U.S. patent number RE36,601 [Application Number 09/059,479] was granted by the patent office on 2000-03-07 for method for making multilayer pad.
This patent grant is currently assigned to M.J. Woods, Inc.. Invention is credited to James M. Woods, Marilyn S. Woods.
United States Patent |
RE36,601 |
Woods , et al. |
March 7, 2000 |
Method for making multilayer pad
Abstract
The invention comprises a method for manufacturing a laminated
pad in a cost-efficient manner. In one embodiment, the method
comprises the steps of applying strips of adhesive to a first
substrate and mounting the first substrate to a second substrate.
Next, adhesive is applied to the entire width of a third substrate
which is in turn mounted to the laminated first and second
substrates to create a laminated sheet. The laminated sheet can be
slit and then die cut into individual laminated pads. The pads
which result from this process have a base pad, an intermediate
layer which is adhered to the base pad and a top layer in which
only a portion of the top layer is mounted to the intermediate
layer.
Inventors: |
Woods; James M. (Pisgah Forest,
NC), Woods; Marilyn S. (Pisgah Forest, NC) |
Assignee: |
M.J. Woods, Inc.
(Hendersonville, NC)
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Family
ID: |
27492902 |
Appl.
No.: |
09/059,479 |
Filed: |
April 13, 1998 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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097274 |
Jul 26, 1993 |
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954688 |
Sep 30, 1992 |
5230119 |
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684593 |
Apr 12, 1991 |
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508967 |
Apr 13, 1990 |
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Reissue of: |
285183 |
Aug 3, 1994 |
05507906 |
Apr 16, 1996 |
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Current U.S.
Class: |
156/271;
15/209.1; 156/250; 156/268; 156/269; 156/291; 156/324; 156/548;
156/578 |
Current CPC
Class: |
A45D
40/26 (20130101); A47K 7/02 (20130101); A61F
13/00987 (20130101); A61M 35/006 (20130101); B32B
37/0076 (20130101); B32B 37/153 (20130101); B32B
38/04 (20130101); A61F 2013/00302 (20130101); A61F
2013/00817 (20130101); B32B 2038/042 (20130101); B32B
2307/7265 (20130101); Y10T 156/1084 (20150115); Y10T
156/1052 (20150115); Y10T 156/1798 (20150115); Y10T
156/1082 (20150115); Y10T 156/1724 (20150115); Y10T
156/1087 (20150115) |
Current International
Class: |
A45D
40/26 (20060101); A61F 13/40 (20060101); A61F
13/00 (20060101); B32B 38/04 (20060101); B32B
37/30 (20060101); B32B 031/12 (); B32B
031/18 () |
Field of
Search: |
;156/250,268,269,270,290,291,320,324,548,578 ;15/209.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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607525 |
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Jul 1926 |
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FR |
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660938 |
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Jul 1929 |
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FR |
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582504 |
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Dec 1976 |
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CH |
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4609 |
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1915 |
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GB |
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6160 |
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Mar 1916 |
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GB |
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1158412 |
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Jul 1969 |
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GB |
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95/03175 |
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Feb 1995 |
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WO |
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Other References
Dia 112 from "Coating and Laminating Machines" by Herbert L. Weiss,
Converting Technology Company, Milwaukee, WI 53211 (1983). .
"Dry Bonding" and "Wet Bonding" from Morton Chemical Adhesives and
Coatings Handbook. .
Booklet published by Kimberly-Clark regarding KIMDURA.RTM.
Synthetic Paper. .
"Accuracy, Consistency, Profit Boost Popularity of Gravure" by
Herbert Weiss, Paper, Film & Foil Converter, Apr. 1992. .
International Application No. PCT/US 91/02525, as published as No.
WO 91/15983 on Oct. 31, 1991..
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Primary Examiner: Mayes; Curtis
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 08/097,274 filed
Jul. 26, 1993, now .[.abandoned. Now.]..Iadd., .Iaddend.which is a
continuation-in-part of U.S. patent application Ser. No.
07/954,688, filed Sep. 30, .[.1991,.]. .Iadd.1992.Iaddend., now
issued as U.S. Pat. No. 5,230,119, which is a continuation of U.S.
patent application Ser. No. 07/684,593, filed Apr. 12, 1991, now
abandoned, which was a continuation-in-part of U.S. patent
application Ser. No. 07/508,967, filed Apr. 13, 1990, now
abandoned.
Claims
We claim:
1. A method of manufacturing a plurality of multilayer pads
comprising the steps of:
providing a web of base pad forming material having a longitudinal
axis, an attachment surface, an application surface and a
prescribed .[.base pad.]. width; providing a web of intermediate
layer forming material having a longitudinal axis, an upper
attachment surface and a lower attachment surface;
providing a web of handle forming material having a longitudinal
axis, a lower attachment surface, an exposed upper surface and a
width substantially equal to the .[.base pad.]. .Iadd.prescribed
.Iaddend.width .Iadd.of the web of base pad forming
material.Iaddend.;
mounting the attachment surface of the base pad forming material to
the lower attachment surface of the intermediate layer forming
material so that substantially the entire lower attachment surface
of the intermediate layer forming material is mounted .[.m.].
.Iadd.to .Iaddend.the upper attachment surface of the base
.Iadd.pad .Iaddend.forming material;
applying .[.a strip.]. .Iadd.strips .Iaddend.of adhesive to a
portion of one of the upper attachment surface of the intermediate
layer forming material and the lower attachment surface of the
handle forming material along a longitudinal axis of said one
surface;
mounting the upper attachment surface of the intermediate layer
forming material to the lower attachment surface of the handle
forming material so that the upper attachment surface of the
intermediate layer forming material is adhered to the lower
attachment at surface of the handle forming .Iadd.material
.Iaddend.along said strips of adhesive; and
simultaneously cutting the base pad forming material, intermediate
layer forming material and handle forming material to create at
least two laterally adjacent multilayer pads having a base pad, an
intermediate layer and a handle, the handle comprising a mounted
portion and a pivotable portion.[., wherein the mounted portion of
the two pads are cut from the same strip of adhesive applied to
said one of the handle forming material and the intermediate layer
forming material.]..
2. A method of manufacturing a plurality of multilayer pads
according to claim 1 and further comprising the step of scoring the
web of the handle forming material between the mounted portion and
the pivotable portion.
3. A method of manufacturing a plurality multilayer pads according
to claim 1 wherein the base pad material is mounted to the
intermediate layer by adhesive.
4. A method of manufacturing a plurality of multilayer pads
according to claim 1 and further comprising the steps of providing
a zone cylinder for applying the strip of adhesive to said one of
the intermediate layer forming material and the handle forming
material and rolling said one material over the zone cylinder, the
zone cylinder having an adhesive applying portion and a smooth
portion wherein the adhesive applying portion conveys adhesive from
the cylinder to said one material and the smooth portion does not
convey adhesive to said one material.
5. A method of manufacturing a plurality of multilayer pads
according to claim 4 wherein said adhesive applying portion of the
zone cylinder comprises a plurality of recesses formed thereon, the
recesses conveying adhesive from a source of adhesive to the one
material.
6. A method of manufacturing a plurality of multilayer pads
according to claim 5 and further comprising the step of applying
multiple strips of adhesive to a portion of one of the upper
attachment surface of the intermediate layer forming material and
the lower attachment, surface of the handle forming material along
a longitudinal axis of said one surface wherein the surface of the
zone cylinder further comprises an alternating sequence along the
length of the cylinder of adhesive applying plurality of recesses
and smooth portions resulting in the creation of said strips of
adhesive on said one material corresponding to the recesses and
smooth portions. .[.7. A method of manufacturing a plurality of
multilayer pads comprising the steps of:
providing a sheet of base pad forming material having a prescribed
width, an attachment surface and an application surface;
providing a sheet of handle forming material having a width
substantially equal to the base pad width, a lower attachment
surface and an exposed upper surface;
applying at least two strips of adhesive to at least one of the
attachment surface of the base pad and the lower attachment surface
of the sheet of handle forming material;
selectively mounting a portion of the attachment surface of the
base pad forming material to the lower attachment surface of the
handle forming material such that less than the entire attachment
surface of the base pad forming material is mounted to the lower
attachment surface of the handle forming material; and
cutting the laminated sheet into at least four individual pads
aligned linearly in a direction substantially normal to the at
least two strips of adhesive such that two laterally adjacent pads
are cut from each strip of adhesive and the handle forming material
of each pad comprises a mounted portion which is mounted to the
base pad material and a pivotable portion which is not mounted to
the base pad material..]..[.8. A method of manufacturing a
plurality of multilayer pads according to claim 7 wherein said at
least two strips of adhesive are applied to the lower attachment
surface of the sheet of handle forming material and further
comprising the steps of:
providing a sheet of an intermediate layer forming material having
an upper attachment surface and a lower attachment surface;
mounting the attachment surface of the base pad sheet to the lower
attachment surface of the intermediate layer sheet such that
substantially the entire lower attachment surface of the
intermediate layer sheet is mounted to the upper attachment surface
of the base pad sheet;
selectively mounting a portion of the upper attachment surface of
the intermediate layer sheet and the lower attachment surface of
the handle forming sheet to the other of the upper attachment
surface of the intermediate layer sheet and the lower attachment
surface of the handle forming sheet creating a laminated sheet such
that less than the entire upper attachment surface of the
intermediate layer forming sheet is mounted to the lower attachment
surface of the handle forming sheet; and
cutting the laminated sheet into at least four individual pads
aligned linearly in a direction substantially normal to the at
least two strips of adhesive such that two laterally adjacent pads
are cut from each strip of adhesive and the handle forming material
of each pad comprises a mounted portion which is mounted to the
intermediate layer and a pivotable portion which is not mounted to
the intermediate layer..]..[.9. A method of manufacturing a
plurality of multilayer pads according to claim 8 and further
comprising the step of scoring the handle forming sheet at the
junction of the mounted portion and the pivotable portion..]..[.10.
A method of manufacturing a plurality of multilayer pads according
to claim 8 wherein the at least two strips of adhesive are applied
to one of the intermediate layer forming sheet and the handle
forming sheet by rolling said one sheet over a zone cylinder
adapted to apply adhesive to the one sheet in said at least two
strips..]..[.11. A method of manufacturing a plurality of
multilayer pads according to claim 10 wherein at least a portion of
the surface of the zone cylinder has a plurality of recesses formed
thereon, the recesses being adapted to convey adhesive from a
source of adhesive to the one sheet..]..[.12. A method of
manufacturing a plurality of multilayer pads according to claim 11
and further comprising the step of passing the handle forming sheet
and the intermediate layer sheet between a pair of opposed rollers
so that said strips of adhesive provided on said one sheet contacts
the other of the attachment surface of the handle forming sheet and
the upper attachment surface of the intermediate layer sheet as the
sheets pass between the opposed rollers..]..[.13. A method of
manufacturing a plurality of multilayer pads according to claim 11
wherein the surface of the zone cylinder comprises an alternating
sequence along the length of the cylinder of the portion of
recesses and a smooth portion resulting in the creation of strips
of adhesive coating on the laminated sheet corresponding to the
portion of recesses and strips of uncoated portions on the
laminated sheet corresponding to the smooth portions..]..[.14. A
method of manufacturing a plurality of multilayer pads according to
claim 13 and further comprising the step of cutting the laminated
sheet such that the pivotable portion of two adjacent pads are cut
from the same strip of uncoated portions of the laminated
sheet..]..[.15. A method of manufacturing a plurality of multilayer
to claim 11 wherein the base material sheet is mounted to the
intermediate layer sheet by an adhesive coating which is applied to
one of the attachment surface of the base material sheet and the
lower attachment surface of the intermediate layer sheet by rolling
said one sheet over a cylinder having a plurality of recesses
formed on the surface of the cylinder, the recesses being adapted
to receive adhesive from a source of adhesive and transfer the
adhesive to the sheet upon contact with the sheet..]..[.16. A
method of manufacturing a plurality of multilayer pads according to
claim 15 and further comprising the step of drying the adhesive by
subjecting the adhesive to a source of heat..]..[.17. A method of
manufacturing a plurality of multilayer pads according to claim 15
and further comprising the step of passing the base pad sheet and
the intermediate layer sheet between a pair of opposed rollers such
that the adhesive coated surface of said one sheet contacts the
other of the attachment surface of the base material sheet and the
lower attachment surface of the intermediate layer sheet..]..[.18.
A method of manufacturing a plurality of multilayer pads according
to claim 7 and further comprising the step of cutting the laminated
sheet so that the laminated pad has at least one arcuate edge and
at least one straight
edge..]..Iadd.19. A method of manufacturing a plurality of
multilayer pads comprising the stems of:
providing a web of base pad forming material having a longitudinal
axis, a width, an attachment surface and an application
surface;
providing a web of intermediate layer forming material having a
longitudinal axis, a width, an upper attachment surface and a lower
attachment surface;
providing a web of handle forming material having a longitudinal
axis, a width, a lower attachment surface and an exposed upper
surface;
applying longitudinally continuous and laterally spaced strips of
adhesive to portions of one of the upper attachment surface of the
intermediate layer forming material and the lower attachment
surface of the handle forming material along the longitudinal axis
of the one surface;
mounting the attachment surface of the base pad forming material to
the lower attachment surface of the intermediate layer forming
material so that the lower attachment surface of the intermediate
layer forming material is mounted to the upper attachment surface
of the base pad forming material over the widths of the webs of
base pad forming material and intermediate layer forming material,
and mounting the upper attachment surface of the intermediate layer
forming material to the lower attachment surface of the handle
forming material so that the upper attachment surface of the
intermediate layer forming material and the lower attachment
surface of the handle forming material are adhered to each other
along the laterally spaced strips of adhesive to produce a
laminated sheet; and
cutting the laminated sheet to produce individual multilayer pads
each having a base pad, an intermediate layer and a handle, the
cutting being such that the handle of each multilayer pad has a
mounted portion adhered to the intermediate layer where adhesive
was applied and a pivotable portion. .Iaddend.
Description
FIELD OF THE INVENTION
The present invention relates to a method of making a disposable
multilayer pad. In particular, the present invention relates to a
method for making an improved hand held laminated pad suitable as a
wipe and/or applicator. The laminated pad has a base pad, an
impervious barrier shield that protects the user from contact with
fluids and solids on the base pad and a flexible, adjustable
handle.
BACKGROUND OF THE INVENTION
Many items are widely used as wipes and applicators for wiping or
applying substances from or to surfaces such as those on a human,
e.g., skin, finger nails, toe nails, or in a human, e.g., internal
organs and bones during a surgical operation. These items are
widely used in both medical and non-medical fields. Small cotton or
rayon balls, pads or gauzes are perhaps the most widely used items
for these purposes on the market today. Small sponges are also
widely used items.
In the medical field, these items are used for cleaning the skin
and other surfaces, such as the surfaces of internal organs, by the
application of a disinfectant or solvent and/or the wiping away of
blood and other fluids, including other body fluids, and other
materials. The cotton balls, sponges and gauze pads are grasped
between the fingers and applied to the area of concern to wipe away
or apply fluids or other materials. One problem with this prior art
approach is that the fingers can easily come into contact with the
fluid being applied or wiped. In light of infectious diseases such
as AIDS and hepatitis contact between a care provider and a patient
should be avoided.
In the cosmetics and personal care fields, cotton balls and the
like are widely used to apply and to remove makeup and to apply
other personal care products such as lotions, creams and nail
polish remover. Unfortunately, the item transfers the makeup or
personal came product to the user's finger which is often
undesirable. For example, when a nail polish remover, which is
usually acetone or acetate based, is being used it can be
transferred to the fingers of the hand holding the item. The nail
polish remover can harm the fingers and remove the nail polish from
the user's finger nails on the hand holding the item even if
removal from these nails was not desired. Also, the nail polish
remover can undesirably remove nail polish from a finger nail
adjacent to the finger from which the nail polish is being removed.
Also, the transfer can result in a waste of the makeup or personal
care product.
These items are often amorphous in that they have no defined shape
and therefore no defined edges. Thus, these items are not ideally
suited to apply or wipe materials to or from surfaces that have an
arcuate edge, e.g., finger nails, and from surfaces that have
straight edges, e.g., the edge formed between the nose and cheek.
Other items only have arcuate or straight edges and are not very
effective when surfaces having a different shape are
encountered.
One example of the prior art approach is disclosed in U.S. Pat. No.
4,053,242, entitled "Disposable Product Applicator and Dispensing
Package Therefor", issued Oct. 11, 1977 to Mast, Jr. Another
example of applicators is illustrated in the Jones, Sr. U.S. Pat.
No. 3,784,998, entitled "Composition Applicator" and its companion
case U.S. Pat. No. 3,737,939 having substantially identical
disclosures. Other prior attempts include U.S. Pat. No. Re. 26,385,
to Gilchrist issued May 7, 1968, which discloses a liquid and paste
applicator formed by sheets of foam; and U.S. Pat. No. 4,506,404 to
Clay which discloses a disposable sponge having a planar body
portion and a pair of upstanding rib members spaced close enough
that they may be grasped and squeezed against each other by the
hand to form a handle or grip.
It is desirable to manufacture an improved laminated pad suitable
for use as an applicator or wipe that overcomes at least some of
the aforementioned shortcomings in a cost effective manner.
SUMMARY OF THE INVENTION
The invention comprises a method of manufacturing a multilayer pad
comprising the steps of providing a base pad forming material
having an attachment surface and an application surface, providing
an intermediate layer forming material having an upper attachment
surface and a lower attachment surface, and providing a handle
forming material having a lower attachment surface and an exposed
upper surface. The attachment surface of the base pad forming
material is mounted to the lower attachment surface of the
intermediate layer forming material such that substantially the
entire lower attachment surface of the intermediate layer forming
material is mounted to the upper attachment surface of the base
forming material. A portion of the upper attachment surface of the
intermediate layer forming material is mounted to the lower
attachment surface of the handle forming material such that less
than the entire upper attachment surface of the intermediate layer
forming material is mounted to the lower attachment surface of the
handle forming material. Finally, the laminated sheet is cut into
individual pads having a mounted portion of the handle forming
material and a pivotable portion of the handle forming
material.
Preferably, the base pad material is mounted to the intermediate
layer by adhesive which is applied by a cylinder having a plurality
of recesses formed therein adapted to transfer adhesive from a
reservoir to the material.
In another embodiment, the intermediate layer forming sheet is
mounted to the handle forming sheet by adhesive which is applied in
strips parallel to one another. Preferably, the parallel strips are
applied to one of the intermediate layer forming sheet and the
handle forming sheet by rolling one of the sheets over a zone
cylinder adapted to apply adhesive to the sheet in the parallel
strips.
In another embodiment, the method comprising the step of cutting
the laminated sheet such that the mounted portion of two adjacent
pads are cut from the same strip of adhesive coating of the
laminated sheet.
In a further embodiment, the method comprises the step of cutting
the sheet such that the pivotable portion of two adjacent pads are
cut from the same strip of uncoated portions of the sheet.
In a further embodiment of the invention, the several layers are
bonded to one another by co-extrusion of the several layers and
passing the layers between a pair of opposed rolls immediately
after extrusion such that the several layers are bonded to one
another.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the laminated
pad manufactured according to the invention;
FIG. 2 is a front elevation view of the laminated pad of FIG.
1;
FIG. 3 is a top plan view of a second embodiment of the laminated
pad manufactured according to the invention;
FIG. 4 is a side elevational view of the laminated pad of FIG.
3;
FIG. 5 is a schematic illustration of the first step of a first
method of manufacturing the laminated pad according to the
invention;
FIG. 6 is a front elevational view of a portion of a zone forming
gravure cylinder for use in the first method of manufacturing a
laminated pad according to the invention;
FIG. 7 is a partial sectional view of the adhesive coating zone,
the zone forming gravure cylinder and doctor blade for use in the
first method of manufacturing a laminated pad according to the
invention;
FIG. 8 is a partial sectional view of the zone forming gravure
cylinder and doctor blade showing the no-coating zone for use in
the first method of manufacturing a laminated pad according to the
invention;
FIG. 9 is a close-up perspective view of the detents of the
adhesive coating zone of the first embodiment of the gravure
cylinder for use according to the invention;
FIG. 10 is a close-up perspective view of the adhesive coating zone
of a second embodiment of the detents of the gravure cylinder for
use according to the invention;
FIG. 11 is a front elevational view of a portion of the full
gravure cylinder for use according to the invention;
FIG. 12 is a schematic illustration of a portion of a second method
of manufacturing the laminated pad according to the invention;
FIG. 13 is an exploded elevational view of the three sheets of
material used to produce the laminated pad showing the adhesive
coatings thereon;
FIG. 14 is a top elevational view of the laminated sheet of
material prior to cutting of the individual pads according to the
invention showing the outline of the pads cut from the sheet in
phantom lines and the alternating zones of adhesive;
FIG. 15 is a schematic illustration of a third embodiment of a
method for manufacturing a laminated pad according to the
invention;
FIG. 16 is a front elevational view of a zone forming cylinder for
use in the third method of manufacturing the laminated pad as seen
in FIG. 15;
FIG. 17 is a front elevational view of an adhesive coating cylinder
for use in the third method of manufacturing the laminated pad as
seen in FIG. 15;
FIG. 18 is a schematic illustration of a fourth embodiment of a
method for manufacturing the pad according to the invention;
FIG. 19 is a schematic illustration of a fifth method of
manufacturing the laminated pad according to the invention;
FIG. 20 is a side elevational view of an array of laminated pads
produced according to the sixth embodiment of the method of
manufacturing as seen in FIG. 19;
FIG. 21 is a top elevational view of the laminated sheet of
material prior to cutting of the individual pads according to the
invention showing the outline of the pads cut from the sheet in
phantom lines and the alternating zones of adhesive;
FIG. 22 is a schematic illustration of a sixth embodiment of a
method for manufacturing a laminated pad according to the
invention.
FIG. 23 is a schematic illustration of a seventh embodiment of a
method for manufacturing a laminated pad according to the
invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
Referring to the drawings, and to FIGS. 1 and 2 in particular, a
first embodiment 12 of a laminated pad produced according to the
invention is illustrated. The pad 12 comprises a base pad 14, an
intermediate layer or impervious shield 16 mounted to the base pad
14 and a handle forming layer 18 mounted to the impervious shield
16. The base pad 14 has an application surface 20 and an upper
mounting surface 22 opposite the application surface 20. Similarly,
the impervious shield 16 has a lower mounting surface 24 and an
upper mounting surface 26. The lower mounting surface 24 of the
impervious shield 16 is bonded to the upper mounting surface 22 of
the base pad 14.
The handle forming layer 18 comprises an upper surface 32 and a
lower surface 34. A portion of the lower surface 34 of the handle
forming layer 18 is mounted to the upper mounting surface 26 of the
impervious shield 16 to create a mounted portion 28 and a handle
portion 30 pivotally mounted to the mounted portion 28 of the
handle forming layer 18. Preferably, a score line 36 is formed on
the upper surface 32 of the handle forming layer 18 along the
junction between the handle portion 30 and the mounted portion 28.
The score line 36 allows the handle portion 30 to freely pivot or
rotate about the score line 36 relative to the mounting portion
28.
In the preferred embodiment, the pad 12 comprises a pair of opposed
parallel edges 38, 40, and a pair of opposed arcuate edges 42, 44.
In addition, the base pad 14, impervious shield 16 and handle
forming layer 18 are coextensive with one another when the handle
portion 30 of the second sheet is folded down, parallel to the base
pad 14.
The shield 16 is preferably formed of a pliable material which is
impervious to fluids and solids to which the base pad 14 is
exposed. Therefore, as the user grasps the handle portion 30 with
his fingers, his fingers will be protected from the fluid or solid
material by the impervious shield 16. An example of a suitable
material for the impervious shield is Kimdura.TM. manufactured by
Kimberly-Clark of Roswell, Ga.
The impervious shield 16 and handle forming layer 18 can be made of
the same material, such as a suitable impervious non-reactant
material. The material is preferably flexible and has structural
integrity such that it can be easily handled and yet support the
base pad 14. The shield 16 and handle forming layer 18 preferably
have a thickness of approximately 2.5 mils. Other suitable
materials for the impervious shield 16 and handle 18 include a
plastic film or paper coated or impregnated with a plastic such as
polyethylene or polypropylene, and the like.
The base pad 14 can be formed of a variety of absorbent or abrasive
materials depending on the particular application for the pad 12.
For example, the pad can be made of a non-woven synthetic material,
e.g. polyester, entangled cotton, woven fabric, dermabrasive,
sanding materials, foam and the like. Preferably, the base pad is
made of a non-woven material that is soft, pliable, and reversibly
absorbent, that is, a dry pad is able to absorb liquid and a wet
pad can be used to apply the solution to a surface. A lintless pad
is suitable for most applications. Preferably, the base pad is
approximately 1/8 inch in thickness.
Suitable mounting of the shield 16 to the base pad 14 and the
shield 16 to the handle forming layer 18 can be accomplished by
mechanical bonding between the materials through the use of
adhesives or a co-extrusion process.
A conventional adhesive can be used to bind the several layers
together provided that the adhesive has sufficient strength to bond
the various laminated layers and which is substantially nonactive
with the laminated materials. In addition, the adhesive should be
resistant to the expected substances to which the laminated pad
will be exposed during use. As described below, the adhesive can be
mounted to the several laminated layers by a wet bonding, a dry
bonding or a hot melt process.
FIGS. 3 and 4 illustrate a second embodiment of the laminated pad
52 comprising the base pad 14, the impervious shield 16 and the
handle forming layer 18 mounted thereto. The handle forming layer
18 has a mounted portion 62 and a handle portion 64. In this
embodiment, the pad 52 has two parallel edges 54, 56, a concave
arcuate edge 58 and a convex arcuate edge 60. The concave and
convex edges 58, 60 can be utilized to enhance the cleaning or
wiping performance of be pad on contoured surfaces.
FIG. 5 is a schematic view of a portion of the first embodiment of
the method for manufacturing the laminated pad 12 according to the
invention and, more specifically, the method for adhering a sheet
of handle material to a sheet of impervious shield material. A
sheet of shield forming material 70 is supplied on a roll 72. The
shield material sheet 70 is discharged from the roll 72 and passes
between a zone forming gravure cylinder 74 and a rubber impression
cylinder 76. The zone forming gravure cylinder 74 is in contact
with a reservoir of liquid adhesive 78. As the gravure cylinder 74
rotates in the counterclockwise direction as seen in FIG. 5,
adhesive adheres to the outer surface of the cylinder 74 and is
ultimately applied to one side of the shield forming sheet 70 as it
passes between the gravure cylinder 74 and the rubber impression
cylinder 76. A doctor blade 80 is mounted between the liquid
adhesive reservoir 73 and the junction between the zone forming
gravure cylinder 74 and the rubber impression cylinder 76. The
doctor blade 80 is mounted closely adjacent to or engages the zone
forming gravure cylinder 74 to remove excess adhesive from the
outer surface of the cylinder 74 to control the amount of adhesive
applied to the sheet of shield forming material 70. Next, the
shield forming material 70 engages a guide roller 82 and enters a
drying tunnel 84 where heat is applied to the adhesive coated sheet
70. The sheet exits the drying tunnel 84 and engages yet another
guide roller 86.
A sheet of handle forming material 88 is supplied on a roll 90 and
engages the adhesive coated side of the shield forming sheet 70
between a pair of opposed nip rollers 92 and 94. The nip rollers
92, 94 apply a controlled amount of pressure to the shield forming
sheet 70 and handle forming sheet 88 as the sheets pass between the
two rollers 92, 94. The pressure applied by the rollers 92, 94 and
the adhesive on the shield forming sheet 70 binds the two sheets
together to create a laminated sheet 96. The laminated sheet 96 is
stored on a roll 98 for further processing.
The adhesive can be applied by a wet bonding or dry bonding
process. In the wet bonding process, the two sheets are combined
while the adhesive is still wet. The adhesives are typically
water-based proteins, starches, silicates, rubber lattices and
resin emulsions. The wet bonding process is typically limited to
applications in which one of the materials being laminated is
porous enough to allow the adhesive solvent to escape. A dry
bonding process is typically used with two non-porous materials. In
this procedure, the adhesive is applied to one of the materials and
the solvent is evaporated in the drying tunnel leaving behind the
adhesive. The dry bonding process is typically used in laminating
two non-porous materials such as the handle forming sheet 88 and
the shield forming sheet 70.
As seen in FIG. 6, the zone forming gravure cylinder 74 comprises a
support axle 100 and a tubular shaped body 102, which is divided
into a plurality of smooth zones 104 and a plurality of gravure
zones 106. The smooth zones 104 have a smooth outer surface with a
diameter equal to the largest diameter of the tubular body 102. As
seen in FIG. 9, the gravure zones 106 comprise an interlocking web
of depressions or recesses 108 with smooth ribs no separating each
of the recesses 108. The diameter of the rib portions 110 of the
gravure zone 106 is substantially equal to the diameter of the
smooth zones 104. However, the diameter of the recesses 108 of the
gravure zone 106 is less than the diameter of the smooth zones 104
or ribs 110.
As seen in FIGS. 5, 7 and 8, the zone forming gravure cylinder 74
engages liquid adhesive 79 in the reservoir 78 and the adhesive 79
adheres to substantially the entire surface of the tubular body
102. As the cylinder 74 rotates, the adhesive encounters the doctor
blade 80 which engages or is mounted closely adjacent to the
outside surface of the tubular body 102. The doctor blade
essentially scrapes or removes excess adhesive from the outer
surface of the tubular body 102 of the cylinder 74. Preferably, the
doctor blade 80 is adjusted to remove all adhesive from the smooth
zones 104 and the ribs no of the gravure zones 106 while leaving
adhesive within the recesses 108 of the gravure zones 106.
As the zone forming gravure cylinder 74 continues to rotate, the
scraped surface of the tubular body 102 of the cylinder 74 engages
one surface of the shield forming sheet 70. The adhesive contained
within each of the several recesses 108 is transferred from the
gravure zones 106 of the zone forming gravure cylinder 74 to one
side of the shield forming sheet 70. In light of the removal of
excess adhesive from the gravure zones 106, a bead-like pattern of
adhesive will be applied to the shield forming sheet 70. In light
of the alternating sequence of gravure zones 106 and smooth zones
104 along the length of the cylinder 74, a series of strips of
adhesive material arm applied to the shield forming sheet 70. When
the shield forming sheet 70 engages the handle forming sheet 88,
only portions of the sheets corresponding to the strips of adhesive
will be bonded to one another.
As seen in FIG. 9, a first embodiment of the recess 108 is a
truncated inverted pyramid. An alternative embodiment of the grave
recesses 109, as seen in FIG. 10, comprises an inverted pyramid.
The spacing between the gravure recesses and the relative depth of
each of the recesses will determine the amount of adhesive which is
applied to the sheet of material according to the process described
above. The recesses are formed in the cylinder by a conventional
mechanical incising, chemical etching or laser etching process.
White the embodiment described above provides for application of
the adhesive to the top surface of the shield forming sheet, it is
to be understood that the same process could be used to apply
adhesive to the attachment surface of the handle forming sheet
88.
The laminated shield forming sheet 70 and handle forming sheet 88
can be mounted to the base forming material according to the same
process as seen in FIG. 5. Namely, a roll of one of the base
forming material or laminated sheet 96 engages an adhesive coated
gravure cylinder, passes through a drying tunnel, and then is
rolled into contact with the other of the base forming material or
laminated sheet 96. However, in this step, a full gravure cylinder
is used to apply adhesive to one of the base forming material or
the laminated sheet 96.
As seen in FIG. 11, the full gravure cylinder 114 used to apply
adhesive to one of the base forming material sheet or shield
forming sheet comprises an axle 116, a tubular shaped body 118
having gravure recesses 108 formed on substantially the entire
surface of the tubular shaped body 118. The gravure recesses 108 of
the second gravure cylinder 114 are identical to the embodiments
shown in FIGS. 9 and 10. As described above, the depth and spacing
of the gravure recesses controls the amount of adhesive applied to
the sheet. Preferably, a second doctor blade (not shown) is used to
remove excessive adhesive from the cylinder 114 after the cylinder
engages an adhesive reservoir.
FIG. 12 shows a second method for manufacturing a laminated sheet
from which the laminated pads 12, according to the invention, are
cut. In this embodiment, a sheet of handle forming material 88 is
discharged from the roll 90 and engages the zone forming gravure
cylinder 74 and rubber impression cylinder 76. The adhesive 79 is
supplied to the zone forming gravure cylinder 74 from the reservoir
78 and the excess adhesive is removed by the doctor blade 80. The
adhesive coated sheet engages a guide roller 87 and passes through
the drying tunnel 84 where it is subjected to heat. After exiting
the drying tunnel 84, the adhesive coated sheet engages a guide
roller 89.
The sheet of shield forming material 70 is supplied from a roll 72
and passes between the full gravure cylinder 114 and a rubber
impression cylinder 120. The full gravure cylinder 114 applies
adhesive to substantially the entire surface of one side of the
shield forming material 70. The adhesive 122 is supplied to the
full gravure cylinder from the reservoir 123 and the excess
adhesive is removed by the doctor blade 124. Next, the sheet
engages a guide roller 82 and enters the drying tunnel 84. The
shield forming sheet 70 exits the drying tunnel and engages guide
rollers 86. A sheet of base forming material 128 is supplied on a
roll 126 and the shield forming sheet 70, handle forming sheet 88,
and base material sheet in pass between the rubber roller 92 and
master heated nip roller 94 to create the laminated sheet 130 which
is stored on a roll 132 for future processing. Alternatively, the
laminated sheet 130 can be transferred directly to a slitter 174
(FIG. 15) and then a die cutter 165 (FIG. 15) for slitting and
cutting of the sheet into individual pads 12.
The second method for manufacturing the laminated sheet according
to the invention can be modified by applying the adhesive from the
full gravure cylinder 114 to the attachment surface of the base
forming sheet 128 and by applying the zones of adhesive to the
upper attachment surface of the shield forming sheet 70.
As seen in FIG. 13, the laminated sheet 130 comprises the shield
forming sheet 70 having adhesive 138 across substantially the
entire surface, the handle forming sheet 88 having longitudinal
strips of adhesive 134 separated by longitudinal strips of uncoated
material 13 and the base forming sheet 128. The particular
orientation and spacing of the strips of adhesive 134 and strips of
uncoated material 136 becomes important when the laminated sheet is
cut into the individual pads as seen in FIG. 14. This figure shows
the outline of several pads 12 in phantom lines which are to be
stamped from the laminated sheet 130 by a conventional die cutting
operation. The strips of adhesive 134 and strips of uncoated
material 136 are coordinated with the die cutting press to create
the handle portion 30 and mounted portion 28 of each pad 12.
Preferably, the strips of adhesive 134 are aligned such that two
mounting portions 28 for two adjacent pads 12 are created from each
strip of adhesive 134. In addition, each strip of uncoated material
136 is cut to create the handle portion 30 for two adjacent pads
12. Therefore, the strips of adhesive 134 and strips of uncoated
material 136 are coordinated with the dies to create the handle
portion and mounted portion of the handle forming sheet 88. After
the laminated sheet 130 has been cut into individual pads, the pads
can be packaged and in some cases sterilized for use by the end
user.
The particular structure of the strips of adhesive 134 and strips
of uncoated material 136 provide a significant advantage for the
manufacturing method. Namely, if the sheet is slightly out of
alignment with the cutting dies, then it is only the relative sizes
of the handle portion or mounted portion of the adjacent pads which
are affected. The pads will still be adequate for most
purposes.
Alternatively, the strips of adhesive 134 can be equal to the width
of the mounted portion 28 of a single pad 12. In addition, the
width of the uncoated portion 136 can be equal to the width of the
handle portion 30 of a single pad 12. This configuration is
depicted in FIG. 21. The pads 12 which are cut from the laminated
sheet 130 are shown in phantom lines. FIG. 21 also depicts a third
embodiment of the pads 142 in which the pads 142 are round and the
outside perimeter of the base pad 14, impervious shield 16 and
handle forming sheet 18 are co-extensive.
FIGS. 5-17 show a third embodiment of the method for producing a
laminated pad 12 according to the invention. In this embodiment,
the sheet of handle forming material 88 is supplied from a roll 90
and passes between a rubber impression cylinder 76 and a zone
forming cylinder 150. The zone forming cylinder 10 picks up
adhesive from the reservoir 152 and applies it to one side of the
handle forming sheet 88.
The sheet of shield forming material 70 is supplied on roll 72 and
passes between a rubber impression cylinder 154 and a full coating
cylinder 156. The full coating cylinder 156 receives adhesive from
a reservoir 158 and applies it to one side of the shield forming
sheet 70.
The base forming sheet 128 is supplied on a roll 126. The base
material 128, handle forming material 88 and shield forming
material 70 pass simultaneously through a pair of opposed nip
rollers 162, 164. The rollers 162, 164 apply pressure to the three
sheets to create the laminated sheet 130. Next, the laminated sheet
130 is slit to an appropriate width for the die cutter 165. The
slitter 174 comprises a support roller 175 and a circular slitting
blade 176. Finally, the laminated sheet 130 passes to the die
cutter 165 comprising a reciprocating cutter 167 and a mandrel 169
which cuts the individual pads from the laminated sheet 130.
As seen in FIG. 16, the zone forming cylinder 150 of the third
embodiment comprises an axle 166 and a plurality of adhesive
coating sections 168. The adhesive coating sections 168 are spaced
from one another and have a width which results in the creation of
a laminated sheet with a plurality of strips of adhesive 134 and
strips of uncoated material 136 as seen in FIGS. 13 and 14.
The full coating cylinder 156 of the third embodiment, as seen in
FIG. 17 applies adhesive to substantially the entire surface of the
sheet of shield forming material 70. The full coating cylinder 156
comprises an axle 170 and a tubular shaped body 172.
A fourth embodiment of the method for manufacturing a laminated pad
according to the invention is seen in FIG. 18. This method is
identical to the third embodiment depicted in FIG. 15 except for
the adhesive which is used to create the laminated sheet 130. In
this embodiment, a wet bonding adhesive is used which does not
require a drying tunnel. The shield forming sheet 70 has a full
coating of adhesive applied thereto and the handle forming sheet 88
has adhesive applied in zones as described above. The shield
forming sheet 70, handle forming sheet 88 and base material sheet
128 are rolled together to create the laminated sheet 130. The
sheet can be transferred to a roll 132, transferred to a slitter
174 (FIG. 15) or transferred directly to the die cutter 165 (FIG.
15) for cutting the laminated sheet into individual laminated pads
12.
The fourth embodiment of the method for manufacturing a laminated
pad according to the invention as seen in FIG. 18 can be modified
to use pressure sensitive adhesive. For example, a full coating of
adhesive can be applied to the shield forming sheet 70 and strips
for zones of pressure sensitive adhesive can be applied to the
handle forming sheet 88. The shield forming sheet 70, handle
forming sheet 88 and base material sheet 128 are then rolled
together to create the laminated sheet 130. As described above, the
laminated sheet 130 can then be silt, rolled and die cut to create
the individual laminated pads.
A fifth embodiment of the method for manufacturing a laminated pad
according to the invention is seen in FIG. 19. In this embodiment,
a first extruder 180 extrudes a member 182 which has an inverted
T-shaped cross section and can be formed of a thin flexible plastic
material having a thickness of approximately 2.5 millimeters. An
adjacent second extruder 184 or dispenser provides a continuous
elongated member 186 of a suitable base pad material. The extruded
members 182, 186 are fed through a pair of opposed rollers 188, 190
that are rotated in the dictions indicated by their respective
arrows. The rollers 188, 190 bring the two members 182, 186
together at the meeting surfaces and bond them into a combined,
unitary structure. This unitary structure proceeds forward toward a
conventional die cutting apparatus 192. The die cutter 192
comprises a back-up mandrel 194 which is disposed below a
reciprocating cutter 196 powered by a suitable hydraulic or air
cylinder 198.
The upper roller 188 biases a central leg 200 of the T-shaped
member 182 downward in a planar position parallel to the shield
member 202 and the cutter 196 simultaneously cuts the members 182,
186. As the cuter 196 is removed, the centre leg or handle 200 will
pop up to its upstanding position. The cutter 196 can be designed
to cut the laminate into individual pads 12 or as illustrated in
FIG. 20 can be aligned to only partially cut the array 204 of pads.
In this case, the adjacent pads 12 are joined to one another by a
web 206. The array of pads can be rolled into a roll or the like
and dispensed by tearing off individual laminated pads from the
array 204. In an embodiment that is not illustrated, the array 204
can have a number of rows and columns of laminated pads 12.
Alternatively, a number of arrays 204 can be stacked and boxed in a
nest-like fashion. A laminated pad is selected for use and the web
206 is torn, separating the selected pad 12 from the array 204. In
an alternative embodiment that is not illustrated, the web 206 is
formed from the shield or handle.
FIG. 22 depicts a sixth embodiment for manufacturing a laminated
pad according to the invention. In this embodiment, the laminated
sheet 130 is created by a hot melt adhesive bonding process. A
sheet of shield forming material 70 is supplied on a roll 72 and
the sheet 70 engages a plurality of guide rollers 212. Next, the
sheet 70 engages a pre-heating roller 214 which heats the sheet 70.
The sheet 70 then passes between a slot coater 216 and an opposed
nip roller 218. The slot coater 216 applies hot adhesive to one
side of the sheet 70. The adhesive is applied in longitudinal
strips as depicted in FIGS. 13, 14 and 21. The coated sheet 70 then
engages a chill drum 220 which cools both the sheet and the hot
adhesive mounted thereto.
A sheet of handle forming material 88 is supplied from a roll 90.
The sheet 88 engages several guide rollers 212 and is mounted to
the adhesive-coated surface of the shield-forming sheet 70 by
passing between a nip roller 222 and the chill drum 220 resulting
in the creation of the laminated sheet 96. The laminated sheet 96
engages several guide rollers 212 and ultimately wound on a roll 98
for further processing. This same process can be used to mount the
base-forming sheet 128 to the laminated sheet 96 by using a full
coating gravure cylinder which applies adhesive along the full
width of the base-forming sheet 128.
FIG. 23 shows a seventh embodiment of the method for manufacturing
a laminated pad according to the invention. In this embodiment, the
laminated sheet 130 is formed solely from a sheet of handle forming
material 70 and abase pad sheet 128 wherein only a portion of the
handle forming sheet is adhered to the base pad sheet through the
selective application of longitudinal strips as depicted in FIG.
14. In this embodiment, the gravure roller 74 applies strips of
adhesive to the attachment surface of the sheet of handle forming
material 70 in the same manner as described above with respect to
FIG. 5. Ultimately, the strips of adhesive on the sheet of handle
forming material 70 are brought into contact with the attachment
surface of the sheet of base pad material 128 by passing through
rollers 92, 94. The resulting structure is a laminated web 130
which can be cut into individual pads as described above. However,
these pads will comprise only a base pad and a handle. The only
difference between this embodiment and the earlier embodiments is
that the shield of impervious material has been deleted from this
embodiment of the laminated pad.
While the embodiment described shove provides for application of
the adhesive to the attachment surface of the sheet of handle
forming material, it is to be understood that base pad
material.
The laminated pad produced according to the invention can be used
for the application of various materials such as liquids, pastes,
powders, and the like to various surfaces and may be utilized for
the removal of such materials. In addition, the laminated pad can
be impregnated with a material to be applied. The laminated pad has
unlimited uses in the medical field such as an absorbent applicator
pad or wipe and in the cosmetic field for removing nail polish by
the application of acetone and other solvents. The pad may also be
used for the application and/or removal of facial and other skin
cleansers, moisturizers, make-up, and tanning cream. The pad can
also be used in the medical field for the application of various
medications, applying cleaning solutions to a patient or absorbing
fluids from a patient. The pad can be packaged and sterilized for
these medical uses.
The method of manufacturing the pad according to the invention
allows for the mass production of pads at a relatively low cost.
Because the pads are produced from a single laminated sheet having
zones of adhesive, the pads can be easily die cut and packaged.
While we have illustrated and described our invention by means of
specific embodiments, it is to be understood that numerous changes
and modifications may be made therein without departing from the
spirit and scope of the invention as defined in the appended
claims.
* * * * *