MXPA99005815A - Method of making an absorbent article having leg cuffs combined with containment flaps - Google Patents

Abstract

The invention relates to methods of fabricating an absorbent article. In one method of the invention, combination containment flaps (98) and leg cuffs (100) are formed on a common substrate. A plurality of elastomeric elements (54) are included in the combination article to assist in forming containment flaps (98). Discrete leg cuff pieces are applied to the substrate at longitudinally spaced locations. In some embodiments, a cutting device slits the substrate substantially along a center line extending the length of the substrate, forming two continuous substrate portions. A glue gun (133) applies adhesive to the substrate portion. The substrate portions are folded lengthwise, using the adhesive to form integral containment flaps and leg cuffs in a composite substrate. The composite substrate is secured to an absorbent article web sausage in forming absorbent articles. In another embodiment, the substrate is a first substrate which supports elastomeric elements (54) used in forming leg cuffs (100) and containment flaps (98). The first substrate is secured to a second substrate, thus forming a base structure, with the elastomeric elements (54) between the first and second substrates. A bodyside liner and an absorbent core are added on one side of the base structure, and an outer cover is added on the second side, to form a web sausage. In both embodiments the web sausage is cut transversely at spaced locations along the length of the web sausage, to form absorbent articles.

Description

METHOD TO MAKE AN ABSORBENT ARTICLE HAVING LEGGES COMBINED WITH CONTAINMENT FINS FIELD OF THE INVENTION The present invention relates to methods for manufacturing absorbent articles. Such methods usually include gluing and may include ultrasonic bonding, to combine elements and form the absorbent articles.

BACKGROUND OF THE INVENTION Conventional methods for making absorbent articles, such as disposable diapers, are well known in the art. These methods usually rest on the joining of the cuffs or leg turns, the containment fins and other elements to the absorbent article as continuous fabrics or fabrics of bonding material. Thus, a continuous strip of material, such as a cuff or leg cuff material, is continuously applied to the frame of an absorbent article. This method allows a high speed of formation of the absorbent articles.

The process of the applicant greatly reduces complexity by placing the leg cuffs and elastomeric fin elements on a continuous substrate or fabric. The continuous fabric is cut and folded to create two containment flaps and combined leg cuffs and then secured to an absorbent article fabric sausage.

By forming the leg cuffs and the containment flaps separately from the cloth sausage, the number of processing steps or operations to manufacture the cloth sausage is reduced. This increases the production speed of the manufacturing process.

Another of the methods of the applicant forms the cuff or leg turn and the containment flaps combined on a substrate and then secures an outer cover to a first side of the substrate and a side-to-body liner and an absorbent core to a second side of the body. substrate, thereby forming an additional single absorbent article.

SYNTHESIS OF THE DESCRIPTION The present invention relates to the methods for manufacturing the absorbent articles, and focuses on the formation of leg cuffs and turns and of containment flaps. More particularly, the methods include applying elastomeric elements to a continuous cloth substrate and applying the leg cuffs at longitudinally spaced locations along the substrate. The leg cuffs are transversely separated from the elastomeric elements. One method further includes cutting the continuous fabric along its length into a centerline to form two continuous portions of fabric substrate, each having the leg cuffs and the elastomeric elements. The two continuous leg portions are bent to form the respective composite substrates of the containment fin material, with the leg cuffs spaced along the length of the containment fin material. The leg cuffs and integral containment flaps are then applied to a cloth sausage.

In one embodiment, the opposing pairs of cuff or leg pieces are longitudinally spaced along the length of each of the respective composite substrates. The opposing pairs of the leg cuff pieces are placed between the outer edges of the respective composite substrates and the elastomeric elements extending longitudinally on the respective composite substrate.

In another embodiment the extendable leg cuffs are stretched, preferably to a dimension representing about 20% to 50% of the stretch distance to the respective stop when secured to the substrate.

In yet another embodiment, the leg cuff parts comprise elastomeric threads secured to a piece of generally non-elastomeric material.

In yet another embodiment, the leg cuff pieces when secured to the substrate essentially cover the leg cuts.

Another embodiment includes the step of applying ultrasonic energy to the respective composite substrates to finish and smooth the raw edges thereon.

In a further embodiment, the adhesive is applied along a central line of the respective composite substrate before being mounted on the fabric or fabric sausage.

In a still further embodiment, the adhesive is applied along the longitudinal outer edge of the respective composite substrate to one side of the respective leg cuff parts prior to application to the fabric sausage.

In another embodiment of the invention, the fabric structures to be used as a combination of a leg cuff and flap for containment are produced by supplying a substantially endowed part of the substrate having a length dimension, securing the cuff pieces for legs extendible to the substrate part at the longitudinally spaced locations, securing the elastomeric elements longitudinally along the length dimension of the substrate part in a transversely spaced relation to the leg cuff pieces, and bending the outer edges longitudinally opposing the portion of the substrate inwardly and securing the outer edges to the front portions of the substrate portion to form a composite containment fin substrate.

Another method for making an absorbent article includes securing the elastomeric elements to a first continuous web substrate, cutting the substrate longitudinally to form a pair of first portions of substrate, securing the first portions of substrate to a second substrate, with the elastomeric elements between the second substrate and the pair of first portions of substrate to form a base structure. An absorbent core and a side-to-body liner are applied to one side of the base structure and an outer cover is applied to the opposite side of the base structure to form a cloth sausage.

In one embodiment, the method includes the steps of folding the outer edges of the base structure inwardly in a substantially J-shaped configuration and ultrasonically joining the edges.

Another embodiment includes the steps of driving the base structure at a first fastening point at a first speed, then driving the base structure through a second fastening point at a slower second speed, so that gathers are formed in the base structure between the first and second fastening points, the second fastening point secures the liner from side to body and the absorbent core to the base structure while the base structure is in the creased condition.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 shows a representative lateral elevation of the apparatus for making the absorbent articles of the invention.

Figure 2 shows a top view of a continuous containment fin substrate that supports the elastomeric elements and spaced leg cuff pieces.

Figure 3 shows a cross-sectional view of the substrate, the elastomeric elements and the leg cuff pieces, and that is taken at point 3-3 of figure 2.

Figure 4 shows a cross-sectional view of the substrate, the elastomeric elements and the leg cuff parts, and that is taken at point 4-4 of Figure 2.

Figure 5 shows a cross-sectional view of the parts of the substrate that are being folded, after separation, with the elastomeric elements and the leg cuffs thereon, and which is taken at point 5-5 of the figure 2.

Figures 6A and 6B show a cross-sectional view of the composite containment fin substrates formed by folding the substrate portions, and is taken at point 6-6 of Figure 2.

Figures 7A and 7B show a cross-sectional view of the composite substrates of Figures 6A and 6B with the adhesive applied thereto.

Figure 8 shows a cross-sectional view showing the composite substrates applied to the cloth sausage.

Figure 9 shows a representative top view of the composite substrates being applied to the fabric sausage.

Figure 10 shows a cross-sectional view of a first embodiment of the absorbent articles formed by the apparatus and methods of the invention.

Figure 11 shows a cross-sectional view of a second embodiment of the absorbent articles formed by the apparatus and methods of the invention.

Figure 12 shows a graphic view of a second embodiment of the apparatus used in the invention.

Figure 13 shows a cross-sectional view of a base structure, and is taken at point 13-13 of Figure 12.

Figure 14 shows a cross-sectional view of the folded base structure -J, and is taken at point 14-14 of figure 12.

Figure 15 shows a cross-sectional view of a cloth sausage formed by the apparatus and by the methods of the invention and which is taken at point 15-15 of Figure 12.

The invention is not limited in its application to the details of the construction and arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other incorporations or of being practiced or carried out in various ways. Also, it should be understood that the terminology and phraseology used herein is for the purpose of description and illustration and should not be viewed as limiting. Equal reference numbers are used to indicate equal components.

DETAILED DESCRIPTION OF THE ILLUSTRATED INCORPORATIONS The present invention is directed to methods for producing absorbent articles, particularly disposable absorbent articles. The articles can be placed against or in proximity to the body of a user to absorb and contain various exudates discharged from the body. An example method forms the leg cuffs and containment flaps of a substrate comprising a continuous cloth of material.

Figure 1 shows an assembly system 8 for forming the absorbent articles. System 8 includes a compression point device 10 that secures a body side liner 12 and an absorbent core 13 (shown in Figures 10 and 11) to an outer cover 14. The compression point device 10 comprises the rollers first and second 16 and 18 forming a first pressure point 20. The first pressure point 20 applies pressure to the liner from side to body 12, to the outer cover 14 and to the absorbent core therebetween, to form a sausage of cloth of absorbent article 22. The absorbent article fabric sausage 22 is then moved to the die cutter 24. Matrix cutter 24 includes an anvil roller 26 and a knife roller 28. Matrix cutter 24 carries out the cuts of leg 30 of a cloth sausage 22 as shown in Figure 9. The cloth sack 22 continues to the ear applicator 32. The ear applicator 32 secures the ears 34, shown in Figure 9, the sausage cloth 22 pair to mount the absorbent article 35 on a user. The ear applicator 32 includes a vacuum transfer roller 36 which supports the ears 34 and blade roller 38. The knife roller 38 cuts the ears 34 of the ear material 40 fed from the supply roll 42. An anvil The elliptical rotator 44 with the discs 46 intermittently forms a pressure point with the transfer roller 36 to secure the lugs 34 on the cloth inlay 22. The rotary anvil 44 rotates in a right-to-left direction shown by the arrow 48 at that the disks 46 move in the same direction as the cloth sausage 22 when the disks interact with the cloth sausage.

Meanwhile, a substrate 50 of a continuous cloth material is pulled from a supply roll 52. One or more elastomeric elements 54 are pulled from one or more elastomeric element supply rolls 56. The elastomeric elements 54 pass through the thread guides 58 of the guide apparatus 60. The guide fingers 62 guide the elastomeric elements 54 through the substrate 50. The glue gun 64 applies adhesive to the elastomeric elements 54. The elastomeric elements 54 preferably extend longitudinally along the length of the substrate already, essentially equal distances from the central axis 87 shown in Figures 2 and 3. The anvil rollers 66 and 68 ensure the attachment of the elastomeric elements 54 to the substrate 50 by applying pressure to the elastomeric elements and to the substrate.

The substrate 50 then moves the leg cuff part applicator 70. Preferably the substrate 50 travels in an essentially straight line path from the supply roll 52 through the anvil rolls 60 68 to the cuff part applicator. for leg 70. The leg cuff applicator 70 includes a glue gun 72 which applies the glue to the leg cuff material 74. The pre-wrap roller 75 assists in pre-aligning / pre-wrapping a knee roll. variable speed vacuum transfer 76. The variable speed vacuum transfer roller 76 includes the discs 78 that support the leg cuff parts 80, and an anvil roller 82 that forms a second attachment point 84 with a roller vacuum 76. A hot knife (not shown) on the vacuum transfer roller 76 cuts the extendable leg cuff pieces 80 to a size preferably larger than that of the "L" length of the opening in the leg cuts 30 shown in Figure 9. The applicator of the leg cuff part 70 then secures the leg cuff pieces 80 on the substrate 50 at transverse and longitudinally spaced locations as shown in the figures 2 and 3. A full description of a vacuum transfer roller 76 as well as a vacuum transfer roller 36 is set forth in United States Patent Application Serial No. 08 / 381,362, entitled "Method and Apparatus. for the Placement of Discrete Parts on a Mobile Fabric ", by Rájala et al., presented on January 31, 1995 and which is incorporated herein by reference in its entirety.

The cutting wheel 86 cuts or slits the substrate 50 into two substrate portions 50A and 50B as shown in Figure 2, forming the slit 85 along the length of the substrate 50. The glue guns 88 and 90 then apply the adhesive to the substrate portions 50A and 50B as shown in Figure 4.

The folding mechanism 92, represented by an angle having the arms aligned with the direction of movement of the substrate 50 in Figure 1, then bends both inner and outer portions of the substrates 50A and 50B to form the containment fin substrates composite 51A and 51B . Each composite containment fin substrate comprises an integral combination of a containment fin 98 and a leg cuff 100 as shown in Figures 6A and 6B.

Then, the anvil rollers 102, 104 apply pressure to the clamping point 106 ensuring that the combination of the containment fins 98 / leg cuffs 100 of the composite substrates 51A and 5IB are adequately bonded by the adhesive and conform to the desired bent configuration. The glue guns 108 and 110 apply adhesive to the respective composite substrates 51A and 51B near the tipping roller 112. The tipping roller 112 turns the respective composite substrates 51A and 51B toward the fabric sausage 22 for securing thereto. The ultrasonic linker 114 then a the substrates of the composite 51A and 5IB comprising the leg cuffs 6 and the containment flaps 98 to a sausage of tel 22, and terminates the edges of the respective composite substrates. The ultrasonic linker 114 includes the first and second linker units, each unit including an ultrasonic rotary anvil roller 116 and a rotating ultrasonic horn 118 forming a respective pressure point 119.

The body side liner 12 can be manufactured from a wide selection of fabric materials, such as porous foams, cross-linked foams, perforated plastic films or natural fibers. For example, the side-to-body liner 12 may comprise wood or cotton fibers. Other possible materials are synthetic fibers, such as polyester or polypropylene fibers or a combination of natural and synthetic fibers. The body side liner 12 is suitably used to help isolate the liquids maintained in the absorbent core 13 from the wearer's skin.

Various woven and non-woven fabrics can be used for the side-to-body lining 12. For example, the body-side liner 12 can be composed of a co-melt blown or spin-bonded fabric of polyolefin fibers. The body side liner 12 may comprise a carded and / or composite fabric composed of natural and / or synthetic fibers. The body liner 12 can also be composed of an essentially hydrophobic material wherein the hydrophobic material is treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity.

In a particular embodiment of the present invention, the body-side liner 12 may comprise a polypropylene spunbond fabric composed of 2.8-3.2 denier fibers formed into a fabric having a basis weight of about 22 grams per square meter and a density of about 0.06 grams per cubic centimeter. A preferred fabric is treated with about 0.3% by weight of a surfactant.

The body side liner 12 may be formed of a single layer, or may comprise a multiplicity of components, layers, or partial layers, which correspond to any of the materials described herein, as well as to others known in the art.

The absorbent core 13 suitably comprises a matrix of hydrophilic fibers, such as a cellulosic liner, preferably in combination with a high-absorbency material commonly known as a superabsorbent material. In a particular embodiment, the absorbent core 13 comprises a mixture of superabsorbent hydrogel forming particles and wood pulp fluff. In place of wood pulp fluff, one can use meltblown, polymeric, synthetic fibers or a combination of blown fiber with melt and natural fibers. The superabsorbent material can be mixed in an essentially homogeneous way with the hydrophilic fibers or can otherwise be combined in the absorbent core.

Alternatively, the absorbent core 13 may comprise a laminate of fibrous fabrics and superabsorbent material or other suitable means for maintaining a superabsorbent material in a localized area The absorbent core 13 can have any of a number of shapes. For example, the absorbent core can be rectangular, T-shaped, or I-shaped. It is generally preferred that the absorbent core 13 be narrower in the crotch portion than in the back and / or front portions. The absorbent core 13 generally does not extend over the entire dimensions of the outer cover 14 or the side-to-body liner 12.

The superabsorbent material in the absorbent core 13 can be selected from natural, synthetic and modified natural material polymers. The high-absorbency materials can be inorganic materials such as silica gels, or organic compounds, such as degraded polymers. The term "degraded" refers to any means for effectively making the materials normally water-soluble essentially insoluble in water but sponge-like, whereby the absorbing properties are available but the foamed material is essentially immobile after absorbing the water-based liquids. Such means may include, for example, physical entanglement, crystalline domains, covalent bonds, complexes and ionic associations, hydrophilic associations, such as hydrogen bonding, and hydrophobic associations or Van der Waals forces.

The outer cover 14 can be formed of a single layer, or of multiple components, layers or partial layers, of material, so that the resulting outer covering is essentially impermeable to liquids. A typical outer cover 14 can be made of a thin plastic film other material impermeable to the flexible liquid. For example, the outer cover 14 can be formed of a polyethylene film having a thickness of from about 0.012 millimeters to about 0.051 millimeters. When it is desired that the outer cover 14 have a more textile fabric type feel, this may comprise a polyethylene film laminated to a surface of a non-woven fabric, such as a cloth bonded by spinning polyolefin fibers. For example, a polyethylene film having a thickness of about 0.015 millimeters may have thermally laminated thereto or otherwise a fabric joined by spinning polyolefin fibers having a thickness of from 1.5 to 2.5 denier per filament, which fabric is not woven has a basis weight of about 24 grams per square meter. In addition, the outer cover 14 can be formed into a woven or non-woven fibrous web which has been fully or partially constructed or treated to impart a desired level of liquid impermeability to selected regions that are adjacent to the absorbent core 13. additionally, the cover 14 can optionally be comprised of a microporous material which allows the vapors to escape from the absorbent core 13 and through the cover 14 while preventing liquid exudates from passing through the outer cover.

The ears 34 preferably comprise the mechanical fasteners such as the hooks of a hook and loop fastening system, and are preferably mounted on the outer cover 14. The cooperating fastening curl material or other fastening surface is provided in eg the surface outer (not shown) of the outer cover 14 on for example the front part of the respective absorbent articles 35. The example curl material is adapted to releasably engage with the hook material in the respective ear. Other well-known fastening systems can also be used to hold the absorbent article 35 on a wearer. For example, a cohesive system, an adhesive fastener system or the like can also be used to secure the absorbent article around the lower trunk and crotch portion of the wearer.

The operation of the absorbent article assembly system 8 is as follows. The first and second anvil rollers 16 and 18 of the compression point device 10 form the first pressure point 20. At least one of the rollers is driven by an impeller (not shown). The rollers 16 and 18 press the continuous fabrics of the side liner to the body 12 and the outer cover 14 one against the other at the pressure point 20, trapping separate elements of the absorbent core 13 therebetween, thereby ensuring the lining side to body 12, absorbent core 13 and cover 14 together at pressure point 20, preferably by gluing. These three elements, when secured to one another, mutually form the absorbent article fabric sausage 22, with the separate elements of the absorbent core 13 being placed between the side-to-body liner 12 and the cover 14. Other known devices can also be used. to form the cloth sausage 22.

The body side liner 12 and the outer shell 14 preferably have the same dimensions in essential shape. The lining fabrics sideways to the body 12 and the outer cover 14 are preferably aligned so that their outer edges are essentially aligned with and contact with each other when the fabric sausage 22 is formed. The fabrics thus bonded from side facing to the body 12, from the cover 14 and from the spaced absorbent core elements 1 comprise the precursors of respective series-aligned absorbent articles 35 along the length of the fabric sausage 22. As shown in FIG. indicated in the drawings, the cloth sausage 22 comprises a continuous cloth sausage.

After leaving the pressure point 20, the cloth inlay 22 then enters the die cutter 24 which carries out the cuts 30. The cut is made by the knife roller 28 in combination with the anvil roller 26. The knife roller 28 has the blades (not shown) arranged in a pattern consistent with the manufacture of the leg cuts illustrated in Figure 9. Preferably both leg cuts 30 on an absorbent article precursor are made simultaneously by the separate blades (not shown). The absorbent core 13 is preferably not contacted by any of the cutter knives 24. Preferably none of the layers forming the cloth emboss 22 contain elastomeric material.

As used herein, "elastomeric material" means material which can be stretched by about 50% to about 450% in one direction, and which will return approximately its original dimensions when it is released. Preferably all of the material removed by die cutter 24 comprises non-elastomeric material.

The ear applicator 32 cuts, and thus creates, the ears 34 of an incoming material of ear material 40 pulled from the supply roll 42, and transfers the ears to the fabric sausage 22. The knife roller 38 rotates with the transfer roller with vacuum 36, cutting the ear material 40 to create the ears. The elliptical rotating anvil 44 rotates about the central axis 47 as shown by the arrow 48 in Figure 1. The rubber discs 46 on the rotary anvil 44 intermittently form a pressure point with the transfer roller 36 and thus assist the securing the ears 34 in the cloth sack 22. After an ear 34 has been secured, the respective rubber disk 46 rotates out of contact with the cloth sausage 22. The opposing disk 46 then rotates to make such contact, so as to mount another ear 34 when the rotary anvil 44 has rotated about 180 degrees. Such a process is repeated by a continuous rotation of the rotating yunker 44 and the transfer roller 36. The ears can be secured to the cloth sausage 22 by adhesive or other methods. The discs (not shown) on the vacuum transfer roller 36 rotate to contact the fabric sausage 22 to transfer the ears 34 to the fabric sausage.

While the compression point device 10, the matrix cutter 24 and the applicator 32 are operating, the substrate 50 comprising a continuous web material is being pulled from the supply roll 52. The elastomeric element supply roll 56 supplies continuous strands of elastomeric elements 54 to the guide apparatus 60. The guide apparatus 60 utilizes the thread guides 58 and the guide fingers 62 to place and secure the elastomeric elements 54 in the substrate 50.

The substrate 50 may comprise any of the materials mentioned as suitable for the body-side liner 12. The substrate 50 preferably comprises a non-woven fabric material. The substrate 50 has a length dimension. The substrate 50 comprises a main body extending along the length dimension, and the opposite outer edges 53.

The glue gun 64 applies the adhesive to the elastomeric elements 54 just before the elastomeric elements are secured to the substrate 50. The elastomeric elements 54 are adhered at the opposite interior locations separated from both the central axis 87 of the substrate 50 as shown in FIG. Figure 2 and the opposite outer edges 53 of the substrate 50. The central axis 87 runs along the length of the substrate 50 and is essentially centered on the substrate. The elastomeric elements 54 preferably run along the entire length of the substrate 50 and are preferably spaced out at substantially equal distances from the central axis 87, inward by substantially equal distances from the respective outer edges 53. Preferably, the separate leg cuff pieces. 80, which will be described in greater detail below, are spaced inward from the elastomeric elements 54 as shown in Figure 2. The substrate 50 then passes through the anvil rollers 66 and 68 which apply pressure to the elastomeric elements. 54 and the substrates 50, ensuring the union of the elastomeric elements to the substrate.

Any number of elastomeric elements 54 can be used in the invention. Figures 3-5 show a total of four elastomeric elements 54 applied to the substrate 50. However, any number of elastomeric elements, preferably an even number, can be secured to the substrate. The elastomeric elements 54 may comprise yarns, tapes, one or more layers of polymeric and / or elastomeric material, such as a rubber material, which is adhered to the substrate 50 in a stretched condition. A suitable elastomeric element can be composed of a LYCRA elastomer of 470 decitex, or LYCRA elastomer of 620 decitex or other elastomers with suitable characteristics. The elastomeric elements 54 creates the elastic tension for the containment fins 98 and therefore must be of an appropriate size and strength.

While the continuous elastomeric elements 54 intermittently stuck to the substrate 50 are the preferred embodiment, the elastomeric elements may be non-continuous, having a length essentially the same as that of the leg cuffs 80 shown in Figure 2. In such embodiment, the elastomeric elements 54 may be attached to the substrate 50 in a manner similar to that of the leg cuff parts 80. Figure 3 shows an embodiment of the invention in cross section including two separate pairs of elastomeric elements 54 around which are bent the containment fins 98.

The glue gun 64 may comprise a single glue gun with multiple ports, or a plurality of individual glue guns for each elastomeric element 54 which is being secured to the substrate 50. The glue guns 64 preferably operate in a manner of matching or synchronized for intermittently gluing the elastomeric elements 54 to the substrate 50. Even when Figure 1 shows the glue gun 64 applying the adhesive to the elastomeric elements 54, the adhesive can instead be applied directly to the substrate 50 in the places where the guide apparatus 60 placed the elastomeric elements on the substrate, or it can be applied to both the substrate 50 and the elements 54. The glued parts of the elastomeric elements 54 preferably extend approximately the same length as the leg cuff pieces 80 and preferably along the same length of the substrate 50 as the leg cuff pieces in registration with the leg cuff parts 80; but the elastomeric elements 54 are preferably spaced inward from the leg cuff pieces 80 when both are applied to the substrate 50.

Although gluing is the preferred method for joining the elastomeric elements 54 to the substrate 50, other known methods may be used, such as melting bonding or heat bonding.

The substrate 50 moves from the guide apparatus 60 through the pressure point formed by the rollers 66 68, and then to the leg cuff part applicator 70. The dotted line in Figure 1 indicates that the elastomeric guide apparatus 60 may be in line with the leg gripper applicator 70 and is placed below the apparatus 60 merely for purposes of illustration.

The leg cuff applicator 70 applies the pairs of opposite leg cuff pieces 80 to the substrate 50 using the variable speed vacuum transfer roll 76 with the discs 78 that support the leg cuffs 80, representatively illustrated in figure 1. The glue gun 72 applies the adhesive to a continuous web of the leg cuff material 74.

In an alternate embodiment (not shown), the glue gun 72 is placed on the side of the substrate 50. The glue gun 72 is synchronized or made to match to intermittently apply adhesive to the spaced apart portions of the substrate 50 and to the adhesive. along a length of the substrate 50 therebetween. The leg cuff 80 is placed on the side of the substrate 50 of the leg cuff pieces with the ends 81 and one side of each leg cuff 80 in register with the adhesive on the substrate 50 and secured to the substrate.

The pre-wrap roller 75 assists the transfer roller with pre-feed / pre-wrap vacuum 76 keeps the leg grip material 74 in continuous contact with the vacuum transfer roll 76 before, during after material cutting of fist for leg. The variable rotational speed of the transfer roller with vacuum 76 is controlled to operate at a first rotational speed by which the speed of a segment of the roller essentially equal to the speed of the leg grip material 74 when a length of the grip material is received. for leg over the roller segment. The continuous web of the leg cuff material 74 is then cut into the individual leg cuff parts 80 by means of a hot blade (not shown) on a vacuum transfer roll 76, and is held by vacuum on a roller transfer with vacuum 76.

When the leg cuffs are to be applied to the substrate 50, the rotational velocity of the respective segment is changed so that the segment velocity essentially equals the velocity of the substrate 50. By equating the sue velocity of the segment to the velocity of the substrate 50, an appropriate transfer is made. The variable speed vacuum roller 76 applies the leg pair fist pieces 80, such as by adhesive pressure, to the substrate 50 with the help of the roller 82.

The individual extendable leg cuff parts 80, at least when they extend, have a length greater than the length of the leg cuffs 30. Prior to securing to the substrate 50, the leg cuff 80 pieces preferably extend to a dimension which represents about 5% to about 95% of its stretch elongation to the stop, and more preferably d from 20% to 50% of its stretch elongation to stop. The leg cuff parts 80 are secured to the substrate 50 in a partially stretched condition, with the substrate 50 preferably extending to its limit d stretch until it is stopped. At a minimum, the elongation d of the leg cuff 80 in the securing to the substrate 50 is greater than the elongation percentage of the substrate 50. Therefore, the leg cuff 80 provides a degree of retraction properties. different from, preferably greater than, the shrink properties of the substrate 50. Figure 3, taken at point 3-3 of Figure 2, shows the preferred separation of the leg cuff pieces 80 on the substrate 50 on the sides of the elastomeric elements 54. The leg cuff pieces 80 are spaced apart at opposite positions with respect to one another along substantially the same length of the fabric substrate 50.

The cloth material 74 used to make the leg cuff pieces 80 may comprise, for example, a laminate including the first and second outer nonwoven front layers on opposite sides of an elastomeric core layer. The elastomeric core layer including a thermoplastic elastomeric composition such as a terylene styrene ethylene butylene styrene terpolymer. The extendable leg cuff parts 80 may also comprise a plurality of elastomeric elements comprising threads, tapes or the like secured in a stretched condition to a non-elastomeric material part, the elastomeric elements extending along the length of the material piece. not elastomeric The leg cuff pieces 80, as shown, are non-continuous structures comprising elastomeric material.

Examples of other materials that may comprise all or some parts of the leg cuff parts 80 include, without limitation, laminated non-woven / spandex fabrics, meltblown fabrics or extruded elastomeric fabrics, cloth materials stretchable in the transverse direction to the machine made with stretchable, nonwoven and stretchable foam fabrics and the like.

From the cuff part applicator 70, the substrate 50 is moved to the cutting wheel 86. The cutting wheel 86 includes a blade which slits the substrate 50 along its length into two substrate portions 50A and 50B as shown in FIG. the dotted central axis 87 in Figure 3. A slit 85 formed by the cutting wheel 86 is shown in Figure 9. Even when the cutting wheel 86 is shown, this invention contemplates other known elements that perform the same function of cut. For example, a tension bar having a stationary or movable blade mounted at an appropriate angle with respect to the substrate 50 may crack the substrate along its length.

The folding mechanism 92 is represented by an angle or bend in the substrate portions 50A, 50B of the substrate. 50 in Figure 1. The folding mechanism 92 bends the substrate portions 50A and 50B to form the composite substrates 51A and 51B. The folding mechanism 92 comprises a well-known apparatus that bends fabrics or substrates. Such a bender apparatus is shown in U.S. Patent No. 4,900,384 issued February 13, 1990 to Sanders et al. And incorporated herein by reference. Other similar bender mechanisms are well known in the art and can be used with the assembly system 8.

The glue guns 88 and 90 apply the adhesive to the substrate portions 50A and 50B respectively as shown in FIG. 4. The folding mechanism 92 then folds the substrate portions 50A and 50B along the continuous length of the plates. same as shown in figure 5 securing the outer edges to the front parts of the main body. When the folding is completed, the composite substrates 51A and 51B are formed. Each continuously folded and integrated composite substrate 51A and 51B comprises an integral leg cuff 100 with a containment flap 98 as shown in Figures 6A and 6B. The driven anvil rollers 102 and 104 which form the pressure point 106, then compress the composite substrates 51A and 5IB to obtain the securing of the adhesive, to thereby ensure bending.

The tumbling roller 112 then flips the composite substrates 51A and 51B toward the ultrasonic linker 114.

The glue guns 108 and 110 apply the adhesive 111 to the composite substrates 51A, 51B preferably as adhesive lines at a central location along the length of the compound substrate, as shown in FIGS. 7A and 7B. The integral leg cuffs 100 and the containment fins 98 d of the integral bent composite substrates 51A, 51B are then moved in a downward position of the cloth sausage 22 com shown in the cross-sectional view of Figure 8, secured thereto. . Of course, the composite substrates 51 and 51B can, in the alternative, be placed on top of the cloth emboss 22 or in any other spaced arrangement. The cloth emboss 22 is then a representation of, for example, the side lining to the body 12, of the absorbent core 13, of the outer cover 14 and of any other element contained between the side-to-body lining 12 and the outer cover. 14 The ultrasonic linker 114 then terminates and straightens the absorbent article. The ultrasonic linker 114 includes the anvil rollers 116 and the rotating ultrasonic horns 118 Each rotating ultrasonic horn 118 is pressed against a respective anvil roller 116. Upon passage of the cloth sausage 22 and the composite substrates 51A and 51B, each The rotating ultrasonic rope 118 vibrates, generating the ultrasonic energy, preferably at a frequency of about 2 KHz. The ultrasonic energy ends and smoothes the brut edges of each of the leg cuffs 100 and smooths the unevenness due to its non-coincident elasticity and gluing. Each ultrasonic horn 118 is placed on a different one of the spaced leg cuff lines 100 which are being secured to the fabric sausage 22. A respective ultrasonic horn 118 typically has a pattern 117 of stitches forming a quilted pattern or other pattern or appearance . This quilted pattern 117 is formed by mixing parts of the composite substrates 51A and 51B in the fabric sausage 22 with ultrasonic energy as shown in Figure 9. This pattern prevents curling of the leg cuffs 100 and / or the cuffs. containment fins 98, caused by their elasticity and their non-coincidence, to alter the appearance, or the consistency of behavior, of the absorbent article 35. Thus, after the ultrasonic treatment, the absorbent articles 35 have a smooth and finished appearance wherein the composite substrates 51A and 5IB are secured to the fabric sausage 22.

Although an ultrasonic linker 114 is described, other well-known devices can be used to join the composite substrates 51A and 51B to the fabric sachet 22. For example, the ultrasonic linker 114 can be replaced by a pair of anvil rollers forming a point of Pressure. The anvil rollers comprise the cloth sausage 22 against the composite substrates 51A and 51B ensuring that the adhesive 111 secures the elements from one another.

Downstream of the ultrasonic linker 114, the cloth sausage 22 is cut into a plurality of absorbent articles or workpieces. A cutting machine (not shown) cuts the cloth sausage 22 transversely across its width. The cutting machine is synchronized or matched to cut the cloth sausage 22 at spaced locations along the length of the cloth sausage, and essentially centered between the longitudinally spaced leg cuffs 80. The cutting machine also cuts the elastomeric elements 54, if they have not been cut earlier in the process.

The cut of the cloth sausage 22 is made of any of a variety of known mu cut machines. For example, a final cutting roller (not shown) having a blade (not shown) extending through the roller, in combination with an anvil roller (not shown) cuts the cloth sausage 22. Preferably there is a separation of about 0.25. inches between the cutter roll and the anvil roller (not shown). The absorbent articles cut from the cloth sausage 22 are transferred by or conveyor to an applicator (not shown).

In the embodiment shown in Figures 7A-7B, the adhesive 111 is placed on a continuous adhesive line between the containment flap 98 and the leg cuff 100. This embodiment forms a "V-cuff" type absorbent article 35 as Shown in Figure 10. The absorbent article 35 includes an absorbent core 13, the body-side liner 12 and the outer cover 14. The leg cuffs 100 extend outwardly from the absorbent core 13, along the lining. sideways to the body 12 and the outer cover 14, and the containment fins 98 extend upwardly at an angle from the general structure formed by an absorbent core 13, the side-to-body liner 12 and the outer cover 14.

Figure 11 shows another embodiment where the adhesive is applied as a continuous line of adhesive along the outside edge of the leg cuff 100, as compared to figure 8. The leg cuff 100 sticks to the cloth inlay 22 and extends outwardly therefrom. The containment flap 98 is bent inwardly to make contact with the wearer's body and contain the exudates. The bending can be achieved by means of a bending device, as described above, or by means of any other conventional bending apparatus. An ultrasonic linker (not shown) can ensure that the bend remains in place by attaching the bent bend away from the fin. The embodiment of Figur 11 generally comprises a "C-fist" type absorbent article 35 having the leg cuffs formed in the C-shaped structure as illustrated in Fig. 11.

Although Figure 1 shows the glue guns 108 and 110 applying the adhesive to the composite substrates 51A and 5IB, the glue can be applied directly to a fabric sausage 22 at the locations that will contact selected portions of the composite substrates 51A and 51B. Again, the adhesive preferably comprises a continuous line of glue along the length of the fabric sausage 22.

Although Figure 1 shows the ear applicator 32 applying the ears 34 to the fabric sausage 22 before applying the substrate portions 50A and 50B to the fabric sausage, the order can be reversed and the ear applicator 32 can follow the spreader ultrasonic 114. Then, the order of the other work stations can be changed, such as of the guide apparatus 60 which applies to the elastomeric elements 54 and that applied to the leg cuff part 70.

INCORPORATION OF BASE STRUCTURE Figure 12 shows another embodiment of the absorbent article assembly system 8 which forms the containment fins 98 and the leg cuffs 100 in a single work piece. The workpiece supports the liner side to the body 12 and the outer cover 14. The attachment device d of the ear piece 120 comprises the ultrasonic horns 122 the anvil rollers 124 intermittently joining the lugs 34 to the outer cover 14. The leg cutting devices 126 perform the leg cuts 30 of the outer cover 14 which moves in a direction shown by the arrow 128.

Elsewhere, the first substrate 50 is fed from the supply roll 52. A cutting device 129 including a cutting wheel 130 and a lower roller 131 having a shoulder, cuts the substrate into two separate parts 50A and 50B. A Z-bar 132 spreads or separates the substrate parts from one another. The elastomeric supply rollers 56 supply the elastomeric elements 54 through the yarn guides 58 to the substrate portions 50A and 50B. The intermittent glue gun 133 applies the adhesive to the elastomeric elements 54 to secure the elements to the respective substrate portions 50A and 50B.

Meanwhile, a second base roller 134 unwinds a second substrate 136, preferably comprising a polyethylene material. The turning roller 148 flips the second substrate 136 down towards the first substrate 50. Then the second substrate 136 and the first substrate 150 is joined by a pair of rollers 150 and 152 forming a clamping point. The first substrate 50 and the second substrate 136 together form a base structure 154 having the elastomeric elements 54 therebetween. The base structure 154 continues to the bending device J 156 including the anvil rollers 158 and 160. The bending device J 156 includes the bending board 161 which bends the outer edges of the base structure 154 inwards and upwards. to form the ends of the containment fins 98. The J-fold connector 162, comprising the anvil rollers 164 and the ultrasonic horns 166, then joins or reinforces the bent edges in J of the base structure 154. The structure of base 154 then moves the elastomeric element cutter 168. The elastomeric element cutter 168 comprises a cutter roll 170 and an anvil roller 172. When the cutter member 174 of the cutter roller 170 contacts the base structure 154 in a clamping point formed between the rollers 170 and 172, the elastomeric elements 54 are crushed, and therefore cut. The cutter roll 176 flips the direction of displacement of the base structure 154.

Elsewhere, the body-side liner supply roll 178 supplies a continuous fabric of liner material to the body 12. The discharge layer supply roll 180 supplies the discharge layer material 182. The layer of discharge 182 enters the discharge layer applicator 184 wherein the discharge layer is cut and applied at the separate locations along the fabric of the lining material from side to body 12. The discharge layer applicator 184 includes u first conveyor 186 receiving the discharge layer material 182. A glue gun 188 applies the adhesive to the discharge layer 182 while the layer is passing through the first conveyor 186. A knife roller 190 and a rotary anvil 192 form a pressure point. When a transverse cutting blade (not shown) on the knife roller 190 makes contact with the discharge layer 182, the discharge layer is cut. Then a second, faster separating conveyor 194 receives the cut segment 193 from the discharge layer 182 and advances the segment to the liner from side to body 12. The segment of the discharge layer 193 is secured to the liner from side to body 12 by glue gun adhesive 188. The body side liner 12, with the segment of the discharge layer 193 secured thereto, then follows a pair of tilt rollers 196 and 198 to the absorbent core applicator 200.

The arrow 201 shows the direction in which the absorbent core material (not shown) is moved to reach the absorbent core applicator 200. The absorbent core applicator 200 places the absorbent core 13 on the liner side to body 12 and the layer of emergence 182.

The absorbent core applicator 200 includes a first conveyor 202 operating at a first speed and a second conveyor 204 operating at a second, faster speed. The absorbent core applicator 200 includes a pad cutting device 206 comprising an anvil roller 208 and a knife roller 209. The pad cutter device 206 cuts an absorbent core 13 of a length of absorbent core material 203 and the Absorbent core 13 is transferred to bending device 210.

The folding device 210 bends a part of the liner from side to body 12 around the absorbent core 13. The glue gun 212 applies adhesive to the liner from side to body 12.

The base structure 154 passes through a first rapid pressure point 214 formed by the anvil rollers 216 and 218. Then the base structure 154 advances to a second pressure point 220, formed by the rollers 222 and 224, whose rollers 222 and 224 are rotated slower than the first pressure point 214. The second pressure point 220 joins the base structure 154 to the side liner to the body 12 holding the absorbent core 13. The folding device 226 then folds to the fins of containment 98 formed in the base structure 54, inwardly and downwardly around the absorbent core 13. The ultrasonic linker 228 comprises the anvil rollers 230 and the ultrasonic horns 232 and then attaches or secures the containment fins 98 of the base structure 154 in a downward direction bent inwards. The bending device 226, as well as the bending device 210 mentioned above, may comprise the bending apparatus of US Pat. No. 4,900,384 or other bender mechanisms well known in the art.

The base structure 154 ignites the turning roller 234 to join the outer cover 14 having the leg cutouts 30 and the ears 34 in the compression point device 236. The glue gun 140 applies adhesive to the outer cover 14. The device of compression point 236 including the anvil rollers 238 and 240 secures the outer cover 14 to the side-to-body lining combination 12 and the base structure 154 forming the fabric sausage 22. The fabric sausage 22 then moves to other work stations along a path shown by arrow 242.

In operation, the ear piece attachment device 120 secures the ears 34 to the outer cover 14. The ears in the outer cover 14 enter along a path shown by the arrow 128. The separate ultrasonic horns 122, in combination with the rotary yunker rollers 124, they join the opposite ears spaced apart on an outer cover 14. The ultrasonic horns 122, preferably, operate at 20 KHz.

Although an ultrasonic attachment device is described, other securing methods such as the adhesive attachment of the ears 34 to the outer cover 14 can be used. In addition, the ears 34 can be attached to the outer cover 14 or the fabric inlay 22 subsequently in the process.

The leg cutting devices 126 then create the leg cuts 30 in the outer cover 14. The cutting locations of the respective leg cutting devices effectively move in and out while the cover 14 passes underneath to form the form of leg cuts 30. A variety of known cutter devices are acceptable for piercing devices 126.

Elsewhere in the absorbent article assembly system 8, the first substrate 50 is fed from the supply roll 52. The substrate 50 preferably comprises a spunbond nonwoven material. However, the substrate 50 can comprise any of the materials described above for the body-side liner 12.

The cutter device 129 cuts the substrate 5 along its length in two substrate portions 50A and 50 having essentially the same width. The cut device 129 includes a rotary blade wheel 130 centered on the substrate 50. The substrate portions 50A and 50B are spaced apart by the Z-bar 132 on a spaced pair of fabrics having approximately the same width. The bar Z comprises a pair of arms angled outwardly spacing the substrate portions 50A and 50B. The separation of the substrate portions 50A and 50B reduces the amount of material used in the manufacturing process, and therefore decreases the cost of the absorbent articles 35 being manufactured. The preferred spacing between the substrate portions 50A and 50B is about 3 to 4 inches.

As the substrate portions 50A and 50B advance, the elastomeric elements 54 of the elastomeric supply rollers 56 travel through the yarn guides 58 to the substrate portions 50A and 50B. The glue gun 133 intermittently applies the adhesive to the elastomeric elements 54 and / or parts of the substrate 50A and 50B depending on the relative positions of the elements.

Meanwhile, a second substrate 136 advances from a second base roller 134 to the direction change roller 148 as shown in FIG. 12. When the second substrate 136 encounters the first substrate portions 50A and 50B on the anvil rollers. rotating 150 and 152, the substrate and the substrate portions are secured to each other. The glue gun adhesive 133 and the pressure between the rolls 150 and 152 secure the elastomeric elements 54 between the first substrate portions 50A and 50B and the second substrate 136, and secure the first substrate portions 50A and 50B to the second Substrate 136 to form the base structure 154 as shown in Figure 13. The base structure 154 has a first body extending along a length dimension, opposite the outer edge portions, and the outer edges opposites 155 on the outer edge portions.

While the second substrate 136 preferably comprises the polyethylene material, this may also comprise the materials set forth above for the outer cover 14 or the side-to-body liner 12. The substrate 136 is preferably impervious to liquids.

The base structure 154 then advances to the J-fold device 156. The bending board 161 bends the ends of the base structure 154 into essentially a J-shape as shown in Figure 14. The base structure bent in J-shape 154 advances to the rotary anvil rollers 158 and 160 forming a pressure point. The pressure point tightens and compresses the base structure 154 so that the ends maintain their shapes.

The base structure 154 advances to the ultrasonic join of the J-shaped fold 162. The J-shaped bending ultrasonic joiner 162 includes the ultrasonic horns 16 that vibrate at ultrasonic frequencies known to those skilled in the art. The rotating anvil rollers 164, combined with the horns 166 form a fastening point. The ultrasonic energy applied to the base structure 154 at the pressure point joins the shape bent into a J shape at the outer edges or wrinkles of the base structure. The pair of ultrasonic horns 166 and the anvil rollers 164 are spaced apart as shown in Figure 12. The ultrasonic linker 162 ensures that the J-shaped bent edges of the base structure 154 maintain their shape shown in the figure. 14 Upon advancing the base structure 154, the elastomeric element cutter 168 sufficiently crushes or weakens the elastomeric elements 54 within the base structure so that the elements jump or break without cutting or damaging any of the substrates 50 and 136. The elastomeric element cutter 168 includes a cutter roll 170 with a cutter member 174 and an anvil roller 172. The cutter member 174 passes transversely through the base structure 154 with the rotation of the cutter roller 170. When the cutter member 174 makes contact with the structure of bas 154, it applies a sufficient pressure sufficient to crush the elastomeric elements within the base structure. The cutter element 174 does not have a sharp enough edge to damage the substrates 50 and 136. The cutting of the elastomeric elements 54 occurs at approximately the upper and lower side edges of the absorbent articles that are still to be formed 35. The turning roller 176 then it flips the base structure 174 towards a work station that mounts the absorbent core 13 and the liner side to body 12 in the base structure. Figure 14, taken between the turning roller 176 and the rapid pressure point 214, shows the base structure 154 reversed or reversed from the position shown in Figure 13 due to the turning roller 176.

Elsewhere in the assembly system 8, the side-to-body liner supply roll 178 feeds the side-to-body liner 12 to the discharge layer applicator 184. The discharge layer supply roll 180 supplies the layer 180 discharge 182 to the discharge layer applicator 184. U first conveyor 186 operating at a first speed receives the discharge layer 182. The glue gun 188, depending on its position, applies adhesive to the first surface of the discharge layer 182 either before or after the layer is on the conveyor. The first conveyor 186 feeds the discharge layer 182 to a cutting mechanism formed by the knife roller 190 and the rotary anvil roller 192. The knife roller 190 includes a knife (not shown) that cuts the transverse discharge layer 182 The direction of travel to create discrete discharge layer segments 193. A detached discharge layer segment 193 then passes to a second conveyor 194 which operates at a speed greater than that of the first conveyor 192. A second conveyor 194 separates the segments. of discharge layer 193 for a separate connection to the liner from side to body 12 and for a final placement on one side of the absorbent core 13.

When the absorbent article 35 is in use on a consumer, the discharge layer segment 193 spreads the exudates across its entire surface to improve the absorption of the absorbent core 13. The discharge layer segments 193 can be made of well-known materials. . In addition, the discharge layer segments and the discharge layer 182 may comprise materials set forth in U.S. Patent Application Serial No. 206,986 of C. Ellis and D. Bishop, entitled "Fabric Discharge Layer No. Fibrous Fabric for Absorbent Articles for Personal Care and Similar, "filed on March 4, 1994, and US Patent Application No. 206,069 of C. Ellis and R. Everett, entitled" Non-Woven Fabric " Fibrous Improved Discharge Management for Absorbent Personal Care and Similar Items ", filed March 4, 1994; whose descriptions are incorporated here also by reference.

The body side liner 12, with the discharge layer segment 193 thereon, then advances around the tumbling rollers 196 and 198 to the absorbent core applicator 200. The arrow 201 indicates the direction of travel of the material of absorbent core 203 that enters the absorbent core applicator 200. The absorbent core applicator 200 includes a first conveyor 202 that advances the absorbent core material 203 to the pad cutting device 206. The pad cutting device 206 includes a rotary blade roller 209 and a rotary anvil roller 208. The knife roller 206 has a blade 207 extending through the roller transverse to the path of travel of the absorbent core material 203. The blade roller 209 cuts the absorbent core material through its length to form the absorbent cores 13. A respective absorbent core 13 advances to the second conveyor 204. The second conveyor 204 operates at a higher speed than that of the first conveyor 202 and separates the consecutive absorbent cores 13 exiting the pad cut-off device 206. When the knife roller 209 has been discussed as the device Preferred cutter, other conventional absorbent core material cutting devices are well within the scope of the invention.

After the conveyor 204 places the absorbent core 13 on one side of the liner from side to body 12, the bending device 210 bends the outer edges of the liner sideways to the continuous body 12 on the absorbent core. After bending, the body side liner 12 preferably extends over the top of the absorbent core 13 for a distance of about one inch.

The glue gun 212 then applies the adhesive to the liner from side to body 12 as the elements advance. The base structure 154 enters the pressure point 214 between the rotating anvil rollers 216 and 218. The rollers 216, 218 of the pressure point 214 rotate at a first surface velocity that is faster than the surface velocity of the surface. rotation of the rollers 222 and 224 at a second pressure point 220 spaced apart from it. The speed difference between the first pressure point 214 and the second pressure point 220 causes the base structure 154 to bulge or wrinkle. The first anvil rollers 216 and 218 preferably operate at about 1.25 times the speed of the second rotary anvil rollers 222 and 224 of the second pressure point 220. The second pressure point 220 secures the wrinkled base structure 154 to the liner side to body 12 with the absorbent core therebetween. The absorbent core 13 generally does not cover the entire surface area of the base structure 154 or the side-to-body liner 120. The base structure 154 comprising the portions of the substrate 50A and 50B and the second substrate 136 extends beyond the lining side to body 12 and still outer cover 14.

While it is preferred to have the speed of the rollers at the first pressure point 214 faster than the speed at the second pressure point 220, the speeds can also be substantially the same. In the first case, the pressure point 214 and the anvil rollers 216 and 218 are not required. In addition, the elastomeric element cutter 168 is not required because the elastomeric elements 54 can be cut when the fabric sausage 22 forms the individual absorbent articles 35.

While the glue gun 212 is shown by applying the adhesive to the liner from side to body 12, said glue gun can be repositioned to apply the adhesive to the base structure 154.

From the second pressure point 220, the combination of the side-to-body liner 12 and the base structure 154 advances to the bending device 226. The bending device 226 bends inward the outer edges 155 of the base structure 154 to form the containment fins 98 as shown in Figures 14 and 15. The ultrasonic linker 228 joins the base structure 154 therein to retain the containment fins 98 in the desired orientation shown in Figure 15. The ultrasonic linker 228 includes the rotating anvil rollers 230 and ultrasonic horns 232. Ultrasonic horns 232, as shown in FIG. 12, send the ultrasonic energy to the two front portions of the base structure 154 to retain the bend 157 of the respective containment fins. Desirably, the ultrasonic horns 232 operate at 20 KHz.

Figure 15 is not a scale drawing. The size or width of many elements has been amplified for illustration purposes.

The combination of the base structure 154 / of the side liner to the body 12 turns over the turning roller 234 and finds the outer cover 14 including the ears 34 and the compression device 236. The compression device 236 includes the anvil rollers 238 and 240 that compress the outer cover 14 to the base structure 154. The glue gun 140 applies the adhesive to the outer cover 14.

In addition, the glue gun 14 can be positioned to provide the adhesive only to the base structure 154, instead of to the outer cover 14. In this manner, the fabric sausage 22 is formed as shown in FIG. 15. fabric sausage 22 then proceeds along the direction shown by arrow 242 to another work station. Other possible work stations include waist piece applicators or the like.

The cloth sausage 22 is eventually cut into absorbent articles 35. This cut can be made by any of a variety of known cutting machines. For example, a final cutter roll (not shown) having a blade (not shown) extending through the roll, in combination with an anvil roll (not shown) can cut the cloth sausage 22. The absorbent articles 35 cut from the sausage of fabric 22 are transferred by a conveyor to a stacker (not shown).The elastomeric elements 54 preferably comprise the continuous threads, the tapes, or one or more layers of a polymeric and / or elastomeric material, such as a rubber material which is adhered to the parts of the substrate. 50A and 50B in a stretched condition. The elastomeric elements 54 can also comprise the materials that are established co with respect to the leg cuff pieces 80 in the first embodiment of the invention. The elastomeric elements 54C as shown in Figure 15 are located at the respective outer edges of the base structure 154. The elastomeric elements 54CF can provide the elastic properties of the containment fins 98 by moving the fins 98 outwardly from the article. absorbent 35 and to make contact with the user's body.

The leg cuffs 100 ensure a suitable notch of the absorbent article 35 on the wearer's body. The elastomeric elements 54LC located inwardly of the outer edges of the base structure 154, provide the elastic properties of the leg cuffs 100. As shown in Figure 15, the leg cuffs 100 are preferably formed by ribbons or yarns. 54LC along the inner part of the substrate portions 50A and 50B. These tapes or yarns 54LC are only glued or otherwise bonded to the base structure 154 in areas which will be close to the leg edges 30 in the assembled absorbent article 35.

The elastomeric elements 54CF for the containment fins 98 are preferably stretched by a greater percentage of their stretch distance to stop than the elastomeric elements 54LC which elasticize the leg cuffs 100; so that the containment fins 98 extend outward toward the user's body. While the two elastomeric elements 54CF are shown for the containment fins 98 and four elastomeric elements 54LC are shown for the leg cuffs 100, any number of respective elastomeric elements can be used for the containment fins or for the leg cuffs.

The various trajectories and sections of the absorbent article assembly system 8 in Figure 12 operate simultaneously at controlled speeds to form the absorbent articles. The various devices can be controlled by a central controller (not shown), such as an analog or digital control system to ensure proper operation and synchronization for each device in each material operation path.

In addition, the devices can be modified as appropriate. For example, the ultrasonic binders 120, 162 and 228 can be replaced with other bonding devices using glue, sewing or other well-known securing methods.

Those skilled in the art will now see that certain modifications can be made to the invention described herein with respect to the illustrated embodiments, if depart from the spirit of the present invention. And even though the invention has been described above with respect to the preferred embodiments, it will be understood that the invention is adapted for numerous arrangements, modifications and alterations, and that all such arrangements, modifications and alterations are intended to be within the scope of the attached clauses. .

To the extent that the following clauses use the media language plus function, it is not meant to include there or in the present description, anything that is not structurally equivalent to what is shown in the interpretations described in the description.

Claims (28)

R E I V I N D I C A C I O N S

1. A method for making an absorbent article, the method comprises the steps of: (a) supplying a substrate having extendable elements there, the substrate having a length dimension, a main body extending along the length dimension, and the opposite outer edges; (b) securing the leg cuff extendable pieces to the substrate at the locations spaced longitudinally along the length dimension of the substrate; Y (c) folding the opposite longitudinal outer edges of the parts of the substrate inwardly and securing the outer edges to the front portions of the main body to form a composite containment fin substrate, therein including longitudinally spaced leg cuff parts.

2. A method, as claimed in clause 1, characterized in that the opposite pairs of the cuff or leg pieces are separated longitudinally along the length dimension of the composite substrate, the opposite pairs of the pieces Leg cuffs are placed between the outer edges of the composite substrate and the elastomeric elements extending longitudinally on the composite substrate.

3. A method, as claimed in clause 1, characterized in that the extendable leg cuff parts comprise the elastomeric threads secured in a stretched condition to a generally non-elastomeric base material.

4. A method, as claimed in clause 1, characterized in that it includes the step of securing the extendable leg cuff pieces to a cloth sausage with the leg cuff pieces stretched to a dimension representing about 20% at about 50% of the stretch dimensions to the respective stopping of the leg cuff pieces, the leg cuff pieces, when so secured, essentially cover the leg cuts.

5. A method, as claimed in clause 1, characterized in that the method further includes the step of securing the composite substrate, including the containment fins and the leg cuffs, to a continuous teller sausage.

6. A method, as claimed in clause 5, characterized in that it includes the step of applying the ultrasonic energy to the composite substrate, after which the composite substrate is secured to the fabric sausage, to finish and smooth the raw edges of the substrate compound.

7. A method, as claimed in clause 1, characterized in that it includes the step of elastically extending the leg cuff pieces before placing said stretchable leg cuff pieces in the transversely opposite and longitudinally spaced places on the substrate.

8. A method for making an absorbent article, the method comprises the steps of: (a) supplying a substrate having extendable element there, the substrate having a length dimension, u main body extending along the dimension d length, and the opposite outer edges; (b) securing the fist pieces for pierces extending to the substrate; (c) cutting the substrate along the longitudinal central line of the substrate to form two continuous substrate portions, each substrate part having elastomeric properties and including some of the leg cuff pieces; Y (d) folding the opposite longitudinal outer edges of the parts of the substrate inwardly and securing the outer edges to the front portions of the parts of the substrate, to form the composite containment fins, including there the extendable leg cuff parts. .

9. A method, as claimed in clause 8, characterized in that the opposing pairs of the leg cuff pieces are longitudinally spaced along the length of the composite substrate length, the opposite sides of the cuff pieces for The legs are placed between the outer edges of each of the composite substrates of the elastomeric elements that extend longitudinally on the composite substrates.

10. A method, as claimed in clause 8, characterized in that the stretchable cuff pieces comprise the elastomeric strands secured in a stretched condition to a generally elastomeric base material.

11. A method, as claimed in clause 8, characterized in that it includes the step of securing the extendable leg cuff pieces to a cloth sausage with the leg cuff pieces stretched to a dimension representing about 20% a about 50% of the stretch dimensions up to the respective stopping of the leg cuff pieces, the leg cuff pieces, when so secured, essentially cover the leg cuffs.

12. A method, as claimed in clause 9, characterized in that it includes the step of applying adhesive to composite substrates essentially along a centerline of each of the composite substrates between the leg cuff pieces and the elements elastomeric

13. A method, as claimed in clause 8, characterized in that it includes the step of applying adhesive to the composite substrates essentially along the longitudinal outer edges of the composite substrates on one side of the respective of the fist pieces for leg.

14. A method, as claimed in clause 8, characterized in that it includes the step of elastically extending the leg cuff pieces before placing said stretchable leg cuff pieces in the transversely opposite and longitudinally spaced places on the substrates.

15. A method for making a composite fabric structure for use as a combination of a leg cuff and a containment flap in an absorbent article, the method comprises the steps of: (a) supplying a substrate having a length dimension, a main body extending along the length dimension, and the opposite outer edges; (b) securing the leg cuff pieces extending to the substrate at longitudinally spaced locations along the length dimension of the substrate; (c) securing the elastomeric elements along the length dimension of the substrate in a transversely spaced relation to the leg cuff pieces, the elastomeric elements being oriented to extend along the length dimension of the substrate; Y (d) folding the opposite longitudinal longitudinal edges of the substrate portion inwardly and securing the outer edges to the front portions of the substrate portion, to form a composite containment fin substrate.

16. A method, as claimed in clause 15, characterized in that it includes the steps of slitting the substrate along a longitudinal center line to form the first and second substrate portions, each part of the substrate having elastomeric properties and one dimension in length and including one of the longitudinally spaced and extendable leg cuff pieces, and the elastomeric elements secured along the length dimension of the second portion of the substrate.

17. A method, as claimed in clause 15, characterized in that the elastomeric leg cuff pieces secured to the substrate help to form the leg cuffs, the elastomeric elements secured to the parts of the substrate help to form the containment flaps.

18. A method, as claimed in clause 17, characterized in that the leg cuffs and the containment fins are integral elements of the composite containment fin surface.

19. A method, as claimed in clause 15, characterized in that the stretchable cuff pieces comprise the elastomeric threads secured in a condition extended to a generally non-elastomeric base material.

20. A method, as claimed in clause 15, characterized in that the leg cuff pieces are stretched to a dimension representing about 20% to about 50% of the respective stretch dimensions to the top of the pieces of leg cuff when secured to the substrate.

21. A method for making an absorbent article, the method comprises the steps of: (a) securing a plurality of elastomeric elements to a first elongate substrate having a dimension of length and width, the elastomeric elements being aligned with the length dimension and positioned transversely across the width of the substrate; (b) securing the first substrate to a second substrate, with the elastomeric elements placed between the second substrate and the first substrate to form a base structure; (c) securing an absorbent core and a liner side to body to the base structure; Y (d) securing a cover exterior to the base structure, such that the base structure is between the outer cover and the liner from side to body.

22. A method, as claimed in clause 21, characterized in that the base structure having a main body extending along the length dimension, the opposite outer edge portions, and the opposite outer edges on the edge portions exterior, the method includes the steps of folding the outer edges of the base structure inwardly in an essentially J-shape and ultrasonically joining the edges to the respective outer edge portions to maintain the J shape.

23. A method, as claimed in clause 22, characterized in that the method includes the step of subsequently cutting the elastomeric elements.

24. A method, as claimed in clause 21, characterized in that it includes the steps of applying adhesive to a first side of one of a discharge layer and its corresponding area of the liner from side to body, cutting the discharge cap, and ensuring the discharge layer to the liner side to body in the respective adhesive.

25. A method, as claimed in clause 21, characterized in that it includes the steps of cutting the absorbent core material to form the absorbent core, and folding the liner from side to body around at least a portion of the absorbent core before of securing the lining from the body to the base structure.

26. A method, as claimed in clause 21, characterized in that it includes the steps of pulling the base structure through a first pressure point at a first speed, then pulling the base structure through a second point of contact. pressure, the rollers of the second pressure point operating at a second speed slower than that of the first speed, so that wrinkles are formed in the base structure between the first and second pressure points, the second pressure point ensures the Lining side to the body and the absorbent core to the base structure.

27. A method, as claimed in clause 21, characterized in that it includes the step of securing the ears to the outer cover before carrying out the leg cuts of the outer cover.

28. A method, as claimed in clause 21, characterized in that it includes after step (b), and with the elastomeric elements placed between the first and second substrates, the step of cutting the elastomeric elements without deleteriously affecting the operation of the base structure. SUMMARY The invention relates to methods for the manufacture of an absorbent article. In a method of the invention, the combination of containment fins and leg cuffs or turns are formed on a common substrate. A plurality of elastomeric elements are included in the combination article to help form the containment fins. The discrete leg cuff pieces are applied to the substrate at longitudinally spaced locations. In some embodiments, a cutting device slits the substrate essentially along a center line extending the length of the substrate, forming two continuous substrate portions. A glue gun applies adhesive to the part of the substrate. The parts of the substrate are bent longitudinally, using the adhesive to form the containment fins and the integral leg cuffs in a composite substrate. The composite substrate is secured to a sausage of absorbent article fabric in the formation of absorbent articles. In another embodiment, the substrate is a first substrate which supports the elastomeric elements used in the formation of the leg cuffs and the containment flaps. The first substrate is secured to a second substrate, thus forming a base structure, with the elastomeric elements between the first and second substrates. A body side liner and an absorbent core are added on one side of the base structure, and an outer cover is added on the second side, to form a cloth sausage. In other embodiments, the fabric sausage is cut transversely at separate locations along the length of the sausage fabric to form the absorbent articles.