg hoop, i.e. a belt like structure around the
legs of the wearer during use.
[0013] Such Plus-designs exhibit great advantages in design
flexibility and hence comfort of the wearer during use, without
compromising sealing functionality which is desirable, e.g. in the
case of absorbent articles, like diapers. As described in the
mentioned documents, a particularly suitable manufacturing process
employs a parallel treatment unit, such as a turret or a slide
track loop, with several essentially identical treatment heads on
which the articles are formed from precursor webs.
[0014] Whilst this approach allows article designs, which could
hitherto not be realized on high speed manufacturing equipment, and
also offers highly flexible manufacturing processes to arrive at
such articles, it requires, that some of the pre-cursor web
elements need to be provided un-assembled to the treatment head, on
which these will be combined and folded to form the shaped article.
This involves a process unit with a high number of moving elements,
respective drive and sensor means. In some cases of simpler product
designs, such high process flexibility may not be required, and the
related investment may not be considered appropriate.
[0015] Thus, the present invention provides a significantly simpler
method to make articles with hoops such as leg or waist hoops by
pre-combining essentially all web elements to an essentially flat
precursor blank before this precursor blank is transferred to a
treatment head, where it is folded and finished to form the
article. The approach will thusly be to form a pre-cursor blank in
a "Plus-" or (+)-shape. On the treatment head, the respective
"arms" of the Plus-shaped blank are folded downwards, and then
adjacently lying edges are connected to form the article comprising
closed structures, also referred to as hoops, around the legs of
the wearer during use, and/or around the waist. In a preferred
embodiment, the article elements are arranged during the
manufacturing such that the front to back orientation in the
article corresponds to the machine direction, while laterally
outwardly extending side panels are oriented in cross machine
direction.
[0016] Optionally, elements for forming a closed hoop in the
finished article, such as waist bands, oriented and optionally
elasticated along their MD direction can be attached to the side
portions. As a consequence, if the article comprises a waist band,
this may be connected in the front and back regions of the article,
rather than in the side regions as will be inevitably the case for
the conventionally manufactured articles.
[0017] The centre piece web may be cut into individual pieces on or
prior to being transferred to the parallel treatment unit, e.g.
after the side portions are attached thereto. In an alternative
process set-up, the sequence of process steps may be such that the
centre piece web is cut in discrete pieces before the laterally
outwardly extending side portions are attached to the discrete
centre pieces. Such sequence is particularly useful if the distance
between subsequent centre pieces is to be altered, and if there are
continuous webs connecting e.g. the side portions of subsequent cut
pieces e.g. at their outer perimeter.
[0018] Preferably, although not necessarily, at least one major
element of the article should be essentially unitary when the
article web is transferred to the parallel treatment unit, to ease
transfer to this unit. In the case of articles without a waist
band, the centre piece of the article may be essentially unitary,
i.e. to extend essentially along the full length of the article
(from front through crotch to the rear), optionally combined with
other elements, such as leg hoop and side-panel materials, prior to
the positioning on the forming head of the parallel treatment unit,
where the article web is cut, and the thusly obtained discrete
articles are formed and finished. In articles with a waistband, the
centre piece web may be cut in discrete pieces, and those pieces
may be connected to each other by unitary waist band webs.
SUMMARY OF THE INVENTION
[0019] Thus, in one aspect, the present invention is a method for
manufacturing shaped articles, which comprise at least one closed
hoop structure and at least a primary and a secondary web material.
The manufacturing can be performed on a high speed manufacturing
equipment, which comprises a web supply means, a blank forming
means, a means for cutting the blank from the web into discrete
elements, a means for transferring the blanks to a parallel
treatment unit, preferably a turret or an endless track. This
parallel treatment unit comprises at least two web treatment
sections for parallel treatment of the blanks, whereby each
parallel treatment section further comprises a treatment head. Such
a treatment head comprises a centre plate, being positioned
essentially parallel to the surface of the parallel treatment unit,
to which the blanks are transferred, longitudinal extension plates
which are positioned or extending forwardly and rearwardly of the
centre plate along the overall manufacturing direction of the
parallel treatment unit, and which are pivotable such that the
forward or rearward ends can be turned downwardly away from the
surface of the parallel treatment unit whilst the respective other
ends of the extension plates remain adjacent to the centre plate.
Optionally, the treatment head further comprises laterally
extending side plates, which may also be pivotably connected to the
centre plate. The pivoting of the longitudinal and/or lateral
extension plates may be achieved by drive means selected from the
group of mechanical drives, preferably cam drives, pneumatic
drives, or electric drives, preferably servo drives. The centre
plate and/or the longitudinal and/or lateral extension plates
preferably comprise a web fixation means, preferably a vacuum
suction means. The treatment head further comprises connecting
means for connecting portions of the blank to other portions of the
blank, and fixation means to temporarily hold web materials and/or
the blanks. The method thus comprises the steps of:
[0020] (a) preparing a pre-cursor blank, which comprises a centre
piece comprising a primary web. The centre piece consists of a
centre region, and a front and a rear region extending
longitudinally from the centre region. The pre-cursor blank further
comprises side portions extending laterally outwardly of both sides
of the centre region comprising the secondary web, thusly forming a
Plus-shaped precursor blank;
[0021] (b) transferring the pre-cursor blank to the parallel
treatment unit comprising the treatment sections, each treatment
section comprising a treatment head;
[0022] (c) temporarily attaching the centre region of the precursor
blank to the surface of the centre plate of the treatment head
which is out- or upwardly facing, and the front and rear regions to
the longitudinal extension plates of the treatment head, whilst
these are in an upwardly folded position essentially aligned with
the centre plate;
[0023] (d) separating the primary web into individual pieces,
before or after having formed the precursor blank;
[0024] (e) pivoting the outward front and rear ends of said
longitudinal extension plates downwardly away from the surface of
the parallel treatment unit whilst the front and rear regions of
the precursor blank remain attached thereto;
[0025] (f) folding the side portions of the pre-cursor blank
downwardly, so as to bring the side margins of the front and rear
regions and the side margins of the side portions into an adjacent
or overlapping positioning;
[0026] (g) connecting respective side margins, thereby forming a
closed article comprising a hoop;
[0027] (h) optionally further treating the article;
[0028] (i) removing the article from the parallel treatment
unit.
[0029] Optionally, the method can comprise a further step of
[0030] j) adding a further web material to the pre-cursor
blank.
[0031] This further web material may be essentially endless and may
connect the side portions of consecutive pre-cursor blanks,
preferably the laterally outward perimeter of the side portions.
Preferably, this further web material is separated into segments
after the precursor blank has been transferred to the treatment
head, and after the longitudinal extension plates with the front
and rear region attached thereto have been downwardly folded, and
more preferably, this separation is executed essentially
concurrently to connecting the cut edges together to form a closed
hoop.
[0032] During step (a), the pre-cursor blank may comprise cut
lines, which extend from the lateral outward perimeter inwardly.
The side portions and the centre piece are connected by means of a
connecting line or region essentially parallel and corresponding in
cross-directional extension to the cut line. Also during step (a)
of this method, a further material can be added for forming a leg
hoop with the side portion material.
[0033] In a preferred embodiment of this method, the step (e) is
executed prior to step (f) so as to create an overlap connection of
the front and rear regions with the side portions forming the
leg/thigh panel, such that in this overlay connection the front and
rear regions are positioned outwardly, relative to the wearer
during use, of the leg/thigh panels.
[0034] In a further aspect, the present invention is an article for
being worn on the lower torso of a wearer comprising leg hoops for
encircling a part of the upper thigh regions and a waist hoop for
encircling the waist of a wearer during use. The article may
further comprise a centre piece comprising a web material
comprising a front region for being positioned in the front
abdominal region of the wearer, and a rear region for being
positioned in the lower back region of the wearer, and a centre
region for being positioned in the crotch region of the wearer, and
two hip/thigh panels comprising web materials for being positioned
on the hips of the wearer and extending downwardly into at least
the upper thigh region of the wearer. In a particular embodiment,
the article may further comprise a further web material for being
positioned on the inner thigh region of the wearer. In this aspect
of the invention, the hip/thigh panels are connected to the centre
region of the centre piece essentially only adjacently to the front
respectively rear region, thereby forming the leg hoops during use.
Further, the hip/thigh panels are connected to the front and back
regions of the centre piece, thereby forming the waist hoop. The
centre region forms a 3D/cup shape sustained by curve-linear fold
lines in the lateral outward position of the centre region and by
the fold lines forming connecting lines, or a perimeter of a
connecting region between the centre regions and the optional
further material for forming the leg hoop, if present.
[0035] The article may further comprise further material comprised
in said waist hoop, which is essentially unitary within the hip
regions, and which is either closed by being connected in a region
corresponding to the front and/or back region of the centre piece
or which forms a gap positioned in the front and/or rear region of
the article. In a preferred execution, the article comprises a
drawstring-type waist element, which allows easy adjustment of the
gap width, e.g. by a caregiver.
[0036] Optionally, at least the centre piece further comprises
liquid absorbent material and a topsheet positioned between the
absorbent material and the user during use.
[0037] A particular embodiment is an article comprising an
additional secondary topsheet positioned between the topsheet and
the wearer during use. Preferably, the secondary topsheet is
positioned at least in the centre region of the centre piece,
overlaying at least partially the topsheet, and it may be connected
to the topsheet in the region of the centre piece, as well as to
the leg cuff forming materials in a region laterally
outwardly/upwardly positioned relative to the folding or connecting
line, or the perimeter of connecting region. This secondary
topsheet comprises an opening for being positioned in the region of
the anal opening of a wearer during use, which has an MD and an CD
extension and a respective perimeter at least during use. The
article may further comprise at least two elastic elements, each
connected to at least a point of the perimeter or in proximity of
the perimeter of the opening, whereby each two connection points
are in a opposing position relative to the centre of the opening,
and at least to a connection point of the topsheet or the secondary
topsheet, the point being positioned outwardly away relative to the
centre point of the opening, thereby creating a force to sustain
the opening. In a specific embodiment, the secondary topsheet
comprises a cross-directional cut line so as to form the opening
positioned in the region of the anal opening of the wearer during
use, wherein the elastic elements, preferably elastic threads or
bands are positioned essentially aligned with the longitudinal
centre line of the article. Further, the elastic elements are
connected to a point on the perimeter of the cut line or to a point
in the proximity of the cut line and to a point longitudinally away
from the cut line, preferably in the waist region of the article,
such that the tensioning of the elastic elements sustains the
opening formed by the cut line.
[0038] The portions as being connected to the primary web to form
the blank may be essentially of rectangular or trapezoidal form,
but may also comprise a curvelinearly shaped perimeter. The side
portion material may also be apertured by having openings, or may
have slits, preferably in MD orientation, and preferably in a
predetermined pattern.
[0039] The connecting means for the various connections in this
article may preferably be glue bonding, thermo bonding, mechanical
fastening means, or adhesive tape fastener.
[0040] The article may further comprise a tear line for allowing
easy tearing at a predetermined location, such as to allow
inspection while it is worn, and it may further optionally comprise
a re-closeable connecting means arranged to re-connect the parts as
separated by the tear line.
[0041] The article of the present invention is particularly
suitably used as a disposable absorbent article, a baby or adult
incontinence article, a training pant, a feminine care article, a
menstrual pant, or pant shaped underwear.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIGS. 1A, B depicts schematically process set ups of the
prior art;
[0043] FIGS. 2 A and B depict schematically processes according to
the present invention;
[0044] FIG. 3 A--represents a Plus-shaped pre-cursor blank laid out
flat;
[0045] FIG. 3 B--shows a magnified view of the connecting
regions;
[0046] FIG. 3 C--shows a perspective view of closed product;
[0047] FIG. 3 D--shows a magnified view of the connecting regions
for a different embodiment;
[0048] FIG. 3 E--hourglass shaped product (prior art);
[0049] FIG. 4--Article with overlap leg cuffs/side panels;
[0050] FIGS. 5 A and C--depict schematically a process set up to
form a Plus-Shaped pre-cursor blank;
[0051] FIGS. 5 B and D show a cross-sectional view through certain
sections of the blank;
[0052] FIGS. 6 A and B show a schematic view of a treatment
head;
[0053] FIG. 7--shows a perspective view of a further article
according to the present invention;
[0054] FIGS. 8 A and B show perspective views of further articles
according to the present invention;
[0055] FIG. 8 C shows a perspective view of a conventional
Article;
[0056] FIGS. 8D and E show schematic views of an article according
to the present invention comprising a drawstring waist feature;
[0057] FIG. 9--shows a schematic perspective view of a secondary
topsheet with an aperture.
[0058] FIG. 10 A to G--show schematic views of the blank during
certain process steps of the manufacture of an article comprising a
secondary topsheet.
[0059] Equal numerals in various Figures refer to corresponding
elements.
DETAILED DESCRIPTION OF THE INVENTION
[0060] In the following, the present invention is explained in more
detail by referring to diapers and pant like structures, to be worn
in the lower region of the torso of a wearer. However, this should
not be understood in any way limiting for the invention. A skilled
person will readily be able to transfer the teachings to the
manufacturing of other garments, such as T-shirts and the like.
[0061] Thus, in one aspect, the present invention is an industrial
manufacturing process for garments, such as pant like structures or
disposable absorbent articles produced from web materials in an
essentially continuous process. The present invention allows to
replace existing processes and the corresponding equipment
completely, but it is also suited to be integrated into existing
processes to perform only certain process steps in the overall
manufacturing process. The present invention presents in certain
aspects an alternative to the process as described in
PCT/EP06/002165, which is incorporated herein by reference for the
general teaching of suitable materials and the general process lay
out, as well as for details of the execution of particular
elements, such as web support means, and/or web handling means,
such as vacuum boxes and the like. Thus, FIG. 1A shows process flow
chart and a schematic equipment set up as disclosed therein.
[0062] In this process, a web material 100 is fed from a web supply
means 210 via web support and guide means (260, 270) and a parallel
treatment unit, here shown as a rotating turret 300, at an overall
process speed and direction 208 to the process end section 900,
from where it may be distributed to further processing step, or
where it may be packed. The turret comprises several parallel
treatment sections 301 . . . 306, wherein the web 100 is treated,
such as folded, or combined with other webs. This treatment is
achieved by positioning the web on web support means 330, 340, and
350, which may be operated at independently programmable speeds and
thus may, for example, form a specific cross-directional fold in
the web. Further, a web treatment head 410, positioned in each of
the parallel treatment sections 301 . . . 306 may cooperate with a
treatment tool 450, here shown stationary such that one such tool
can cooperate with all of the treatment heads as they pass by the
tool upon rotating, such as combining specific sections of the web
to other sections.
[0063] The originally essentially continuous web 100 may be cut
into discrete pieces prior to be fed to the turret, on the turret,
or after being removed from the turret.
[0064] An important element of this equipment is the use of web
support means 330, 340, 350 arranged in the web treatment sections
301, . . . 306, such as programmable vacuum belts to transfer the
web 100 to a treatment head 410, after a cross-directional fold has
been formed by appropriate adjustment of the transport speed and/or
direction of the web support means. Adjacently positioned sections
of the webs are respectively connected on this treatment head,
thereby forming the basic form and shape of the article.
[0065] In a configuration as schematically depicted in FIG. 1B, two
webs 102 and 104 are fed to the treatment sections 301 . . . 306 of
a parallel treatment unit, here a turret 300, and separated to the
appropriate length, e.g. by cutting means 395, 397. Upon
appropriate movement of the web support means 330, 340, 350, and
360, and further by radial movement of at least one thereof--here
shown by the position 350'--the first web 104 is CD-folded and
moved through the gaps 380 and 385 to be positioned on the
treatment head 410, where it is combined with the second web
material 102 upon further rotation of the turret, e.g. by
combination tools 450 or 450'.
[0066] This setup provides a high level of flexibility, both for
making product variants, and for making different sizes of a
specific product. However, this level of flexibility may not be
necessary or desirable, like when the product to be made is clearly
defined or of a single size.
[0067] Thus, the present invention provides a simpler, yet high
speed compatible alternative for a process and an equipment design,
for which one embodiment is schematically depicted in FIG. 2A.
[0068] In analogy to the prior art process described hereinabove, a
primary essentially endless web material 100 is provided on a web
supply means 210 via web support and/or guide means 260, 270 at an
overall process speed 208, which may be as high or higher than 8
msec web speed, which may correspond to over 1000 articles per
minute. For certain embodiments the primary web material may be cut
by a separation means 406 prior to being combined with other
materials to form the pre-cursor.
[0069] A second essentially endless web material 1100 as being
supplied from a second web supply means 1210 is cut e.g. by a cut
and slip unit 1400 in discrete pieces, transferred to the primary
web and attached such that it extends on both sides laterally
outwardly of the primary material, to regions which will correspond
to the crotch region when the finished article will be worn. This
material may be supplied essentially unitary, and separated on
line, or two web supply means may provide separate webs.
Optionally, these material(s) may already form a composite
material, such as being partly elasticated, such that e.g. the
non-elastic portion is connected to the centre piece, whilst the
elastic portion may be positioned laterally outwardly thereof, e.g.
to later form a part of waist hoop.
[0070] Optionally, a further essentially endless web material 2100
may be supplied from a further web supply means 2210, such as to
form a waist hoop in a finished product. This further web material
may be in the form of two relatively narrow material stripes,
optionally elasticated, which extend essentially parallel to the
orientation of the centre piece material 100, and which may be
connected to the laterally outward edges of the second web material
1100.
[0071] The primary web 100, the secondary web(s) 1100, and
optionally the further web(s) 2100 can be combined by conventional
means, such as so called cut- and slip units, 1400, and
conventional connecting means to form a pre-cursor web or a
sequence of pre-cursor web pieces 110, as depicted in FIG. 3A as a
piece of pre-cursor blank 3000 and discussed in more detail herein
below.
[0072] The pre-cursor blank 110 is then transferred to a parallel
treatment unit for parallel treatment of at least two blank pieces
110, here shown as rotatable drum or turret 300, comprising at
least two web treatment sections, here shown as six units 301 to
306. Each of these sections comprises a treatment head 2410, which
further comprises
[0073] a centre plate 2420 having a first surface 2422 oriented
outwardly of the rotating drum 300;
[0074] two longitudinal (in the direction of movement of the web;
x-direction) extension plates 2430, which are pivotable such that
the forward or rearward ends can be turned downwardly or inwardly
away from the surface of the parallel treatment unit whilst the
respective other ends of the extension plates remain adjacent to
the centre plate. This can be by connecting these plates by a hinge
2432 to the centre plate 2420, so as to allow pivoting them
downwardly to an essentially perpendicular position to the centre
plate. Alternatively, these extension plates may be moveably
affixed to the frame of the treatment section.
[0075] and optionally two side plates (not shown in FIG. 2), being
positioned laterally outwardly to the lateral side edges of the
centre plate 2420 in an essentially rectangular downward (towards
the centre of the drum) position.
[0076] Whilst the plates and surfaces of the treatment head are
generally described as being flat, this refers to the overall
extension of these plates or surfaces, whilst the exact shape may
be somewhat rounded or edged. Thus, the centre plate may have a
shape corresponding to the surface of the turret (i.e. the segment
of a cylinder) or approximate the shape of the finished article,
e.g. be adapted to the surface of the lower torso to be wrapped by
the finished product, or each longitudinal extension may be formed
of two plates in an angular configuration.
[0077] The webs may be treated, such as by connecting specific
sections to other sections, such as by connecting tools, so as to
form the finished article 999, and may be removed from the turret
300 such as by using a removal means, here shown as rotating disk
950 positioned adjacent the turret 300 and comprising one or more
moveable finger(s) 960 arranged to engage into the treatment head
2410 and the article positioned thereon, so as to allow pulling out
of the formed article 999 upon further rotation of the turret and
the at least one rotating disk, optionally by using further web
support or guide means 260.
[0078] With such a set up of the equipment, the preferred process
sequence of forming an article according to the present invention
as depicted in FIGS. 3A to D comprises the following steps, which
are further discussed in more detail herein below:
[0079] (a) preparing a pre-cursor blank 110 which comprises a
centre piece 3100 comprising the primary web 100, consisting of a
centre region 3115 and a front (3112) and a rear (3118) region
extending longitudinally from the centre region, further comprising
side portions 3117 extending laterally outwardly of the centre
region comprising a secondary web 1100, thusly forming a
Plus-shaped precursor blank,
[0080] (b) transferring the pre-cursor blank 110 to a parallel
treatment unit 300 comprising treatment section 301 . . . 306, each
treatment section comprising a treatment head 2410;
[0081] (c) temporarily attaching the centre region 3115 of the
precursor blank 110 to the surface 2422 of the centre plate 2420 of
the treatment head 2410 which is out- or upwardly facing, and the
front (3112) and rear regions (3118) to the longitudinal extension
plates 2430 of the treatment head 2410, whilst these are in an
upwardly folded position essentially aligned with the centre
plate;
[0082] (d) separating the primary web into individual pieces,
before or after having formed the precursor blank;
[0083] (e) pivoting the longitudinal extension plates 2430
downwardly whilst the front and rear regions remain attached
thereto;
[0084] (f) folding the side portions 3117 of the pre-cursor blank
110 downwardly, so as to bring the side margins of the front and
rear regions (3113 and 3123, respectively) and the front/rear
margins 3116 and 3126 of the side portions 3117 into an adjacent or
overlapping positioning;
[0085] (g) connecting respective side margins, thereby forming a
closed article comprising a hoop;
[0086] (h) optionally further treating the article;
[0087] (i) removing the article 999 from the parallel treatment
unit.
Detailed Discussion of the Individual Process Steps:
Ad (a) (Preparing a Pre-Cursor Blank):
[0088] The pre-cursor blank 110 is formed from a web material 100,
which may be an essentially continuous web or an essentially
continuous sequence of web pieces as cut from a continuous web.
Typically, but not necessarily, the web material 100 will be
supplied oriented such that the front to back direction of an
article made of a web piece cut from the web corresponds to the MD
direction of the web material 100 as well as to production
direction of the equipment (MD), generally depicted as MD-direction
3050.
[0089] A suitable pre-cursor blank is depicted in FIG. 3A, showing
the principle of a Plus-shaped precursor blank 3000, and 3C,
showing a perspective view of an article 999 made from such a blank
with a centre piece 3100, comprising a front region 3112, a rear
region 3118, and a connecting centre region 3115, arranged along
the machine direction 3050 of the web 100, which preferably
corresponds to the machine direction of the parallel treatment unit
300. Two side portions 3117, which form the hip/thigh panels of the
finished article, are extending laterally outwardly of the centre
region 3115 of the centre piece 3100. FIG. 3B shows a magnified
view of one of the four connections, for the embodiment of a blank
with extra material applied as to cover the inner thigh regions of
the leg hoop, additionally depicting a connecting region 3120,
whereby the side portions 3117 are connected to the centre region
along the demarcation line 3127 between the centre and the
front/rear region. The connection may be achieved by conventional
means, such as by gluing, heat bonding and the like. The connection
is preferably executed in the form of a fine line, but may cover a
certain area, which, however, should be minimized for fit reasons.
For the embodiment of a product without an extra material applied
as to cover the inner thigh regions, slits or cuts 3125 adjacently
to the connecting region are performed along the demarcation lines
3127 between the centre and the front/rear region, preferably while
the connecting lines or regions 3120 are made, FIG. 3D. Whilst this
cut line is shown as a straight line with a cross-directional
orientation, it may be arranged in other angles, but not parallel
to the side margin of the centre region in that section. The cut
line may also be executed curve-linearly, which, however, might
make the creation of the connecting line/region, which should
essentially follow the cut line, more difficult. The length of the
connecting lines or regions and the cut line impact on the form and
shape of the leg cuff and thus of the leg opening, which is later
formed on the forming head. As the side portions 3117 are not
connected to the centre region 3115 other than by the connecting
line or region, they will loosely overlay the centre piece in the
overlay region 3131, from which later the leg cuff and leg opening
3130 will be formed in the finished article.
[0090] The Plus-shaped blank, as depicted in FIG. 3A to D, may
further comprise a further material 3119 arranged to form a waist
hoop in the finished article. To this end, an essentially endless
narrow stripe of this material, which is preferably elasticated, is
attached to the outward edges of the side portions 3117.
[0091] Additional elements may be added to the pre-cursor blank,
such as in case of manufacturing absorbent articles, the absorbent
members (cores) may be combined with any of the web materials or
with the pre-cursor blank. In contrast to conventional articles,
especially the herein above referred to hourglass shaped articles,
the cup-like shaped centre region of the article according to the
present invention allows--in addition to improving sealing
performance against leakage especially in the thigh region--to
position further liquid absorbing capacity in the crotch region, or
even in the leg cuffs, as formed by the side portions and laterally
outwardly positioned regions of the centre region.
[0092] Whilst the FIG. 3 shows an isolated Plus-shaped blank,
consecutive blanks may be connected to each other on the production
line, such that the centre pieces may be connected before these
will be cut, and folded on the treatment head (see below).
Additionally or alternatively, the further material 3119 may form
continuous stripes connecting consecutive pre-cursor blanks e.g. at
both lateral perimeters of the side portions 3117.
[0093] FIG. 3A shows a preferred embodiment of the MD-orientation
3050 of an essentially unitary centre piece 3100 corresponding to
the front-to-back orientation of the finished article. The
pre-cursor blank 3000 may be supplied to the parallel treatment
unit by any conventional means, such as guide rolls or bars, web
support means such as transport belts, optionally equipped with web
fixation means such as vacuum means etc.
[0094] The parallel treatment unit can be a conventional rotating
essentially cylindrical drum, also referred to as a turret, and
schematically depicted in FIG. 2A. The turret rotates around its
longitudinal centre axis, and direction of rotation corresponds to
the overall web transport direction, such that a web may be
supplied to the turret tangentially, may be affixed to the outer
surface of the cylindrical drum, and may after treatment and
forming of the article be expelled from the turret about radially
outwardly.
[0095] The turret may be in the form of a full cylinder, or may
also be designed in a conventional manner by using rods, bars, or
struts, such that a cross-section of the turret perpendicularly to
the rotating axis may correspond to a polygon. Preferably, the
turret comprises an even number of web treatment sections. These
treatment sections comprise a treatment head, but may comprise
further elements, such as further web support means (like vacuum
belts), web guide means (like guide rolls), or web treatment means
(like web cutting means).
[0096] In an alternative embodiment, the parallel treatment unit
can be an endless track guiding a number of web treatment sections,
as schematically depicted in FIG. 2B, such as well known in
principle from e.g. US patent publication US-A-2002/084017. In such
a design, the terms describing the positioning of e.g. the
treatment head will need to be reformulated, e.g. "radially
outwardly" will then correspond to "upwardly", "tangentially" will
correspond to "parallel to the slide track", etc. As shown in FIG.
2B, a continuous series of pre-cursor blanks 110 is transferred to
a corresponding series of treatment heads 2410, which are moved
along a closed, or endless, track 309. The shown oval arrangement
of such a track is preferred, as it allows straight and hence
relatively easy arrangement of the various treatment tools
interacting with the treatment head, respectively with the
materials thereon. The oval form allows to use one essentially
straight process track 310 and return track 315. The finished
article 999 may be removed from the treatment head 2410 at the end
of the process track by a removal unit 950 as described herein
above.
Ad (B): Transferring the Pre-Cursor Blank 110 to the Parallel
Treatment Unit 300;
[0097] The pre-cursor blank is transferred to the parallel
treatment unit by conventional means, such as web support means
260, or web guide means 270. In case of the parallel treatment unit
being a turret, the pre-cursor is essentially tangentially
transferred to one of the treatment sections with the treatment
head 2410. Before receiving the plus-shaped pre-cursor blank, the
treatment head 2410 is in an upfolded configuration. This refers to
a configuration, where the two longitudinally extending plates
2430, which can be pivotably connected to the centre plate 2420
such as by a hinge 2432, essentially form a continuous surface with
the centre plate 2420. Essentially continuous refers to the fact,
that, if the centre plate and the extension plates were plane,
these would be straight aligned. If the centre plane is (e.g.
cylindrically) shaped, there would be a smooth transition via an
essentially 0.degree. hinge angle. Instead of the hinged connection
between the centre plate and the extensions plates, the latter may
be affixed by different means e.g. to the frame of the treatment
section, and may follow the movement by other means.
[0098] Ad (c): temporarily attaching the pre-cursor blank 110 to
the outer surface 2422 of the treatment head, whereby the centre
region 3115 is positioned on the centre plate 2420, and the front
and rear regions (3112, 3118) to the longitudinal extension plates
2430 of the treatment head 2410. The attachment can be achieved by
conventional means, such as vacuum.
[0099] In case the precursor blank is formed as a continuous web
wherein the centre pieces of subsequent blanks are connected, these
may be disconnected before they are attached to the treatment head,
or on the treatment head.
[0100] The side regions 3117 of the precursor blank extend
laterally outwardly of the centre plate 2420, optionally supported
by lateral extension plates (not shown).
[0101] (d) Separating the Primary Web into Individual Pieces,
Before or after Having Formed the Precursor Blank.
[0102] This separation of the primary web into a sequence of pieces
may be performed at any time in the process before the material is
folded, provided the then cut pieces may still be transported
appropriately. The transport can be achieved by support means, such
as vacuum belts, or by other continuous webs connecting subsequent
pieces. (see optional process step (j). In a preferred execution,
the blanks are separated at the time they are transferred to the
treatment head on the turret. The separation can be performed by
any suitable conventional means, such as by rotating blades, laser
cutting, etc.
Ad (e) Pivoting the Longitudinal Extension Plates Downwardly in the
Direction Towards the Centre of the Rotating Drum;
[0103] The front and rear regions of the blank as initially
supported by the longitudinal extension plates can readily be
folded downwardly by pivoting these plates, e.g. at an angle of
about 90.degree. to the centre plate.
Ad (f) Folding the Side Portions 3117 of the Pre-Cursor Web 110
Downwardly, Optionally Employing Guide Means or Downwardly Foldable
Lateral Support Plates;
[0104] The side portions 3117 may either be supported by
corresponding laterally extending support plates, which may be also
pivotably affixed to the centre plate, and which may be then
pivoted downwardly.
[0105] Alternatively, the side portions may be supported by
alternative guide means such as stationary guide plates which may
be affixed to a base of the turret (and hence do not rotate), and
at the appropriate position these support means terminate so as to
allow the sideways extension to be folded downwardly, such as by
being pulled downwardly by the appropriately connected waist hoop
material towards the centre of the turret. If these stripes of
optionally elasticated and extended materials are connecting
consecutive blanks (i.e. if these are not yet disconnected or cut)
they will by nature of the curvature of the path on the turret,
automatically pull the side panels appropriately downwards, thus
not necessitating a support plate or guide means.
[0106] The downward folding of the lateral portions of the centre
region 3115 of the Plus-shaped blank 110 occurs along a
curve-linear folding line 3300 as indicated in FIGS. 3A and C will
create a bulging of the centre region, thereby forming a cup-shaped
structure in the finished article 999 reflecting body shaped
contours during use, as described in more detail in co-pending
patent application PCT/EP06/002166. This bulging may optionally be
eased by appropriately shaping the outwardly facing surface 2422 of
the centre plate of the treatment head, and by respective creases
in the side areas of the centre region.
Ad (g): Connecting Respectively Adjacently Positioned Side
Margins;
[0107] After the front (3112) and rear (3118) regions as well as
the side portions 3117 of the Plus shaped pre-cursor blank have
been folded downwardly, the side-margins of respectively adjacently
positioned extension regions are positioned to allow respective
connecting to form a closed structure (refer to FIGS. 3 A and C),
i.e. side margins 3113 of the front region 3112 will be positioned
adjacent to the forward margins 3116 of the side portions, and the
side portions 3123 of the rear region 3118 will be positioned
adjacent to the rearward margins 3126 of the side portions.
[0108] In the simple arrangement as shown in FIG. 3 of the blank
forming a Plus-shape with the arms being essentially rectangularly
arranged, the folding steps along essentially perpendicularly
arranged folding lines will bend these arms out of the original
plane of the blank and arrange cross-directionally oriented edges
adjacent to longitudinally oriented edges, such that the subsequent
step of connecting these to each other will then fix the 3D-shape
of the article. Thus, by the simple downward folding and subsequent
connecting, complex structures may be formed, and edges extending
essentially perpendicularly on the (flat/plus-sign shaped) blank
can now be connected to each other. The order of the downward
folding of the side portions relative to the front and/or rear
regions depends on the desired design, e.g. this defines which
region or portion will overlap the other. Insofar, the order of the
steps as described and claimed herein does not necessarily define
the chronological order.
[0109] The connecting can be achieved by various conventional
techniques such as described in more detail in the above references
co-pending application PCT/EP06/002165, e.g. by applying adhesives
and subsequent compressing, or by using heat, or ultrasonic energy
or the like, or by joining the male and female components of
mechanical fasteners to each other under slight pressure. Depending
on the type of connecting, some or all of the web materials may
project beyond the respective edges of the support means. There can
be one or more sets of treatment tools interacting with the
treatment head. The connecting tools may comprise an active and a
passive element, such as an (active) pressing tool, and the passive
anvil. Treatment tools may be affixed rotatingly to the same axis
as the turret, or to an axis essentially perpendicular to the axis
of the turret, such that the turret segments (and hence treatment
head) pass rotatingly.
[0110] The present invention provides a wide flexibility for
selecting the connecting means and tool, in particular as it allows
two sided working on the bonding, as the materials overlay the
treatment head and may then be treated by one or more corresponding
treatment tools, which may interact with the treatment head in any
way.
Ad (h) Optionally Further Treating the Article;
[0111] After the downward folding of the extensions, the basic form
of the article is defined and fixed by the connecting. A particular
useful further step is the combination with a further web material
forming a hoop 3119, thusly also stabilizing e.g. the unsupported
side portions as described under point (g), if the pre-cursor blank
110 does not already comprise such a material. Also, further
connecting means may be added, e.g. reuseable closures, and the
like, or certain parts may be specifically treated, such a by being
mechanically treated to impart different mechanical properties, or
the surfaces, preferably oriented towards the wearer during use,
may be treated with lotions, creams, or the like, for improved skin
friendliness or purposes of therapeutic treatment.
Ad (i) Removing the Article from the Web Handling Equipment.
[0112] Once all appropriate operations are performed on the now
shaped article, this may be removed from the turret, by employing
various means, such as may be vacuum suction, air pressure, and the
like.
[0113] A particularly suitable way is further shown in FIG. 2A,
showing a rotating disk 950 positioned adjacent the turret 300 and
comprising radially moveable fingers 960 arranged to engage into
the treatment head 2410 and the leg openings 3130 of the article,
so as to allow pulling out of the formed article 999 upon further
rotation of the turret 300 and the rotating finger disk 950. One of
such disks may be positioned on each side of the turret. Web
support means 260 may further transport the formed article 999,
such as to a packaging station (not shown). Care should be taken
during this step to not unduly press or deform the resulting
product, as it may form a "3D-Article", which might not be foldable
flat with all seams also laying flat on a plane, but which might
crumple during this step.
[0114] In addition to the just described process steps, the process
may further include other process steps, in particular step
[0115] (j) adding a further material to the pre-cursor blank.
[0116] In particular, such a material may be a waistband material
3119, as depicted in FIGS. 3A and 3C, which may be added from a
supply roll 2210 as web material 2100 as shown in FIG. 2A. Such a
material may also be pre-combined with another further material, as
described herein below, when a leg cuff material is pre-combined
with a side portion material, and the combined material is then
added to the centre piece (refer to FIG. 5 A to D).
[0117] The present invention also relates to products as may be
manufactured by the manufacturing methods as described herein, and
which are distinctly and beneficially different to typical
conventional designs having a shape, that, when the article is cut
open along lines extending longitudinally through the side portions
of the article and laid on a flat surface, being narrower in the
crotch region of the article than in the waist region(s). Such
articles are often also referred to as "hourglass shaped" articles
4000 (see FIG. 3E--showing front (4012), rear (4018) and centre
(4015). It should be noted, that typically such designs comprise
elastic sealing elements 4100, such as well known leg elastics
and/or elasticated barrier cuffs, which run from the front to the
rear along the crotch crease of the wearer during use. Thus, these
elements will unavoidably create a force, upon which the article
will "sag" or be pulled downwards (on a standing wearer).
[0118] In contrast, articles according to the present invention and
as may be produced by the above described process comprise a
primary or centre piece web material to which laterally outwardly
extending side portions are attached and later connected, such that
this pre-cursor material forms a Plus-shape--refer to FIG. 3. The
outwardly extending portions are only partly attached to the centre
web at the inwardly oriented front and rear corners (refer to FIG.
3A to D), and loosely overlay the centre web between these
connecting points. Upon the folding and connecting of the
respective regions, these overlay regions correspond to the leg
openings 3130 of the article.
[0119] If the article comprises elasticated elements such as to
perform a sealing function in the case of liquid absorbent
articles, these may be positioned circumferentially around the
waist and/or the leg of the wearer, and thus will not induce the
"sag" as described for conventional hourglass shaped articles.
[0120] The side portions of the pre-cursor blank may also be
referred to as hip/thigh panels in a finished article 999, as
these--in contrast to conventional side or hip panels--not only
cover the hip of the wearer during use but extend further down to
the thighs of the wearer. Thus, the present invention provides
articles with a closed structure encircling the legs of a wearer,
which may also referred to as a leg hoop. Such a leg hoop may be
formed of a section of the hip/thigh panel and the laterally
outward section of the centre region, as delimited from the
remainder of the centre region, which may be referred to as centre
crotch region, by the curvelinear fold line 3300, as depicted in
FIG. 3D. Alternatively, as shown in FIG. 3C, a further material may
be connected to the crotch region along a curvelinear connecting
line, or a connecting region delimited by a curve, which may be
further connected to the hip/thigh panel and thus form the leg hoop
or cuff.
[0121] Typically, the resulting article cannot be laid flat on a
flat surface with all connecting lines or regions also being laid
flat on the plane, but which can be laid flat upon cutting open
connecting lines (or borders of connecting regions), then forming a
plus-sign (or cross) shape blank.
[0122] Whilst the above description aimed at explaining the present
invention in simple terms, there are a number of particular
embodiments for the process and the finished product, some of which
are described herein below. However, these embodiments should not
be seen in any way limiting the scope of the invention. It should
also be noted, that the following executions can be combined.
[0123] In one particular execution, the present process allows the
manufacture of articles wherein a leg hoop is formed by the side
portion material 3117 encircling the outer hip and thigh of the
wearer and by a further inner leg cuff material, as schematically
depicted in FIG. 4, showing a perspective view of such an
article.
[0124] The making of the pre-cursor blank is further explained by
referring to FIG. 5, depicting schematically the process steps to
arrive at such a design, within the overall process lay out as
shown in FIG. 2A. To this end, a side portion material 1100,
running along the MD direction 3050 aligned with the MD direction
of the Plus-shaped pre-cursor, is combined with pieces of a leg
cuff forming material 2500. This cuff forming material 2500 runs
initially parallel to the side portion material and is
longitudinally downwardly folded by 180.degree. on a folding
station, indicated at the position 2600, to a predetermined width
of overlap. Thus after the folding station, the perimeter 2505 of
the material is indicated by the dashed line. This web is then run
over a 45.degree. turning bar or roll 2610, inverting the web, such
that the perimeter 2505 becomes visible. The upwardly facing folded
region 2625 can now be treated such as by applying glue by a glue
applicator 2620. This web is now cut by a cutting unit 2630 to the
appropriate length for forming the height of the leg hoop, and
attached with the glue treated folded regions to the side portion
material, as depicted in FIG. 5A. Commercially available tape
cutting units equipped with a rotating head and a side-fed windowed
anvil may be employed for this cutting operation. The receiving web
1100 may be slightly moved downwards by the rotating cutting head,
and pressed against the glue treated folded region of web 2505,
thereby overlapping respective regions and closing the leg hoops.
FIG. 5B shows a schematic cross-sectional view of this combination
1110 of the side portion 1100 with a leg hoop material (2500)
attached thereto and after being separated from the continuous web
1100, e.g. by a cutting tool 2640, cut to the appropriate length.
This cutting may be achieved simultaneously with transferring the
combined material 1110 to the continuous centre piece material 100
(ref. to FIG. 5C). There, it may be attached by means of a
curve-linear connecting line 3300, e.g. a glue line. FIG. 5D shows
a schematic cross-sectional view through this composite. As further
shown in FIG. 5C, the process may include the addition of yet a
further material 2100, which will form a waistband hoop in the
finished article. This material may be supplied over conventional
guide and/or support means, and may be attached to the side portion
material, here shown as being attached to the lateral outward side
margins of the side portion material. When the thusly described
process is mirrored for a second side portion, the Plus-shaped
blank 110 is finalized, and may be transferred to the turret,
before or on which consecutive blanks are separated along the
separation line 111.
[0125] A further particular execution of the present invention
relates to article designs, where the centre piece extends longer
in the MD-direction than the extensible web-material 2100, which
will form the waist hoop 3119 in the article, even when this is at
least partially extended (see waist hoop material 2100 in FIG. 5C).
In one execution, the waist material 2100 may be extended,
preferably elastically extended, so as to match the length of the
centre piece 3100. In another execution, an extra length of waist
web material may be metered in, such that the waist material can be
extended to the desired level, the extra length of (surplus) waist
material forming an overlap in the front and back parts of the
waist hoop, or the extra length of waist material being removed
when the left and right waist hoop portions are joined. In addition
or alternatively, the centre pieces of subsequent blanks may be
separated, and separated end regions may be positioned in a partly
overlapping arrangement ("shingling") before the waist material is
added to the blank.
[0126] When forming an article without a separate web material
forming the waist hoop in the finished article (i.e. such as shown
in FIG. 3), the front- and rear regions of the centre piece and the
side pieces can readily be folded downwardly on the forming head
(refer to step (e) in the above description). In case of a web
material, which is intended to form the waist hoop in the finished
article is already attached to the lateral perimeter of the side
regions, a particularly useful design of the forming head 2410 may
be used. Therein, each of the longitudinal extension plates 2430
may consist of two sub-plates, e.g. in a triangular shape, as
depicted in FIG. 6A. Simultaneous with the downward folding, the
plates also rotate around the bi-directional hinge point 2432, such
that the medial corners 2433 or the front extensions are oriented
at about 45.degree. forward and inwardly, as depicted in FIG. 6B.
The pivoting as well as the rotation may be achieved by
conventional means, such as cam systems, pneumatic or electric
systems, spring loaded systems, or servo motors. As shown in FIG.
6, the lateral extension plates 2440 of the treatment head, are
downwardly affixed by somewhat more than 90.degree., e.g. by
100.degree., such that the now downwardly oriented peripheral ends
are positioned at a smaller CD distance than the CD width of the
centre plate. As shown in FIG. 6A, this may be achieved by sideways
extension plates, which may or may not be pivotable, but which are
narrower at the lower end than at their upper end, and against
which the side panel materials may be pressed. This execution will
allow easy connecting respectively closing of the waist material,
e.g. by heat or glue pressing against the extension plates,
essentially concurrently with the cutting thereof near the medial
corners 2433.
[0127] A further particular execution within the scope of the
present invention relates to the positioning of the hinge-points
2432 of the longitudinal extension plates. As these hinge points
are typically arranged below (e.g. towards the centre of the
turret) the surface of the centre plate 2420, the downward folding
will create an extension of the web material in its MD direction.
This may be compensated by the elastic properties of the web.
Alternatively, the hinge-points may be affixed moveably along the
MD-direction relative to the extension plates, thusly compensating
the extension of the web. Such designs are well known to a skilled
person, refer e.g. to EP-A-0717972.
[0128] The downward folding of the front and rear regions and the
side portions (i.e. the steps d) and e) as described hereinabove)
may be executed simultaneously or one after the other, thereby
defining if and how the individual panels overlap. Depending on the
intended design, the front region material may overlap the outside
of the hip/thigh panel (relative to a wearer being "inside"), as
shown in FIG. 3, or--conversely--the hip/thigh panel may overlap
the front region, as shown in FIG. 4. Similarly, a piece of
material in the front or rear region adjacent to the cut 3125
(refer to FIG. 3B) may be folded and connected inwardly or
outwardly, or it may be cut away.
[0129] Further particular considerations relate to the centre
region web piece, which may be a continuous, unitary piece of
material, or which may be--prior to be transferred to the treatment
head--composed of several pieces of material connected to each
other so as to form the centre piece. For example, the rear region
may comprise an elastic material, or it may be at least extensible
in the MD direction, so as to remain body conforming during
use.
[0130] Similarly, the side portions 3117 forming the hip/thigh
panels may be composed of different materials, or may be composed
of one material, which may have sub-regions with different
properties, which may, for example, be induced by a treating these
regions differently, such as mechanically or thermally.
[0131] This allows to design very cost effective yet very well
fitting articles, as--for example--relatively expensive
elastication can be limited to regions where required, but other
regions may be inelastic, or elasticized to a lesser degree. As an
example, the elastic contractive force may be desired to be at a
higher level in the waist region, lower in the hip regions, and
higher again in the leg region. Also, the higher contractive forces
may be achieved by varying degrees of pressure on the wearer, for
example, in the waist region, the forces may be spread over a
smaller area (thus creating higher pressure on the body), whilst
for the leg hoops, a larger area resulting in lower pressure may be
used to apply these forces. If desired, areas of the hip/thigh
panel can also be coated with materials raising the coefficient of
friction to the skin, thus providing good fit of the product with
minimum surface pressure on the skin.
[0132] Further, because of the specific bending and folding in the
process, materials, which are delivered in machine direction, may
be applied in the article such that their original MD direction
extends now cross-directionally to the orientation of the article.
This will--for example--allow to use elastic material more
efficiently, as MD-oriented stretch is much easier and more cost
effective to induce to a material than CD-oriented stretch.
[0133] In addition to connecting regions permanently, such as
adhesively or thermally, the present invention allows to produce
articles comprising a hoop, e.g. a waist hoop in a pant like
article, which may be connected by means of mechanical fasteners,
glue or thermal bonds, or macro fasteners in the front and/or rear
regions rather than in the side panel regions, such as depicted in
FIG. 7, showing an article as of FIG. 4, additionally comprising a
predetermined tear line 7100 in each hip/thigh regions. This tear
line 7100 may be created in the side portion material 1100 (ref.
also to FIG. 5A), prior to the addition of the leg hoop material
2500. Such a tear line may be created by partial perforation, so as
to allow a user e.g. to inspect an article. In case it is decided
to continue the use of the article, it may be closed again by the
secondary closure means, here shown in form of mechanical fasteners
7200, designed to engage e.g. with the side portion material,
respectively with the hip/thigh panel.
[0134] Such recloseable connecting means may further be employed in
combination with permanent connection means, such as glue lines.
Then, the re-closeable means may be used in addition, e.g. to
adjust the size, or they may replace the permanent ones, once these
are destructively opened, but the article may be otherwise suitable
for further use. The re-fastenability may also be designed such
that the article may be fully opened before being applied to a
wearer, optionally in a further process step, but preferably by a
caregiver. Then, the line 7100 may fully separate the material,
which is then held together by the re-closable connecting means
7200, e.g. mechanical fastener hooks. This design allows to apply
the article in a conventional manner as currently applied for baby
diapers.
[0135] The present invention allows particular flexibility in the
design of the waist features of an article. Conventional industrial
manufacturing processes did not allow waist features--such as waist
shields, or waist bands--to be connected or even interrupted in the
front or back region of the article, as schematically depicted in
FIG. 4, showing a waist hoop 3119 closed by two connections in the
front and the rear of the wearer respectively, and further in FIG.
8A, showing a waist hoop 8119 connected only in the front region of
the wearer. FIG. 8B shows an interrupted hoop, with two gaps 7400,
one in the front region and one in the back region of the wearer.
This is in contrast to conventional high speed produced articles,
where the seam in the waist feature had to be positioned in the
side or hip regions of the wearer, refer to FIG. 8C, showing a
training pant 1000, connected by side seams 1010, and a waist
element 1015, which is also connected at the sides.
[0136] A particular waist feature is schematically depicted in FIG.
8D. It may comprise two pieces of elasticated waist belt material
3119, each connected with one end only along a connecting region or
line 7300 to the region of the hip/thigh panel 3117 overlapping the
rear region 3118 of the centre piece, respectively connected to the
hip/thigh panel in the proximity of the connection to the rear
region of the centre piece. The pieces may then be loosely held
like a draw string in an envelope, e.g. formed by back folded
extensions of the hip/thigh panels, in the figures indicated by the
foldover perimeter 7500. The draw strings may be re-closeably
connected to each other in the front region 3112 of the centre
piece, or each may be connected to the front region 3112 directly.
In a preferred embodiment, this may be achieved by the use of
mechanical fastening means 7200. This design allows, e.g. the
caregiver, to readily adjust the waist circumference of the article
to the user, as indicated in FIG. 8E, showing the same article as
in FIG. 8D, but with the drawstring pulled closer, thusly having a
smaller gap width 7400', e.g. adapted for a smaller waist
circumference. The drawstring material may be an essentially
unitary material, and may be at least in certain regions elastic.
It may be composed of various materials, e.g. being elasticated in
the regions corresponding to the hip regions, and being
non-elastic, e.g. a conventional non-woven or non-woven film
laminate, in the closure region. Typically, it will be made of a
web material, e.g. in form of a band, which for comfort reasons has
preferably a width of more than about 1 mm but less than about 120
mm. During manufacturing, the drawstring may advantageously be
connected to the side portion material, before this is connected to
the centre piece to form the Plus-shaped blank. At that time, it
may also be enveloped by the side portion material being folded
over. The folded material may be trimmed at the front end, so as to
allow easier access to the waist material during the process or
upon use. The drawstring material may already comprise mechanical
fasteners in its front portion. Such mechanical fastener may have a
unidirectional engagement functionality, such that they can be
readily dis-engaged if pulled forwardly (e.g. during the process or
by the caregiver), but they strongly engage if strained along the
other orientation.
[0137] This drawstring design principles may evenly be applied to
leg hoops, i.e. they may each comprise one piece of elasticated leg
hoop material, connected with one end only to the region of the
hip/thigh panel overlapping the rear region of the centre piece,
respectively connected to the hip/thigh panel in the proximity of
the connection to the rear region of the centre piece. The piece
may then be loosely held like a draw string in an envelope, e.g.
formed by back folded extensions of the hip/thigh panels, and may
be re-closeably connected to the centre piece, or directly to the
inner leg cuff piece.
[0138] Yet a further embodiment showing a particular advantage of
the present invention relates to an article comprising a so called
secondary topsheet, as well known in disposable absorbent articles,
such as baby diapers. Such materials, typically light-weight
non-woven materials, are positioned between a (first) topsheet
overlaying the core, e.g. the absorbent core, and the skin of the
wearer, and they are supposed to allow fecal material to pass
through an opening therein, which is in registry with the anal
opening of the wearer. Then, the secondary topsheet either masks
the fecal material and/or prevents it from contacting wearer's
skin. However, all conventional designs, as shown e.g. in WO
03/009795, do not adequately support the tasks of (i) keeping the
secondary topsheet in contact with the skin of the wearer whilst
keeping the opening (ii) sufficiently open and (iii) in registry
with the anal opening to allow the fecal material to pass through,
as well as (iv) providing the void space required to take on and
store the fecal material. The present invention provides a
particularly suitable design, as schematically depicted in FIG. 9,
overcoming such disadvantages as well as a simple process for the
manufacturing thereof, as further explained in reference to FIG. 10
A to G.
[0139] In its simplest form, the secondary topsheet 9100 may be of
any material suitable for this purpose, such as conventional
non-woven materials, not needing any elastic properties. The
opening for being positioned in the region of the anal opening of a
wearer during use has a MD and a CD extension and a respective
perimeter at least during use. The article may further comprise at
least two elastic elements extended to a predetermined extension,
each connected to at least a point of the perimeter or in proximity
of the perimeter of the opening, whereby each two connection points
are in an opposing position relative to the centre of the opening,
and at least to a connection point of the topsheet or the secondary
topsheet, the point being positioned outwardly away relative to the
centre point of the opening, thereby creating a force to sustain
the opening. In a specific embodiment, the secondary topsheet
comprises a cross-directional cut line so as to form the opening
positioned in the region of the anal opening of the wearer during
use, wherein the elastic elements, preferably elastic threads or
bands are positioned essentially aligned with the longitudinal
centre line of the article. Further, the elastic elements are
connected to a point on the perimeter of the cut line or to a point
in the proximity of the cut line and to a point longitudinally away
from the cut line, preferably in the waist region of the article,
such that the tensioning of the elastic elements sustains the
opening formed by the cut line.
[0140] As depicted in FIGS. 9 and 10, the elastics are positioned
along the longitudinal centre line of the web, respectively of the
article 3050. The elastic can readily be extended to a
predetermined extension, and should be connected to the secondary
topsheet material at least at a point 9500 at the perimeter of the
opening, respectively a cut 9400, which may then form the opening.
The elastic material is further connected at least to two further
points 9550 longitudinally offset. This web may then be apertured,
such as by being cross-directionally cut at a width corresponding
to the desired opening width at a position corresponding to the
anal opening of the wearer during use. Then the elastic material
9300 will create the appropriate forces to maintain the opening
9400. In one exemplarily described manufacturing process, the
elastic 9300 is first combined to the web material, and this
composite, preferably trimmed to an hourglass shape, as indicated
in FIG. 10A, is added to the centre piece 3100 of the pre-cursor
blank on the surface opposite to the one where the side portions
are or are to be connected, corresponding to the inner side of the
article after folding. The cross-directional cut may be introduced
at that point in time, or preferably before combining the composite
to the centre piece.
[0141] The secondary topsheet is connected to the pre-cursor blank
3100 at its front and rear perimeter along connecting lines 9120,
which may be any conventional connecting means, preferably fine
glue lines (see FIGS. 10 A and D). In a second step, the centre
piece 3100 with the secondary topsheet 9100 is longitudinally
folded along fold lines 9600, such that the secondary topsheet is
not folded in the narrower centre region, but rather in wider front
and rear regions. This fold, as shown in FIGS. 10B and B will
overlay the outer parts of the secondary topsheet. The secondary
topsheet can now be connected to the edge of the centre piece, as
indicated as bond line 9700 in FIG. 10F, but only in a region
corresponding to the region of the cut towards the anal opening.
Now, the z-fold can be removed, leaving the parts of the cuffs
attached to the secondary top sheet, and the front and rear parts
of the cuffs to the hip/leg panel, thereby exposing parts of both
surfaces of the cuffs at the same time. Now, the precursor blank,
as depicted in FIGS. 10C and G, may be transferred for further
processing.
[0142] During use, the secondary topsheet will be held closely to
the skin of the wearer, and the opening will be maintained open in
longitudinal direction by the contractive forces of the elastic.
Furthermore, it will be maintained open cross-directionally because
of the connection to the side margins of the centre piece, now
being upwardly folded towards the crotch crease of the wearer,
thereby providing the void space required.
[0143] In an alternative execution, the elastic may be applied
cross-directionally in the article, whilst the cut to create the
opening is applied perpendicularly thereto. In yet a further
alternative, the opening may already be created by cutting out a
piece of the secondary topsheet material, and elastics at any
orientation may be applied to maintain the opening in place. In yet
a further alternative, the secondary topsheet may be made of a
material exhibiting in itself elastic properties, or it may be a
composite of such a material and other non-elastic materials.
[0144] In a preferred embodiment, the secondary topsheet material
may be particularly treated to enhance liquid penetration in
certain regions, e.g. regions intended for receiving aqueous
exudates, such as urine, whilst other regions, such as the regions
surrounding the opening, are treated to prevent e.g. feces to
penetrate through.
[0145] A further preferred execution of a secondary topsheet
includes means for enhancing skin friendliness, such as by being
highly air permeable, or by comprising particularly skin friendly
substances, such as cream or lotions.
[0146] A further particular design feature relates to articles,
such as pant-style articles, which may, for example fit lower in
the front of the wearer than in the back. Such products can be
readily achieved by shaping the hip/thigh panels not rectangularly,
but, for example, trapezoidal, and the front and rear region of the
centre piece will also have a corresponding difference in
length.
[0147] Whilst the present discussion focused of the forming of the
article from essentially flat web materials, each of these
materials may be a composite, made partly or fully of several
layers of web materials. In particular, for the application as an
absorbent article, an absorbent core may be inserted, which may be
also an essentially web-like material, or a sheet, or which may be
in a three-dimensional shape itself, or which may comprise an
acquisition system comprising at least one extra layer of material
with high strike through performance"
[0148] The present invention may be applied to a wide variety of
articles. Without wishing to imply any limitation, it may be used
for the making of disposable absorbent articles, such as baby
diapers design, where the connecting of the front region to the
hip/leg panel is achieved by recloseable means, such as mechanical
fastening means, or tapes, pre-closed pants and training pants,
menstrual pants, adult incontinence articles and the like; of
disposable articles as such, such as disposable underwear; of
non-disposable articles, such as underwear, swimwear, etc.
[0149] Similarly, the present invention covers the articles as
produced by the present invention, as well as particular
embodiments of articles, which hitherto have not been able to be
manufactured in industrial scale on high speed production
machinery.
* * * * *