U.S. patent application number 14/014678 was filed with the patent office on 2015-03-05 for folded absorbent article.
The applicant listed for this patent is Kimberly-Clark Worldwide, Inc.. Invention is credited to Patsy Ann Benedict, Brooke Ann Robaidek, Leila Joy Roberson, Gay Lynn Wolf.
Application Number | 20150064416 14/014678 |
Document ID | / |
Family ID | 52583634 |
Filed Date | 2015-03-05 |
United States Patent
Application |
20150064416 |
Kind Code |
A1 |
Wolf; Gay Lynn ; et
al. |
March 5, 2015 |
Folded Absorbent Article
Abstract
A method of making a folded absorbent article includes the steps
of: providing an absorbent structure; providing a
liquid-impermeable back sheet having a body-facing surface and a
substrate-facing surface; joining the absorbent structure in facing
relation to the body-facing surface of the back sheet to define an
absorbent article; applying adhesive to the substrate-facing
surface of the back sheet to define a first adhesive zone and a
second adhesive zone; treating portions of the substrate-facing
surface of the back sheet to define a first treated zone and a
second treated zone; folding the absorbent article to align the
first adhesive zone in facing relation with the first treated zone;
and folding the absorbent article to align the second adhesive zone
in facing relation with the second treated zone.
Inventors: |
Wolf; Gay Lynn; (Neenah,
WI) ; Roberson; Leila Joy; (Kimberly, WI) ;
Benedict; Patsy Ann; (Omro, WI) ; Robaidek; Brooke
Ann; (Menash, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kimberly-Clark Worldwide, Inc. |
Neenah |
WI |
US |
|
|
Family ID: |
52583634 |
Appl. No.: |
14/014678 |
Filed: |
August 30, 2013 |
Current U.S.
Class: |
428/195.1 ;
156/226 |
Current CPC
Class: |
A61F 2013/15048
20130101; A61F 13/56 20130101; B32B 3/16 20130101; B01J 20/2804
20130101; A61F 13/15 20130101; C09J 7/20 20180101; B32B 3/04
20130101; Y10T 156/1049 20150115; A47C 31/105 20130101; Y10T
428/24802 20150115; A61F 13/551 20130101; C09J 2301/204 20200801;
Y10T 428/28 20150115; C09J 7/29 20180101; B01J 20/30 20130101; Y10T
428/24826 20150115 |
Class at
Publication: |
428/195.1 ;
156/226 |
International
Class: |
B01J 20/28 20060101
B01J020/28; B01J 20/30 20060101 B01J020/30 |
Claims
1. An absorbent article comprising, a back sheet having a
body-facing surface and a substrate-facing surface, an absorbent
structure joined in facing relation with the body-facing surface of
the back sheet to define the absorbent article, the
substrate-facing surface of the back sheet comprising an adhesive
zone and a treated zone, and the absorbent article being folded
along a fold line such that the adhesive zone and the treated zone
are aligned in facing relation.
2. The absorbent article of claim 1 wherein the absorbent article
defines a longitudinal direction and a lateral direction
perpendicular to the longitudinal direction and wherein the fold
line is parallel with either the lateral direction or the
longitudinal direction.
3. The absorbent article of claim 1 wherein the absorbent article
defines a longitudinal direction and a lateral direction
perpendicular to the longitudinal direction and wherein the fold
line is non-parallel with either the lateral direction or the
longitudinal direction.
4. The absorbent article of claim 1 wherein the back sheet
comprises, a first adhesive zone, a second adhesive zone, a first
treated zone, and a second treated zone each positioned on the
substrate-facing surface, the absorbent article being folded along
a first fold line such that the first adhesive zone and the first
treated zone are aligned in facing relation, and the absorbent
article being folded along a second fold line such that the second
adhesive zone and the second treated zone are aligned in facing
relation.
5. The absorbent article of claim 4 wherein the absorbent article
is folded at a third fold line to position the body-facing surface
in a protected condition.
6. The absorbent article of claim 5 wherein the absorbent article
is folded at a third fold line to position the first adhesive zone
and the second adhesive zone in a protected condition.
7. The absorbent article of claim 4 wherein the first adhesive zone
and the second adhesive zone comprise pressure sensitive hot melt
adhesive having a concentration between 10 and 60 grams per square
meter.
8. The absorbent article of claim 4 wherein the first treated zone
and the second treated zone comprise silicone.
9. The absorbent article of claim 4 wherein the back sheet
comprises, a first adhesive zone, a second adhesive zone, a third
adhesive zone, a fourth adhesive zone, a first treated zone, a
second treated zone, a third treated zone, and a fourth treated
zone, each on the substrate-facing surface, the absorbent article
being folded along a first fold line such that the first adhesive
zone and the first treated zone are aligned in facing relation and
the second adhesive zone and the second treated zone are aligned in
facing relation, and the absorbent article being folded along a
second fold line such that the third adhesive zone and the third
treated zone are aligned in facing relation and the fourth adhesive
zone and the fourth treated zone are aligned in facing
relation.
10. A method of making a folded absorbent article comprising,
providing an absorbent structure, providing a liquid-impermeable
back sheet having a body-facing surface and a substrate-facing
surface, joining the absorbent structure in facing relation to the
body-facing surface of the back sheet to define an absorbent
article, applying adhesive to the substrate-facing surface of the
back sheet to define a first adhesive zone and a second adhesive
zone, treating portions of the substrate-facing surface of the back
sheet to define a first treated zone and a second treated zone,
folding the absorbent article to align the first adhesive zone in
facing relation with the first treated zone, and folding the
absorbent article to align the second adhesive zone in facing
relation with the second treated zone.
11. The method of claim 10 further comprising, folding the
absorbent article to define a protected condition wherein only the
substrate-facing surface is exposed.
12. The method of claim 11 further comprising repeating the steps
to provide a plurality of absorbent articles in the protected
condition and placing the plurality of absorbent articles into a
package while in the protected condition.
13. The method of claim 10 wherein the treating step includes
applying silicone to the substrate-facing surface of the back sheet
to define the first treated zone and the second treated zone.
14. The method of claim 10 wherein the absorbent article defines a
longitudinal direction and a lateral direction and wherein the
folding step includes folding the absorbent article along a first
line that is parallel to the longitudinal direction or folding the
absorbent article along a second line that is parallel to the
lateral direction.
15. The method of claim 10 wherein the absorbent article defines a
longitudinal direction and a lateral direction and wherein the
folding step includes folding the absorbent article along a first
line that is neither parallel to the longitudinal direction nor the
lateral direction.
16. The method of claim 14 wherein the folding step includes
folding the absorbent article along a third line that is neither
parallel to the longitudinal direction nor the lateral
direction.
17. A method of making a folded absorbent article comprising,
providing an absorbent structure, providing a liquid-impermeable
back sheet made of polyethylene film and having a body-facing
surface and a substrate-facing surface, joining the absorbent
structure in facing relation to the body-facing surface of the back
sheet to define an absorbent article, applying adhesive to the
substrate-facing surface of the back sheet to define a first
adhesive zone, a second adhesive zone, a third adhesive zone, and a
fourth adhesive zone, treating portions of the substrate-facing
surface of the back sheet with silicone to define a first treated
zone, a second treated zone, a third treated zone, and a fourth
treated zone, folding the absorbent article to align the first
adhesive zone in facing relation with the first treated zone,
folding the absorbent article to align the second adhesive zone in
facing relation with the second treated zone, folding the absorbent
article to align the third adhesive zone in facing relation with
the third treated zone, folding the absorbent article to align the
fourth adhesive zone in facing relation with the fourth treated
zone, and folding the absorbent article to define a protected
condition wherein only the substrate-facing surface is exposed.
18. The method of claim 17 wherein the absorbent article defines a
longitudinal direction and a lateral direction and wherein the
folding step includes folding the absorbent article along a first
line that is parallel to the longitudinal direction or folding the
absorbent article along a second line that is parallel to the
lateral direction.
19. The method of claim 17 wherein the absorbent article defines a
longitudinal direction and a lateral direction and wherein the
folding step includes folding the absorbent article along a first
line that is neither parallel to the longitudinal direction nor the
lateral direction.
20. The method of claim 18 wherein the folding step includes
folding the absorbent article along a third line that is neither
parallel to the longitudinal direction nor the lateral direction.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to disposable
absorbent articles for absorbing fluids and more particularly to a
disposable absorbent article having adhesive for adhering the
article to a substrate. While disposable absorbent articles are
known to protect mattresses, linens, furniture, and the like from
body fluids, there remains a need for a disposable absorbent
article that adheres to various surfaces but requires no release
sheet.
SUMMARY OF THE INVENTION
[0002] In one aspect, the present invention provides an absorbent
article having a back sheet and an absorbent structure wherein the
back sheet has a body-facing surface and a substrate-facing surface
and wherein the absorbent structure is joined in facing relation
with the body-facing surface of the back sheet to define the
absorbent article. The substrate-facing surface of the back sheet
also includes an adhesive zone and a treated zone. The absorbent
article is folded along a fold line such that the adhesive zone and
the treated zone are aligned in facing relation.
[0003] In various embodiments, the absorbent article defines a
longitudinal direction and a lateral direction perpendicular to the
longitudinal direction and the fold line is parallel with either
the lateral direction or the longitudinal direction. In some
embodiments, the fold line is non-parallel with either the lateral
direction or the longitudinal direction. In some embodiments, the
absorbent article includes a fold line that is parallel with the
lateral direction and/or the longitudinal direction and also
includes a fold line that is non-parallel with either the lateral
direction or the longitudinal direction.
[0004] In various embodiments, the back sheet includes a first
adhesive zone, a second adhesive zone, a first treated zone, and a
second treated zone each positioned on the substrate-facing
surface. The absorbent article is folded along a first fold line
such that the first adhesive zone and the first treated zone are
aligned in facing relation. The absorbent article is also folded
along a second fold line such that the second adhesive zone and the
second treated zone are aligned in facing relation. In some
embodiments, the absorbent article is folded at a third fold line
to define a folded configuration having complete protection of the
body-facing surface (i.e., the protected condition). In some
embodiments, the absorbent article is folded at a third fold line
to define a folded configuration having complete protection of the
first adhesive zone and the second adhesive zone.
[0005] In various embodiments, the first adhesive zone and the
second adhesive zone include pressure sensitive adhesive that has
been applied in a slot coat pattern. In some embodiments, the first
treated zone and the second treated zone include silicone that has
been applied in a spray pattern.
[0006] In various embodiments, the back sheet includes a first
adhesive zone, a second adhesive zone, a third adhesive zone, a
fourth adhesive zone, a first treated zone, a second treated zone,
a third treated zone, and a fourth treated zone, each on the
substrate-facing surface. In these embodiments, the absorbent
article is folded along a first fold line such that the first
adhesive zone and the first treated zone are aligned in facing
relation and the second adhesive zone and the second treated zone
are aligned in facing relation. Additionally, the absorbent article
is folded along a second fold line such that the third adhesive
zone and the third treated zone are aligned in facing relation and
the fourth adhesive zone and the fourth treated zone are aligned in
facing relation.
[0007] In another aspect, the present invention provides a method
of making a folded absorbent article. The method includes providing
an absorbent structure, providing a liquid-impermeable back sheet
having a body-facing surface and a substrate-facing surface, and
joining the absorbent structure in facing relation to the
body-facing surface of the back sheet to define an absorbent
article. The method further includes the step of applying adhesive
to the substrate-facing surface of the back sheet to define a first
adhesive zone and a second adhesive zone. The method further
includes the step of treating portions of the substrate-facing
surface of the back sheet to define a first treated zone and a
second treated zone. The method further includes the steps of
folding the absorbent article to align the first adhesive zone in
facing relation with the first treated zone and folding the
absorbent article to align the second adhesive zone in facing
relation with the second treated zone.
[0008] In various embodiments, the method may further include the
step of folding the absorbent article to define a protected
condition wherein only the substrate-facing surface is exposed. In
some embodiments, the method further includes repeating these steps
to provide a plurality of absorbent articles in the protected
condition and placing the plurality of absorbent articles into a
package while in the protected condition.
[0009] In various embodiments, the treating step includes applying
silicone to the substrate-facing surface of the back sheet to
define the first treated zone and the second treated zone.
[0010] In various embodiments, the absorbent article defines a
longitudinal direction and a lateral direction and the folding step
of the method further includes folding the absorbent article along
a first line that is parallel to the longitudinal direction or
folding the absorbent article along a second line that is parallel
to the lateral direction.
[0011] In various embodiments, the absorbent article defines a
longitudinal direction and a lateral direction and the folding step
of the method further includes folding the absorbent article along
a first line that is neither parallel to the longitudinal direction
nor the lateral direction.
[0012] In another aspect, the present invention provides a method
of making a folded absorbent article. The method includes providing
an absorbent structure, providing a liquid-impermeable back sheet
made of polyethylene film and having a body-facing surface and a
substrate-facing surface, and providing a top sheet made of
non-woven spun bond polymer. The method further includes joining
the absorbent structure in facing relation to the body-facing
surface of the back sheet to define an absorbent article. The
method further includes applying adhesive to the substrate-facing
surface of the back sheet to define a first adhesive zone, a second
adhesive zone, a third adhesive zone, and a fourth adhesive zone.
The method also includes treating portions of the substrate-facing
surface of the back sheet with silicone to define a first treated
zone, a second treated zone, a third treated zone, and a fourth
treated zone.
[0013] The method further includes folding the absorbent article to
align the first adhesive zone in facing relation with the first
treated zone, folding the absorbent article to align the second
adhesive zone in facing relation with the second treated zone,
folding the absorbent article to align the third adhesive zone in
facing relation with the third treated zone, and folding the
absorbent article to align the fourth adhesive zone in facing
relation with the fourth treated zone. The method also includes the
step of folding the absorbent article to define a protected
condition wherein only the substrate-facing surface is exposed.
[0014] In some embodiments, the absorbent article defines a
longitudinal direction and a lateral direction and the folding step
includes folding the absorbent article along a first line that is
parallel to the longitudinal direction or folding the absorbent
article along a second line that is parallel to the lateral
direction.
[0015] In some embodiments, the folding step includes folding the
absorbent article along a first line that is neither parallel to
the longitudinal direction nor the lateral direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of an exemplary disposable
absorbent.
[0017] FIG. 2 is a top view of the disposable absorbent article of
FIG. 1 with the body-facing surface towards the viewer and with a
portion of the top sheet cut away to illustrate the underlying
structure.
[0018] FIG. 3 is a bottom view of the disposable absorbent article
of FIG. 1 with the substrate-facing surface towards the viewer.
[0019] FIG. 4 is a cross-section view of the absorbent article of
FIG. 2 taken along line 4-4.
[0020] FIG. 5 is a perspective view of the disposable absorbent
article of FIG. 1 placed on a bed and attached to a bottom sheet
thereof.
[0021] FIG. 6 is a top view of another exemplary disposable
absorbent article in a first folded configuration.
[0022] FIG. 6A is a cross-section view of the absorbent article of
FIG. 6 taken along the line 6A-6A.
[0023] FIG. 7 is a top view of the absorbent article of FIG. 6 in a
second folded configuration.
[0024] FIG. 7A is a cross-section view of the absorbent article of
FIG. 7 taken along the line 7A-7A.
[0025] FIG. 8 is a top view of the absorbent article of FIG. 6 in
an unfolded configuration with the body-facing surface towards the
viewer and with portions cut away to illustrate the underlying
structure.
[0026] FIG. 9 is a bottom view of the absorbent article of FIG. 6
in an unfolded configuration with the substrate-facing surface
towards the viewer.
[0027] FIG. 10 is a top view of another exemplary absorbent article
in a first folded configuration.
[0028] FIG. 11 is a top view of the absorbent article of FIG. 10 in
a second folded configuration.
[0029] FIG. 12 is a top view of the absorbent article of FIG. 10 in
a third folded configuration.
[0030] FIG. 13 is a top view of the absorbent article of FIG. 10 in
a fourth folded configuration.
[0031] FIG. 14 is a top view of the absorbent article of FIG. 10 in
a fifth folded configuration.
[0032] FIG. 15 is a top view of the absorbent article of FIG. 10 in
an unfolded configuration with the body-facing surface towards the
viewer and with portions cut away to illustrate the underlying
structure.
[0033] FIG. 16 is a bottom view of the absorbent article of FIG. 10
in an unfolded configuration with the substrate-facing surface
towards the viewer.
[0034] FIG. 17 is a top view of another exemplary absorbent article
in a first folded configuration.
[0035] FIG. 18 is a top view of the absorbent article of FIG. 17 in
a second folded configuration.
[0036] FIG. 19 is a top view of the absorbent article of FIG. 17 in
a third folded configuration.
[0037] FIG. 20 is a top view of the absorbent article of FIG. 17 in
a fourth folded configuration.
[0038] FIG. 21 is a top view of the absorbent article of FIG. 17 in
an unfolded configuration with the body-facing surface towards the
viewer.
[0039] FIG. 22 is a bottom view of the absorbent article of FIG. 17
in an unfolded configuration with the substrate-facing surface
towards the viewer.
[0040] FIG. 23 is a flow chart illustration of an exemplary method
of the present invention.
[0041] FIG. 24 is a flow chart illustration of another exemplary
method of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0042] FIGS. 1-5 illustrate an exemplary disposable absorbent
article 100 configured to absorb fluid, such as bodily fluid. FIG.
1 is a perspective view of the disposable absorbent article 100
with the body-facing surface towards the viewer. FIG. 2 is a top
view of the disposable absorbent article 100 of FIG. 1 with the
body-facing surface towards the viewer and with a portion of the
top sheet cut away to illustrate the underlying structure. FIG. 3
is a bottom view of the disposable absorbent article 100 of FIG. 1
with the substrate-facing surface towards the viewer. FIG. 4 is a
cross-section view of the absorbent article 100 of FIG. 2 taken
along the line 4-4. FIG. 5 is a perspective view of the disposable
absorbent article 100 of FIG. 1 placed on a bed and attached to a
bottom sheet thereof. Other suitable absorbent articles are
described in U.S. publication 20130115437, Ser. No. 13/291,871,
filed on Nov. 8, 2011, the entirety of which is incorporated herein
by reference where not contradictory.
[0043] The illustrated disposable absorbent article 100 is sized
and shaped for placing on a bed 101 (FIG. 5). More specifically,
the illustrated disposable absorbent article 100 is adapted to be
adhered to a bottom (e.g., a fitted) sheet 103 of the bed and
underlie a child sleeping in the bed. Thus, as described in more
detail below, the disposable absorbent article 100 inhibits bodily
fluid (e.g., urine) released from the child while sleeping in the
bed 101 from wetting the bed sheet 103 or a mattress of the bed. In
various embodiments, the disposable absorbent article 100 may be
placed between the bed sheet 103 and the mattress of the bed 101.
In such a configuration, the disposable absorbent article 100 can
be adhered directly to the mattress. In various embodiments, the
disposable absorbent articles described herein may be used to
protect any suitable surface from contact with fluids. For example,
the disposable absorbent articles described herein may be used to
protect furniture, flooring, automobile fabric, and the like from
contact with various fluids. In various embodiments, the disposable
absorbent articles may be used to absorb any suitable bodily fluids
and other types of fluids (e.g., spilled drinks). In various
embodiments, the disposable absorbent articles may be used for
individuals besides children including, but not limited to,
infants, elderly, and the bedridden. In addition, in various
embodiments, the disposable absorbent articles may be used for
pets.
[0044] The disposable absorbent articles of the present invention
have a longitudinal direction 10 and a lateral direction 20. The
illustrated disposable absorbent article 100, for example, has a
length L (i.e., the extent of the disposable absorbent article in
the longitudinal direction 10) of approximately 880 millimeters and
a width W (i.e., the extent of the disposable absorbent article in
the lateral direction 20) of approximately 780 millimeters. Thus,
the illustrated disposable absorbent article 100 is generally
rectangular. In various embodiments, the articles can have any
suitable length and/or width. In some embodiments, the length of
the disposable absorbent articles described herein can range from
about 12 inches (305 millimeters) to about 84 inches (2,135
millimeters), and the width of the disposable absorbent articles
can range from about 12 inches (305 millimeters) to about 72 inches
(1,829 millimeters). In various embodiments, the disposable
absorbent articles can have any suitable shape (e.g., square,
circular, elliptical).
[0045] In some embodiments, the absorbent articles include a top
sheet 102, a back sheet 104 and an absorbent structure 106 disposed
between the top sheet and the back sheet. In general, the absorbent
articles define a body-facing surface 30 and a substrate-facing
surface 32. In the illustrated embodiments, the exposed surface of
the top sheet 102 defines the body-facing surface 30 of the
absorbent article. Likewise, in the illustrated embodiments, the
exposed surface of the back sheet 104 defines the substrate-facing
surface 32 of the absorbent article.
[0046] In the illustrated embodiments, the top sheet 102 and back
sheet 104 extend beyond the periphery of the absorbent structure
106 and are adhesively bonded to each other to capture the
absorbent structure. In various embodiments, the top sheet and the
back sheet may be bonded together about the periphery of the
absorbent structure using any suitable bonding technique. In some
embodiments, the top sheet, the back sheet, and the absorbent
structure may be coextensive. In some embodiments, the absorbent
structure may extend beyond the top sheet and/or the back
sheet.
[0047] In various embodiments, the absorbent structure 106 may be
adhesively bonded to both the top sheet 102 and the back sheet 104.
In addition, the top sheet 102 may be adhesively bonded to the back
sheet 104 about the periphery of the absorbent structure 106. In
various embodiments, the top sheet 102, the back sheet 104, and/or
the absorbent structure 106 may be bonded together using other
suitable bonding techniques in addition to or in place of adhesive.
In some embodiments, the top sheet 102 may be free from direct
bonding with either the back sheet 104 or the absorbent structure
106, or the back sheet may be free from direct bonding with either
the top sheet or the absorbent structure.
[0048] One suitable way to form the illustrated disposable
absorbent articles includes placing the discrete absorbent
structure 106 on a continuous web to which adhesive has been
uniformly applied. In some embodiments, the continuous web may be
the back sheet 104. Next, a continuous web of nonwoven material (or
other material suitable for use as the top sheet 102), which has
adhesive applied thereto, may be laid over the absorbent structure
106. The resulting laminate structure may then be passed through a
suitable nip (e.g., a rubber/steel nip) to assure pad
integrity.
[0049] The absorbent structure 106 is configured to absorb body
fluids including, but not limited to, urine that passes through the
top sheet 102. The absorbent structure 106 may have one or more
layers of absorbent materials. That is, the absorbent structures
106 may be a single layer of absorbent materials or may be a
multilayer structure. Each of the layers of the absorbent structure
106 can contain similar materials or different materials.
[0050] Suitable materials which can be used to form the absorbent
structure 106 include those materials conventionally used in
absorbent articles and include materials, such as, for example,
cellulose, wood pulp fluff, rayon, cotton, and meltblown polymers
such as polyester, polypropylene or coform. Coform is a meltblown
air-formed combination of meltblown polymers, such as
polypropylene, and absorbent staple fibers, such as cellulose.
[0051] The absorbent structure 106 of the various embodiments can
also be formed from a composite comprised of a hydrophilic material
which may be formed from various natural or synthetic fibers, wood
pulp fibers, regenerated cellulose or cotton fibers, or a blend of
pulp and other fibers. One particular example of a material which
may be used as the absorbent structure is an airlaid material.
[0052] In some embodiments, the absorbent structures 106 may
include a superabsorbent material, in addition to or in place of
the hydrophilic material, which increases the ability of the
absorbent structure to absorb a large amount of fluid in relation
to its own weight. Generally stated, the superabsorbent material
can be a water-swellable, generally water-insoluble,
hydrogel-forming polymeric absorbent material, which is capable of
absorbing at least about 15, suitably about 30, and possibly about
60 times or more its weight in physiological saline (e.g., saline
with 0.9 wt % NaCl). The superabsorbent materials can be inserted
into the absorbent structure 106 as particles or in sheet form. The
superabsorbent material may be biodegradable or bipolar. In various
embodiments, the superabsorbent material may be uniformly
distributed or selectively placed within the absorbent structure
106. The amount of superabsorbent material may be selected to hold
an anticipated quantity of liquid such as urine, for instance
during over-night usage. The amount of superabsorbent material may,
for example, be from about 5 grams to about 100 grams of a highly
absorbent polyacrylate.
[0053] The hydrogel-forming polymeric absorbent material may be
formed from organic hydrogel-forming polymeric material, which may
include natural material such as agar, pectin, and guar gum;
modified natural materials such as carboxymethyl cellulose,
carboxyethyl cellulose, and hydroxypropyl cellulose; and synthetic
hydrogel-forming polymers. Synthetic hydrogel-forming polymers
include, for example, alkali metal salts of polyacrylic acid,
polyacrylamides, polyvinyl alcohol, ethylene maleic anhydride
copolymers, polyvinyl ethers, polyvinyl morpholinone, polymers and
copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides,
polyvinyl pyridine, and the like. Other suitable hydrogel-forming
polymers include hydrolyzed acrylonitrile grafted starch, acrylic
acid grafted starch, and isobutylene maleic anhydride copolymers
and mixtures thereof. The hydrogel-forming polymers may be lightly
crosslinked to render the material substantially water insoluble.
Crosslinking bonds may, for example, be by irradiation or covalent,
ionic, Van der Waals, hydrogen bonding, or combinations thereof.
Hydroxyfunctional polymers have been found to be good
superabsorbents for sanitary napkins. Such superabsorbents are
commercially available from Dow Chemical, Hoechst-Celanese, and
Stockhausen, Incorporated, among others, and are a partially
neutralized salt of cross-linked copolymer of polyacrylic acid and
polyvinyl alcohol having an absorbency under load value above 25
grams of absorbed liquid per gram of absorbent material (g/g).
Other types of superabsorbent materials known to those skilled in
the art can also be used.
[0054] The absorbent structure 106 of the various embodiments may
include pattern bonding defined by a plurality of bonds. The bonds
may have any suitable size and/or shape and may be arranged in any
suitable pattern. In one suitable embodiment, the bonds may be
circular and have a diameter of less than about 10 millimeters and
suitably, between about 0.5 millimeters and about 3 millimeters. In
one suitable embodiment, more than 1 percent of the absorbent
structure 106 is bonded by the point bonds. Suitably, 10 percent to
60 percent of the absorbent structure 106 is bonded by the point
bonds. More suitably, 15 percent to 45 percent of the absorbent
structure 106 is bonded by the point bonds. In one suitable
embodiment, for example, approximately 17.5 percent of the
absorbent structure 106 is bonded by the point bonds.
[0055] It is understood that the pattern bonding can be formed
using any suitable pattern including continuous and discontinuous
patterns. For example, the pattern bonding can comprise the
discontinuous point bonds or can include a continuous line diamond
pattern. It is also understood that the pattern bonding can be in
the form of a decorative figure, e.g., an animal, a cartoon
character, or other playful character. It is contemplated that the
pattern bonding could be achieved in any suitable manner including
heated rollers, ambient temperature rollers, or ultrasonic
bonding.
[0056] In some embodiments, the absorbent structure 106 can be made
by distributing cellulose fluff uniformly onto a tissue paper
layer. Next, particles of suitable super absorbent material (SAM)
are generally uniformly distributed onto the fluff. Then another
layer of tissue paper is placed over the cellulose fluff containing
the SAM to form a composite. The composite is then compacted using
any suitable means. In one example, the composite can be passed
through a steel/steel nip. In one suitable embodiment, the
steel/steel nip comprises an embossing roll and an associated anvil
roll. Suitably, either the embossing roll or the anvil roll is
heated and, more suitably, both the embossing roll and the anvil
roll are heated.
[0057] It is contemplated that the absorbent structures 106 can be
formed as a continuous web or as discrete units. If the absorbent
structures 106 are formed as a continuous web comprising a
plurality of interconnected absorbent structures, the method of
forming the absorbent structures could include a suitable device to
cut the interconnected absorbent structure into discrete piece. For
example, one suitable cutting device is a knife and an associated
anvil roll.
[0058] In various embodiments, the top sheet 102 may comprise a
liquid permeable material, which allows fluids to pass through the
top sheet and into the underling absorbent structure 106. In some
embodiments, the top sheet 102 can be adapted to direct bodily
fluids (e.g., urine) away from the user and toward the absorbent
structure 106. That is, the top sheet 102 can be configured to
retain little to no fluid in its structure and readily allow body
fluids to pass there through. Suitably, the top sheet 102 can be
configured to provide a relatively comfortable and non-irritating
surface for the user.
[0059] The top sheet 102 can include a layer constructed of any
operative material, and may be a composite material. For example,
the top sheet 102 can include a woven fabric, a nonwoven fabric, a
polymer film, a film-nonwoven fabric laminate or the like, as well
as combinations thereof. Examples of a nonwoven fabric useable in
the top sheet 102 include, for example, an airlaid nonwoven web, a
spunbond nonwoven web, a meltblown nonwoven web, a bonded-carded
web, a hydroentangled nonwoven web, a spunlace web or the like, as
well as combinations thereof. Other examples of suitable materials
for constructing the top sheet 102 can include rayon, bonded-carded
webs of polyester, polypropylene, polyethylene, nylon, or other
heat-bondable fibers, finely perforated film webs, net-like
materials, and the like, as well as combinations thereof. These
webs can be prepared from polymeric materials such as, for example,
polyolefins, such as polypropylene and polyethylene and copolymers
thereof, polyesters in general including aliphatic esters such as
polylactic acid, nylon or any other heat-bondable materials. When
the top sheet 102 is a film or a film laminate, the film may be
sufficiently apertured or otherwise worked to allow fluids to flow
through the top sheet to the absorbent structure 106.
[0060] Other examples of suitable materials for the top sheet 102
are composite materials of a polymer and a nonwoven fabric
material. The composite materials are typically in the form of
integral sheets generally formed by the extrusion of a polymer onto
a nonwoven web, such as a spunbond material. In a particular
arrangement, the top sheet 102 can be configured to be operatively
liquid-permeable with regard to the liquids that the article is
intended to absorb or otherwise handle. The operative
liquid-permeability may, for example, be provided by a plurality of
pores, perforations, apertures or other openings, as well as
combinations thereof, that are present or formed in the top sheet
102. The apertures or other openings can help increase the rate at
which bodily fluid (e.g., urine) can move through the thickness of
the top sheet 102 and penetrate into the absorbent structure
106.
[0061] In the illustrated embodiments, the top sheet 102 extends
beyond the absorbent structure 106 and is adhesively bonded to the
back sheet 104. It is contemplated, however, that the top sheet 102
can have the same extent as the absorbent structure 106 and/or back
sheet 104 or can have an extent less than the absorbent structure
and/or back sheet. It is further contemplated that in some
embodiments (not shown), the top sheet 102 can be omitted. Thus, in
such an embodiment, the disposable absorbent article 100 would
comprise only the absorbent structure 106 and the back sheet
104.
[0062] Additional layers or substrates, such as, a liquid
acquisition and distribution layer, also referred to as a surge or
transfer layer, and an optional tissue layer can be incorporated
into the absorbent structure 106 of the absorbent articles. The
distribution layer may be shorter than the absorbent structure 106
or have the same length as the absorbent structure. The
distribution layer serves to temporarily hold an insulting fluid to
allow the absorbent structure sufficient time to absorb the fluid,
especially when a superabsorbent material is present.
[0063] The back sheet 104 of the various embodiments is generally
liquid impermeable and is attached to the absorbent structure 106
to prevent fluid entering the absorbent structure 106 from flowing
through the absorbent structure and onto the substrate (e.g., bed
sheet 103 of FIG. 5) to which the disposable absorbent articles are
adhered. More specifically, the back sheet 104 has a
substrate-facing surface 110 and an opposing body-facing surface
112. As illustrated in FIG. 4, the absorbent structure 106 is
attached (e.g., adhesively bonded) to the body-facing surface 112
of the back sheet 104. It is understood that the substrate to which
the disposable absorbent article is adhered can be any suitable
substrate including, but not limited to, bed sheets (cotton,
fleece, cotton/synthetic fiber blends, bamboo), mattresses, bed
mats, chairs, sofas, car seats, and floors (carpet, vinyl covering,
wood flooring).
[0064] The liquid impermeable back sheet 104 may be a polymeric
film, a woven fabric, a nonwoven fabric or the like, as well as
combinations or composites thereof. For example, the liquid
impermeable back sheet 104 may include a polymer film laminated to
a woven or nonwoven fabric. The polymer film can be composed of
polyethylene, polypropylene, polyester, or the like, as well as
combinations thereof. Additionally, the polymer film may be
micro-embossed, have a printed design, have a printed message to
the consumer, and/or may be at least partially colored.
[0065] The back sheet 104 may be made from a liquid/moisture
permeable material that is rendered moisture proof by means of
hydrophobic additives. It is understood that the back sheet 104 can
be made from a fibrous (e.g., a nonwoven) material or other
suitable permeable material. In such an embodiment, the disposable
absorbent article may include a suitable barrier layer.
[0066] In various embodiments, the substrate-facing surface 110 of
the back sheet 104 also includes at least one zone 114 having
adhesive 116 applied thereto. For example, referring now to FIG. 3,
the substrate-facing surface 110 of the back sheet 104 includes
four zones 114 having adhesive 116 applied thereto. As seen in FIG.
3, each of the four zones 114 is positioned generally adjacent the
corners of the substrate-facing surface 110 of the back sheet 104.
It is contemplated that the substrate-facing surface 110 of the
back sheet 104 can have more or fewer zones 114 of adhesive 116
than the four zones of adhesive illustrated in FIG. 3. It is also
contemplated that the adhesive 116 can be applied to other portions
of the substrate-facing surface 110. Thus, the adhesive 116 can be
applied to portions of the substrate-facing surface 110 spaced from
its corners.
[0067] In various embodiments, the adhesive 116 covers about 5-100
percent, about 10-60 percent, or about 10-40 percent of the
substrate-facing surface 110 of the back sheet 104. In some
embodiments, the adhesive may cover about 16 percent of the
substrate-facing surface 110 of the back sheet 104.
[0068] In various embodiments, the adhesive 116 is applied to the
substrate-facing surface 110 of the back sheet 104 in a range
between about 10 grams per square meter (gsm) and about 60 gsm.
Suitably, approximately 40.+-.5 gsm of adhesive 116 is applied to
the substrate-facing surface 110 of the back sheet 104. It is
understood, however, that the quantity of adhesive 116 applied to
the back sheet 104 can differ from those disclosed herein. Rather,
any suitable quantity of adhesive 116 can be applied to the
substrate-facing surface 110 of the back sheet 104.
[0069] In some embodiments, each zone 114 of adhesive 116 has a
substantially rectangular shape as illustrated in FIG. 3. It is
contemplated, however, that each of the zones 114 of adhesive 116
may have any suitable shape and/or size. For example, in some
embodiments, each zone 114 of adhesive 116 has a substantially
triangular shape as illustrated in FIGS. 16 and 22. It is also
contemplated that the adhesive 116 can be applied to the
substrate-facing surface 110 of the back sheet 104 in any suitable
pattern (e.g., strips, dots).
[0070] In various embodiments, the adhesive 116 is an adhesive that
enables the disposable absorbent article 100 to be removably
attached to the bed sheet 103. That is, the adhesive 116 enables
the disposable absorbent article 100 to be held in place on the bed
sheet 103 during use and the disposable absorbent article may be
readily removed from the bed sheet after use. Suitably, little or
no residual adhesive 116 will remain on the bed sheet 103 after the
disposable absorbent article 100 is removed therefrom. It is also
preferred that the adhesive 116 does not permanently or temporarily
mark or otherwise discolor the bed sheet 103. Several suitable
adhesives are available from HB Fuller with an office in St. Paul,
Minn., U.S.A. and available under product numbers 1827S and
CHM1056ZP.
[0071] In various embodiments, the substrate-facing surface 110 of
the back sheet 104 also includes at least one treated zone 118
having one or more surface treatments applied thereto. The treated
zone 118 is releasably joined in facing relation with a respective
adhesive zone 114 to define an adhesive protected condition. This
configuration protects the adhesive 116 from contamination prior to
use but allows the adhesive zone 114 to be readily released from
the treated zone 118 when ready to use.
[0072] In some embodiments, the substrate-facing surface 110 of the
back sheet 104 includes one, two, three, four, or more zones that
have been treated. For example, FIG. 9 illustrates four treated
zones 118 positioned generally adjacent the adhesive zones 114 of
the substrate-facing surface 110 of the back sheet 104. The treated
zones are localized and are separated from other treated zones by
areas of the back sheet that have not been treated in the same
manner. In various embodiments, the treated zones 118 are applied
to the substrate-facing surface 110 of the back sheet 104 using any
suitable process and/or release agent to render the back sheet more
releasable in the treated areas as compared to the untreated areas
119. For example, one or more of the treated zones 118 may be
coated with silicone to reduce the force needed to separate the
adhesive zone 114 from the treated zone 118 and thus transition the
absorbent article from the adhesive protected condition to the
adhesive application condition. In some embodiments, the treated
zones 118 may be defined by localized application of silicone to
reduce the force needed to separate the adhesive zone 114 from the
treated zone 118. Other suitable coatings may include
polytetrafluoroethylene.
[0073] In various embodiments, any suitable silicone or silicone
blend may be utilized to define the treated zones 118. In various
embodiments, the silicone may be applied using any suitable
technique, such as, spraying, slot coating, printing, dipping, and
the like, and combinations thereof. In various embodiments, the
silicone may be applied in any suitable concentration to achieve
the desired level of adhesive release.
[0074] In various embodiments, the treated zones 118 may cover
about 10-50 percent of the substrate-facing surface 110 of the back
sheet 104. In some embodiments, the treated zones may cover about
20 percent of the substrate-facing surface 110 of the back sheet
104. In various embodiments, the treated zones may have a treated
zone surface area and the adhesive zones may have an adhesive zone
surface area that is less than the treated zone surface area. In
various embodiments, the treated zone surface area may be 100 to
150%, 100 to 125%, or 100 to 115% the adhesive zone surface area.
In some embodiments, the treated zone surface area may be at least
105% the adhesive zone surface area to better ensure the entire
adhesive zone surface area is aligned within the treated zone
surface area.
[0075] In the embodiment of FIG. 9, each treated zone 118 has a
substantially rectangular shape. It is contemplated, however, that
each of the treated zones 118 may have any suitable shape and/or
size. For example, in some embodiments, each treated zone 118 has a
substantially triangular shape like illustrated in FIGS. 16 and 22.
It is also contemplated that the treated zones 118 can be applied
to the substrate-facing surface 110 of the back sheet 104 in an
intermittent pattern (e.g., strips, dots) or continuous pattern. In
various embodiments, the treated zones may have a shape that is the
same as the shape of the adhesive zones. In other embodiments, the
treated zones may have a shape that is different than the shape of
the adhesive zones.
[0076] The absorbent articles described herein are folded to
protect the adhesive from contamination prior to use. Specifically,
the absorbent articles are folded along at least one fold line such
that at least one adhesive zone is aligned in facing relation with
at least one treated zone. In use, the absorbent articles are
unfolded to release the adhesive zones from the treated zones and
to expose the adhesive zones for attachment to the desired
substrate.
[0077] Referring now to FIGS. 6-9, another exemplary absorbent
article 160 is illustrated in various folded and unfolded
configurations. In use, the absorbent article 160 may be presented
to the user in any suitable configuration. In some embodiments, the
absorbent article 160 may be presented to the user in a first
folded configuration 120 as illustrated in FIGS. 6 and 6A wherein
FIG. 6A is a cross-sectional view of the absorbent article 160 in
the first folded configuration 120 and taken along the line 6A-6A.
To use, the absorbent article 160 is unfolded along a first fold
line 126 in the direction indicated by the arrow 128.
[0078] The partially unfolded absorbent article 160 is now in a
second folded configuration 122 as illustrated in FIGS. 7 and 7A.
FIG. 7A is a cross-sectional view of the absorbent article 160 of
FIG. 7 in the second folded configuration 122 and taken along the
line 7A-7A. The absorbent article 160 is next unfolded along a
second fold line 130 and a third fold line 131 by moving the edge
138 in the direction indicated by the arrow 132. Unfolding the
absorbent article 160 along the second fold line 130 and the third
fold line 131 separates the first adhesive zone 140 from the first
treated zone 142 and also separates the second adhesive zone 144
from the second treated zone 146 (FIG. 9). The first adhesive zone
140 and the second adhesive zone 144 are now exposed and ready for
securement to any suitable substrate like the bed 101 as
illustrated in FIG. 5.
[0079] The absorbent article 160 is next unfolded along a fourth
fold line 134 and a fifth fold line 135 by moving the edge 148 in
the direction indicated by the arrow 136. Unfolding the absorbent
article 160 along the fourth fold line 134 and the fifth fold line
135 separates the third adhesive zone 150 from the third treated
zone 152 and also separates the fourth adhesive zone 154 from the
fourth treated zone 156 (FIG. 9). The third adhesive zone 150 and
the fourth adhesive zone 154 are now exposed and ready for
securement to any suitable substrate like the bed 101 as
illustrated in FIG. 5.
[0080] Referring now to FIG. 8, the absorbent article 160 is
illustrated in an unfolded configuration with the body-facing
surface 30 towards the viewer. Portions of the absorbent article
160 are cut away to illustrate the underlying structure. The
absorbent article 160 includes a top sheet 102, a back sheet 104
and an absorbent structure 106 disposed between the top sheet and
the back sheet. In the illustrated embodiment, the top sheet 102
and back sheet 104 extend beyond the periphery of the absorbent
structure 106 and are adhesively bonded to each other to capture
the absorbent structure. The absorbent article 160 also includes
adhesive zones 116 on the substrate-facing surface 32 (FIG. 9) of
the absorbent article 160.
[0081] Referring now to FIG. 9, the absorbent article 160 is
illustrated in an unfolded configuration with the substrate-facing
surface 32 of the absorbent article 160 towards the viewer. The
back sheet 104 of the absorbent article 160 includes a first
adhesive zone 140, a second adhesive zone 144, a third adhesive
zone 150, and a fourth adhesive zone 154. Each of the adhesive
zones includes adhesive 116 applied thereto. The back sheet 104 of
the absorbent article 160 also includes a first treated zone 142, a
second treated zone 146, a third treated zone 152, and a fourth
treated zone 156. The absorbent article 160 is folded along fold
line 131 such that first adhesive zone 140 is in facing relation
with first treated zone 142 and second adhesive zone 144 is in
facing relation with second treated zone 146. Likewise, the
absorbent article 160 is folded along fold line 134 such that third
adhesive zone 150 is in facing relation with third treated zone 152
and fourth adhesive zone 154 is in facing relation with fourth
treated zone 156. This alignment of adhesive zones and treated
zones protects the adhesive during packaging, transport, and
storage but allows the adhesive to be utilized when necessary
without the use of one or more separate release sheets. Numerous
alternative folds are also possible in combination with this
embodiment. For example, the absorbent article 160 may additionally
be folded to fully envelope the top sheet 102 and thus help keep
the body-facing surface clean as illustrated in FIGS. 6 and 6A.
Additional folds are also contemplated while still maintaining
complete protection of the body-facing surface 30 of the absorbent
article 160.
[0082] As seen in FIG. 9, the absorbent article 160 is folded
multiple times in a direction essentially parallel with the lateral
direction 20. However, in various embodiments, the absorbent
article may be additionally or alternatively folded in a direction
essentially parallel with the longitudinal direction. For example,
the absorbent article 160 illustrated in FIG. 6 may be folded one
or more additional times along a line that is essentially parallel
with the longitudinal direction 10.
[0083] In various embodiments, the first adhesive zone 140 and the
second adhesive zone 144 may be combined into a single adhesive
zone extending along a first edge of the absorbent article 160 (not
shown). Likewise, the third adhesive zone 150 and the fourth
adhesive zone 154 may be combined into a single adhesive zone
extending along a second edge, opposite the first edge, of the
absorbent article 160 (not shown). In yet other embodiments, the
first adhesive zone 140 and the third adhesive zone 150 may be
combined into a single adhesive zone extending along a third edge
of the absorbent article 160 (not shown). Likewise, the second
adhesive zone 144 and the fourth adhesive zone 154 may be combined
into a single adhesive zone extending along a fourth edge, opposite
the third edge, of the absorbent article 160 (not shown). In each
of these alternative embodiments, the treated zones may also be
combined and oriented to accommodate face to face alignment with
the respective adhesive zones.
[0084] Referring now to FIGS. 10-16, another exemplary absorbent
article 170 is illustrated in various folded and unfolded
configurations. In various embodiments, the absorbent article 170
may be presented to the user in any suitable folded or unfolded
configuration. In some embodiments, the absorbent article 170 is
presented to the user in a first folded configuration 171 as
illustrated in FIG. 10. To use, the absorbent article 170 is
unfolded along a first fold line 172 in the direction indicated by
the arrow 173.
[0085] The partially unfolded absorbent article 170 is now in a
second folded configuration 174 as illustrated in FIG. 11. The
absorbent article 170 is next unfolded along a second fold line 175
by moving the edge 176 in the direction indicated by the arrow 177.
The partially unfolded absorbent article 170 is now in a third
folded configuration 178 as illustrated in FIG. 12. The absorbent
article 170 is next unfolded along a third fold line 179 by moving
the edge 180 in the direction indicated by the arrow 181.
Consecutively or simultaneously, the absorbent article 170 is
unfolded along a fourth fold line 182 by moving the corner 183 in
the direction indicated by the arrow 184. Likewise, consecutively
or simultaneously, the absorbent article 170 is unfolded along a
fifth fold line 185 by moving the corner 186 in the direction
indicated by the arrow 187.
[0086] Unfolding the absorbent article 170 along the fourth fold
line 182 and the fifth fold line 185 separates the first adhesive
zone 204 from the first treated zone 206 and also separates the
second adhesive zone 208 from the second treated zone 210 (FIG.
16). The first adhesive zone 204 and the second adhesive zone 208
are now exposed and ready for securement to any suitable substrate
like the bed 101 as illustrated in FIG. 5.
[0087] The partially unfolded absorbent article 170 is now in a
fourth folded configuration 188 as illustrated in FIG. 13. The
absorbent article 170 is next unfolded along a sixth fold line 189
by moving the edge 190 in the direction indicated by the arrow 191.
The partially unfolded absorbent article 170 is now in a fifth
folded configuration 192 as illustrated in FIG. 14.
[0088] The absorbent article 170 is next unfolded along a seventh
fold line 193 by moving the edge 194 in the direction indicated by
the arrow 195. Consecutively or simultaneously, the absorbent
article 170 is unfolded along an eighth fold line 196 by moving the
corner 197 in the direction indicated by the arrow 198. Likewise,
consecutively or simultaneously, the absorbent article 170 is
unfolded along a ninth fold line 199 by moving the corner 200 in
the direction indicated by the arrow 202.
[0089] Unfolding the absorbent article 170 along the fold line 193
and the fold line 196 separates the third adhesive zone 212 from
the third treated zone 214 and also separates the fourth adhesive
zone 216 from the fourth treated zone 218 (FIG. 16). The third
adhesive zone 212 and the fourth adhesive zone 216 are now exposed
and ready for securement to any suitable substrate like the bed 101
as illustrated in FIG. 5.
[0090] Referring now to FIG. 15, the absorbent article 170 is
illustrated in an unfolded configuration with the body-facing
surface 30 towards the viewer. Portions of the absorbent article
170 are cut away to illustrate underlying structure. The absorbent
article 170 includes a top sheet 102, a back sheet 104 and an
absorbent structure 106 disposed between the top sheet and the back
sheet. In the illustrated embodiment, the top sheet 102 and back
sheet 104 extend beyond the periphery of the absorbent structure
106 and are adhesively bonded to each other to capture the
absorbent structure. The absorbent article 170 also includes
adhesive zones 116 on the substrate-facing surface of the back
sheet 104 (FIG. 16).
[0091] Referring now to FIG. 16, the absorbent article 170 is
illustrated in an unfolded configuration with the substrate-facing
surface 32 towards the viewer. The back sheet 104 of the absorbent
article 170 includes a first adhesive zone 204, a second adhesive
zone 208, a third adhesive zone 212, and a fourth adhesive zone
216. Each of the adhesive zones includes adhesive 116 applied
thereto. The back sheet 104 of the absorbent article 170 also
includes a first treated zone 206, a second treated zone 210, a
third treated zone 214, and a fourth treated zone 218.
[0092] The absorbent article 170 is folded along fold line 182 such
that first adhesive zone 204 is in facing relation with first
treated zone 206. The absorbent article 170 is also folded along
fold line 185 such that second adhesive zone 208 is in facing
relation with second treated zone 210. Likewise, the absorbent
article 170 is also folded along fold line 196 such that third
adhesive zone 212 is in facing relation with third treated zone
214. Finally, the absorbent article 170 is folded along fold line
199 such that the fourth adhesive zone 216 is in facing relation
with fourth treated zone 218. This alignment of adhesive zones and
treated zones keeps the adhesive protected during packaging,
transport, and storage but allows the adhesive to be utilized when
necessary without the use of one or more separate release sheets.
Numerous alternative folds are also possible in combination with
this embodiment. For example, the absorbent article 170 may
additionally be folded to help keep the body-facing surface 30
clean by completely enveloping the top sheet 102 within the back
sheet 104 (as illustrated in FIG. 10) until the absorbent article
170 is unfolded.
[0093] Referring now to FIGS. 17-22, another exemplary absorbent
article 230 is illustrated in various folded and unfolded
configurations. In use, the absorbent article 230 may be presented
to the user in any suitable folded or unfolded configuration. In
the illustrated embodiment, the absorbent article 230 is presented
to the user in a first folded configuration 232 as shown in FIG.
17. To use, the absorbent article 230 is unfolded along a first
fold line 234 in the direction indicated by the arrow 236.
[0094] The partially unfolded absorbent article 230 is now in a
second folded configuration 238 as illustrated in FIG. 18. The
absorbent article 230 is next unfolded along a second fold line 240
by moving the edge 242 in the direction indicated by the arrow 244.
The partially unfolded absorbent article 230 is now in a third
folded configuration 246 as illustrated in FIG. 19. The absorbent
article 230 is next unfolded along a third fold line 248 by moving
the edge 250 in the direction indicated by the arrow 252. The
absorbent article 230 is now in a fourth folded configuration 254
as illustrated in FIG. 20.
[0095] Consecutively or simultaneously, the absorbent article 230
is unfolded along a fourth fold line 256 and a fifth fold line 258
by moving the corner 260 in the direction indicated by the arrow
262. Likewise, consecutively or simultaneously, the absorbent
article 230 is unfolded along the fourth fold line 256 and a sixth
fold line 264 by moving the corner 266 in the direction indicated
by the arrow 268.
[0096] Unfolding the absorbent article 230 along the fifth fold
line 258 separates the first adhesive zone 270 from the first
treated zone 272 (FIG. 22). Unfolding the absorbent article 230
along the sixth fold line 264 separates the second adhesive zone
274 from the second treated zone 276 (FIG. 22). The first adhesive
zone 270 and the second adhesive zone 274 are now exposed and ready
for securement to any suitable substrate like the bed 101 as
illustrated in FIG. 5.
[0097] Still referring to FIG. 20, consecutively or simultaneously
with other steps, the absorbent article 230 is unfolded along a
seventh fold line 278 and an eighth fold line 280 by moving the
corner 282 in the direction indicated by the arrow 284. Likewise,
consecutively or simultaneously, the absorbent article 230 is
unfolded along the seventh fold line 278 and a ninth fold line 284
by moving the corner 286 in the direction indicated by the arrow
288.
[0098] Unfolding the absorbent article 230 along the eighth fold
line 280 separates the third adhesive zone 290 from the third
treated zone 292 (FIG. 22). Unfolding the absorbent article 230
along the ninth fold line 284 separates the fourth adhesive zone
294 from the fourth treated zone 296 (FIG. 22). The third adhesive
zone 290 and the fourth adhesive zone 294 are now exposed and ready
for securement to any suitable substrate like the bed 101 as
illustrated in FIG. 5.
[0099] Referring now to FIG. 21, the absorbent article 230 is
illustrated in an unfolded configuration with the body-facing
surface 30 towards the viewer. The absorbent article 230 includes a
top sheet 102, a back sheet 104 (FIG. 22) and an absorbent
structure 106 disposed between the top sheet and the back sheet. In
the illustrated embodiment, the top sheet 102 and back sheet 104
extend beyond the periphery of the absorbent structure 106 and are
adhesively bonded to each other to capture the absorbent
structure.
[0100] Referring now to FIG. 22, the absorbent article 230 is
illustrated in an unfolded configuration with the substrate-facing
surface 32 towards the viewer. The back sheet 104 of the absorbent
article 230 includes a first adhesive zone 270, a second adhesive
zone 274, a third adhesive zone 290, and a fourth adhesive zone
294. Each of the adhesive zones include adhesive 116 applied
thereto. The back sheet 104 of the absorbent article 230 also
includes a first treated zone 272, a second treated zone 276, a
third treated zone 292, and a fourth treated zone 296.
[0101] The absorbent article 230 is folded along fold line 258 such
that first adhesive zone 270 is in facing relation with first
treated zone 272. The absorbent article 230 is also folded along
fold line 264 such that second adhesive zone 274 is in facing
relation with second treated zone 276. Likewise, the absorbent
article 230 is also folded along fold line 280 such that third
adhesive zone 290 is in facing relation with third treated zone
292. Finally, the absorbent article 230 is folded along fold line
284 such that the fourth adhesive zone 294 is in facing relation
with the fourth treated zone 296. This alignment of adhesive zones
and treated zones keeps the adhesive protected during packaging,
transport, and storage but allows the adhesive to be utilized when
necessary without the use of one or more separate release sheets.
Numerous alternative or additional folds are also possible in
combination with this embodiment.
[0102] In various embodiments, the absorbent articles of the
present invention may be folded about fold lines that are parallel
with the lateral direction 20 and/or folded about fold lines that
are parallel with the longitudinal direction 10, and/or folded
about fold lines that are parallel with neither the lateral
direction 20 nor the longitudinal direction 10 (i.e.,
non-parallel). For example, the absorbent article 160 illustrated
in FIG. 9 includes fold lines 126, 130, 131, 134, and 135 that are
parallel with the lateral direction 20. In another example, the
absorbent article 170 illustrated in FIG. 16 includes fold lines
172 and 175 that are parallel with the longitudinal direction 10,
fold lines 179, 189, and 193 that are parallel with the lateral
direction 20, and fold lines 182, 185, 196, and 199 that are
parallel with neither the longitudinal direction 10 nor the lateral
direction 20 (i.e., non-parallel with the longitudinal direction 10
or the lateral direction 20). In yet another example, the absorbent
article 230 illustrated in FIG. 22 includes fold lines 234 and 240
that are parallel with the longitudinal direction 10, fold lines
248, 256, and 278 that are parallel with the lateral direction 20,
and fold lines 258, 264, 280, and 284 that are parallel with
neither the longitudinal direction 10 nor the lateral direction 20
(i.e., are non-parallel with the longitudinal direction 10 or the
lateral direction 20).
[0103] The absorbent articles of the present invention can be made
using any suitable method. In some embodiments, the absorbent
articles of the present invention may be made using a method 300 as
illustrated in FIG. 23. The method 300 includes the step 302 of
providing an absorbent structure. The method 300 further includes
the step 304 of providing a liquid-impermeable back sheet. The back
sheet defines a body-facing surface and a substrate-facing surface.
The method 300 also includes the step 306 of joining the absorbent
structure in facing relation to the body-facing surface of the back
sheet to define an absorbent article.
[0104] The method 300 further includes the step 308 of applying
adhesive to the substrate-facing surface of the back sheet to
define a first adhesive zone and a second adhesive zone like those
described herein. The method 300 further includes the step 310 of
treating portions of the substrate-facing surface of the back sheet
to define a first treated zone and a second treated zone like those
described herein. The method 300 further includes the step 312 of
folding the absorbent article to align the first adhesive zone in
facing relation with the first treated zone. Finally, the method
300 includes the step 314 of folding the absorbent article to align
the second adhesive zone in facing relation with the second treated
zone.
[0105] In some embodiments, the method 300 may further include the
step 316 of folding the absorbent article to define a protected
condition wherein only the substrate-facing surface of the
absorbent article is exposed. For example, FIG. 6 illustrates the
absorbent article 160 wherein only the substrate-facing surface 32
is exposed. Likewise, FIG. 10 illustrates the absorbent article 170
with only the substrate-facing surface 32 exposed. Finally, FIGS.
17, 18, and 19 illustrate the absorbent article 230 in various
configurations wherein only the substrate-facing surface 32 is
exposed. In these embodiments, the body-facing surface 30 is
completely folded within the substrate-facing surface 32. This
configuration may help protect the body-facing surface 30 from
contamination prior to use and may help protect the adhesive from
contamination prior to use.
[0106] In some embodiments, the method 300 may include repeating
steps 302 through 316 to provide a plurality of absorbent articles
in the protected condition. The method 300 may also include the
step 318 of placing the plurality of absorbent articles into a
package while in the protected condition.
[0107] In another embodiment, the absorbent articles of the present
invention may be made using a method 330 as illustrated in FIG. 24.
The method 330 includes the step 332 of providing an absorbent
structure. In some embodiments, the step 332 may include providing
an absorbent structure having a mixture of cellulose fibers and
superabsorbent particles intermixed therein. The method 330 may
further include the step 334 of providing a liquid-impermeable back
sheet having a body-facing surface and a substrate-facing surface.
In some embodiments, the step 334 may include providing a back
sheet made of polyethylene film. In other embodiments, the step 334
may include providing a back sheet made of polyethylene film
laminated with a nonwoven facing layer.
[0108] The method 330 may further include the step 336 of providing
a top sheet. In some embodiments, the step 336 may include
providing a top sheet made of nonwoven spun bond polymer. The
method 330 may further include the step 338 of joining the
absorbent structure between the body-facing surface of the back
sheet and the top sheet to define an absorbent article.
[0109] The method 330 may further include the step 340 of applying
adhesive to the substrate-facing surface of the back sheet to
define a first adhesive zone, a second adhesive zone, a third
adhesive zone, and a fourth adhesive zone. In various embodiments,
the step 340 may include applying adhesive to the substrate-facing
surface of the back sheet using a pressure sensitive hot melt
adhesive. In some embodiments, the pressure sensitive hot melt
adhesive may be applied using any suitable method such as slot
coat, swirl, melt blowing, bead, printing, or the like, or
combinations thereof. In some embodiments, the hot melt adhesive is
applied using a slot coat adhesive applicator at any suitable
concentration to achieve the desired peel force.
[0110] The method 330 also includes the step 342 of treating
portions of the substrate-facing surface of the back sheet. In some
embodiments, the step 342 may include treating portions of the
substrate-facing surface of the back sheet with silicone to define
a first treated zone, a second treated zone, a third treated zone,
and a fourth treated zone. In various embodiments, the silicone may
be applied to the back sheet using any suitable method such as slot
coat, swirl, melt blown, bead, printing, or the like, or
combination thereof. In some embodiments the silicone is applied
using spray nozzles at any suitable concentration to achieve the
desired release characteristics.
[0111] The method 330 also includes the step 344 of folding the
absorbent article to align the first adhesive zone in facing
relation with the first treated zone, the step 346 of folding the
absorbent article to align the second adhesive zone in facing
relation with the second treated zone, the step 348 of folding the
absorbent article to align the third adhesive zone in facing
relation with the third treated zone, and the step 350 of folding
the absorbent article to align the fourth adhesive zone in facing
relation with the fourth treated zone.
[0112] The method 330 also includes the step 352 of folding the
absorbent article to define a protected condition wherein only the
substrate-facing surface is exposed. In some embodiments, the steps
344, 346, 348, and/or 350 may include folding the absorbent article
along a first line that is parallel to the longitudinal direction
of the absorbent article or folding the absorbent article along a
second line that is parallel to the lateral direction of the
absorbent article. In some embodiments, the steps 344, 346, 348,
and/or 350 may include folding the absorbent article along a first
line that is neither parallel to the longitudinal direction nor the
lateral direction. In some embodiments, at least one of the steps
344, 346, 348, and/or 350 may include folding the absorbent article
along a first line that is parallel to the longitudinal direction
of the absorbent article or folding the absorbent article along a
second line that is parallel to the lateral direction of the
absorbent article and at least one of the steps 344, 346, 348,
and/or 350 may include folding the absorbent article along a third
line that is neither parallel to the longitudinal direction nor the
lateral direction.
[0113] In various embodiments, the adhesive 116 is configured to
provide a shear strength between the disposable absorbent articles
and the substrate of between about 1,500 grams per square inch and
about 3,500 grams per square inch. Suitably, the adhesive 116 is
configured to provide a shear strength between about 2,000 grams
per square inch and about 3,000 grams per square inch. More
suitably, the adhesive 116 is configured to provide a shear
strength between about 2,200 grams per square inch and about 2,500
grams per square inch as measured relative to cotton sheets using a
2 inch by 6 inch sample of adhesive coated polyethylene. The
samples are rolled with a 2 kg weight and then pulled apart in
shear at a rate of 20 inches/min. The samples are pulled apart in
shear until a break occurs or the poly releases from the cotton
fabric. The results are normalized to provide a force per square
inch equivalent.
[0114] It is contemplated that the disposable absorbent articles
can be adapted to provide the shear strength between the article
and the substrate in other suitable ways in addition to adhesive.
For example, the articles can include mechanical fasteners (e.g.,
hook and loop fasteners, slot and tab, magnets) to provide suitable
shear strength between the articles and the substrates. In another
suitable example, the back sheet 104 of the articles can comprise a
high coefficient of friction material.
[0115] In some embodiments, the adhesive 116 is also configured to
provide a peel strength between the absorbent articles and the bed
sheet 103 when the absorbent article is adhered to the bed sheet
between about 200 grams per inch and about 500 grams per inch. In
some embodiments, the adhesive 116 is configured to provide a peel
strength between about 250 grams per inch and about 450 grams per
inch. In other embodiments, the adhesive 116 is configured to
provide a peel strength between about 300 grams per inch and about
350 grams per inch as measured relative to cotton sheets using a 2
inch by 6 inch sample of adhesive coated polyethylene. The samples
are rolled with a 2 kg weight and then pulled apart in peel at a
rate of 20 inches/min. The samples are pulled apart in peel until a
break occurs or the poly releases from the cotton fabric. The
results are normalized to provide a force per square inch
equivalent.
[0116] The attachment between the absorbent structure 106 and the
top sheet 102 and/or the back sheet 104 may have an internal
cohesive force of between about 45 grams per square inch and about
100 grams per square inch. Suitably, the attachment between the
absorbent structure 106 and the top sheet 102 and/or the back sheet
104 may have an internal cohesive force between about 55 grams per
square inch and about 80 grams per square inch, more suitably,
about 64 grams per square inch.
[0117] While the invention has been described in detail with
respect to specific embodiments thereof, it will be appreciated
that those skilled in the art, upon attaining understanding of the
foregoing will readily appreciate alterations to, variations of,
and equivalents to these embodiments. Accordingly, the scope of the
present invention should be assessed as that of the appended claims
and any equivalents thereto. Additionally, all combinations and/or
sub-combinations of the disclosed embodiments, ranges, examples,
and alternatives are also contemplated.
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