Embodiments of the invention relate generally to absorbent sanitary products and, more particularly, to an improved apparatus and method for manufacturing an elastic composite structure for use in an absorbent sanitary product that minimizes or eliminates the use of consumable adhesives such as glue.
Absorbent sanitary products, such as disposable diapers, are typically equipped with elastic composite structures that include one or more elastic threads. These elastic composite structures are positioned at various locations throughout the product, including in the waistbands, leg cuff regions, and throughout all or portions of the front or back panels of the product. During the typical manufacturing process of an elastic composite structure, the elastic threads are held in a tensioned state and an adhesive is used to secure the elastic threads between the two facing layers of non-woven materials or webs. The tension in the elastic threads is subsequently released, causing the web material to pucker or fold in the areas that contain the adhered elastic threads.
The use of adhesives to bond the elastic threads within elastic composite structures presents a number of disadvantages in both the end product and manufacturing method, including costs associated with the consumable material and undesirable tactile properties of the end product (e.g., stiffness). While thermal or ultrasonic welding techniques have been proposed as alternatives for bonding elastic threads within an elastic composite structure, movement or shifting of the elastic threads between or outside of notches on the anvil during the manufacturing process may result in a given elastic thread breaking or being unanchored over one or more portions of its length.
Accordingly, there is a need for an improved apparatus and method for fabricating an elastic composite structure of an absorbent sanitary product that reduces thread breakage and improves the reliability of bonds that anchor elastic threads in position within an elastic composite structure. It would further be desirable for such an apparatus and method to eliminate or minimize the use of consumable adhesives to secure the elastic threads to the facing web layers.
In accordance with one aspect of the invention, an apparatus for manufacturing an elastic composite structure includes at least one means for transporting a first web layer and a second web layer in a machine direction and at least one means for transporting an elastic thread in the machine direction in a tensioned state. The apparatus also includes a bonding unit configured to bond the first web layer to the second web layer via a bond pattern comprising at least one bond line having at least one pair of adjacent bonds and anchor the elastic thread within a passage defined by the at least one pair of adjacent bonds, the passage having a cross-sectional area smaller than a cross-sectional area of the elastic thread in a non-tensioned state.
In accordance with another aspect of the invention, a method of manufacturing an elastic composite structure includes positioning at least one tensioned elastic thread between a first web layer and a second web layer and bonding the first web layer to the second web layer via a bond pattern comprising at least one bond line having at least one pair of adjacent bonds. The method also includes anchoring the at least one elastic thread within a passage formed between the first web layer, the second web layer, and facing edges of the at least one pair of adjacent bonds, wherein the passage has a cross-sectional area that is smaller than a cross-sectional area of the at least one elastic thread in a non-tensioned state.
In accordance with another aspect of the invention, an elastic composite structure includes a first web layer, a second web layer coupled to the first web layer by a bond pattern comprising at least one bond line having at least one pair of adjacent bonds, and at least one elastic thread extending through a passage defined by facing edges of the at least one pair of adjacent bonds. The passage has a cross-sectional area that is smaller than a cross-sectional area of the at least one elastic thread in a non-tensioned state.
These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings.
The drawings illustrate embodiments presently contemplated for carrying out the invention.
In the drawings:
Embodiments of the present invention provide for a method and apparatus for manufacturing an elastic composite structure usable in an absorbent sanitary product such as, for example, a diaper, disposable adult pant, or feminine care product.
During the manufacture of absorbent sanitary products, it is often desirable to secure elastic threads between facing layers of non-woven material to form contoured or elasticized regions within the product. Such products are typically manufactured on an assembly or manufacturing line in which the product moves substantially continually longitudinally in what is referred to as the “machine direction.”
Referring now to
A series of individual elastic threads 18 are positioned between the first and second web layers 12, 16. The elastic threads 18 travel in the machine direction 14 under tension from a creel assembly (not shown) or similar device. The elastic threads 18 may be composed of any suitable elastic material including, for example, sheets, strands or ribbons of thermoplastic elastomers, natural or synthetic rubber, or LYCRA, as non-limiting examples. Each elastic thread 18 may be provided in the form of an individual elastomeric strand or be a manufactured multifilament product that includes many individual elastomeric filaments joined together, such as by a dry-spinning manufacturing process, to form a single, coalesced elastic thread 18. Each elastic thread 18 may be in the range of approximately 200-1500 decitex (dTex), in non-limiting embodiments. In an embodiment where an elastic thread 18 is a multifilament product, the elastic thread 18 may have an overall decitex of 400 dTex, in an exemplary and non-limiting embodiment, with the individual elastomeric filaments of the elastic thread 18 individually having a decitex of ten percent or less of the overall 400 dTex value. As just a few examples, a multifilament thread with a decitex of 680 and up may include 55 individual elastomeric filaments while a multifilament thread with a decitex lower than 680 may include 47 individual elastomeric filaments.
Elastic threads 18 may have any suitable cross-sectional shape that facilitates formation of an elastic composite structure having desired elasticity, visual aesthetic, and manufacturability. As non-limiting examples, elastic threads 18 may have a cross-sectional shape that is round, rectangular, square, or irregular as may be the case where each elastic thread 18 is a multifilament product (as illustrated in detail in
While first web layer 12 and second web layer 16 are depicted in
Manufacturing line 10 includes one or more guide rollers 20 that are employed to transport, accurately position and (optionally) tension the elastic threads 18 as it travels in the machine direction 14. In some embodiments, manufacturing line 10 may include one or more optional tension monitoring devices 24 (shown in phantom) that are positioned along the path of travel of the elastic threads 18. In such an embodiment, feedback from the tension monitoring devices 24 may be utilized to control the tension (i.e., elongation) in the elastic threads 18 as they travel in the machine direction 14.
As shown in further detail in
Guide rollers 20 operate to accurately position and tension individual elastic threads 18 as they travel toward a strand guide roller 36 that is positioned upstream of bonding unit 38, which is referred to hereafter as ultrasonic bonding apparatus 38. Manufacturing line 10 also includes one or more structures that are configured to transport and guide the first and second web layers 12, 16 in the machine direction 14. In the illustrated embodiment, these guide structures include an upper roller 40 and a lower roller 42 are positioned to guide the first web layer 12 and the second web layer 16, respectively, toward the ultrasonic bonding apparatus 38.
Ultrasonic bonding apparatus 38 may be a rotary ultrasonic welding system or a blade ultrasonic welding system in alternative embodiments. In the illustrated embodiment, ultrasonic bonding apparatus 38 is a rotary ultrasonic welding system that includes a rotary anvil 44 and a horn 46 that cooperate with each other to bond the first web layer 12 to the second web layer 16. The elastic threads 18 are secured or anchored in position relative to the first and second web layers 12, 16 as described in detail below. Ultrasonic bonding apparatus 38 also includes one or more frames 48 that support and/or house a motor (not shown) that drives the horn 46, a vibration control unit (not shown) that causes the horn 46 to vibrate, and a second motor (not shown) that drives the anvil 44. The horn 46 and anvil 44 are positioned in a spaced relationship relative to one another to facilitate ultrasonically bonding the first and second web layers 12, 16 to one another while the elastic threads 18 are held in tension in the space between the horn 46 and anvil 44. While horn 46 is illustrated as a rotary horn in
The face 50 of the anvil 44 includes an arrangement of projections and notches that facilitate securing the combined elastic thread assemblies 34 in position relative to the first and second web layers 12, 16. Exemplary embodiments of this arrangement of projections and notches are described in detail below relative to FIGS. 3-11. In one non-limiting embodiment, the face 52 of the horn 46 has a smooth or substantially smooth surface contour. In alternative embodiments, face 52 may include an arrangement of projections and/or notches that mate or align with the surface pattern of the anvil 44 to further facilitate bonding the first and second web layers 12, 16 together and securing the elastic threads 18 in position relative to the first and second web layers 12, 16.
While embodiments of the invention are described relative to an ultrasonic bonding assembly and ultrasonic bonding technique, it is contemplated that the techniques described herein may be extended to any other known thermal or pressure bonding techniques.
Referring now to
During the manufacturing process, the first and second web layers 12, 16 are positioned between the face 50 of the anvil 44 and the face 52 of the horn 46. An elastic thread 18 is positioned between the first and second web layers 12, 16 in a tensioned state and aligned above notch 200. As shown in
When the manufactured elastic composite structure 86 shown in
As shown in
Each of notches 200 in
As used herein the phrase “strand diameter” refers to the smallest measurable cross-sectional width of the elastic thread 18 in its non-tensioned state. In embodiments where a given elastic thread 18 is a monofilament structure, the strand diameter is the minor diameter or smallest measurable width of the monofilament structure in its non-tensioned state. In embodiments where a given elastic thread 18 is a structure that includes many individual filaments 116 (i.e., elastic thread 18 is a multi-filament structure), the elastic thread 18 typically will have an irregular cross-sectional area similar to that shown in
Each of
In addition to the projections 202, 204 that form bonds 100, 101, welding line 68 of
In one non-limiting embodiment notches 200, 242, and 244 of anvil 44 are manufactured using a multi-step machining process that includes machining a pattern of similarly sized “anchoring” notches on the face 50 of the anvil at the desired location of each notch 200, 242, 244. In the illustrated example, the manufacturing process would include initially machining notches 200, 242, and 244 to all have the notch geometry or profile of notch 200, as indicated by dashed lines 254, 256. In a subsequent machining step, additional material is removed from select notch locations to define the final notch geometry of the larger, non-anchoring notches 242, 244.
Referring now to
In the illustrated embodiment, the contact surfaces 78 of the projections 202, 204 have side surfaces 80 oriented at an angle 82 relative to the circumferential axis 70 such that no hypothetical arc 83 drawn from adjacent welding lines 68 is parallel to the circumferential axis 70 of the anvil 44. In such an embodiment, the facing surfaces 80 of adjacent projections 202, 204 are non-parallel to the circumferential axis 70 as shown. As a result, projections 202, 204 of adjacent welding lines 68 are not aligned with one another along the circumferential axis 70. Instead, a given projection 72A in one welding line 68A is offset from a given projection 72B in an adjacent welding line 68B by a pitch 84 defined by an angle 82. Projections 202, 204 thus define a threaded pattern that extends around the circumferential face 50 of the anvil 44.
It is contemplated that the contact surfaces 78 of the projections 202, 204 may have different geometries in alternative embodiments. As non-limiting examples, projections 202, 204 may be circular, rectangular, crescent shaped, or have irregular shapes that may be selected to form a desired overall pattern on the end product. In yet another embodiment, corresponding projections 202, 204 of adjacent welding lines 68A, 68B may be aligned with one another in a line parallel to the circumferential axis 70. Alternatively, projections 202, 204 of sequential welding lines 68A, 68B may be offset from one another in the cross-machine direction thereby defining a stepped or non-linear passage through the bond lines that are formed on the first and second web layers 12, 16.
The ultrasonic bonding operation results in a continuous and repeating pattern of bond lines 90 that mirror the welding lines 68 on the anvil 44 and bond or fuse the first web layer 12 to the second web layer 16. Thus, in embodiments where welding lines 68 are sinusoidal, the resulting bond lines 90 have a similar sinusoidal bond pattern. As shown in the detailed view provided in
The apparatus and methods described herein can be used to make elastic composite structures for waist regions, below-waist regions, and/or leg cuff regions of a single-piece or three-piece diaper, as non-limiting examples, without the use of glue. By eliminating the use of glue, the resulting elastic composite is softer to the touch and has a more uniform ruffling pattern in the cross-machine direction (i.e., the direction perpendicular to the machine direction). From a manufacturing standpoint, the elastic threads are anchored within dedicated passages of the elastic composite structure that are defined based on notch geometries of the bonding assembly that improve the reliability of the bonds that anchor the elastic threads in position and reducing the likelihood of thread breakage during manufacture. Accordingly, embodiments of the invention disclosed herein provide a more reliable manufacturing process than existing prior art approaches and result in an end product that is visually and tactilely more pleasing to the end customer.
Therefore, according to one embodiment of the invention, an apparatus for manufacturing an elastic composite structure includes at least one means for transporting a first web layer and a second web layer in a machine direction and at least one means for transporting an elastic thread in the machine direction in a tensioned state. The apparatus also includes a bonding unit configured to bond the first web layer to the second web layer via a bond pattern comprising at least one bond line having at least one pair of adjacent bonds and anchor the elastic thread within a passage defined by the at least one pair of adjacent bonds, the passage having a cross-sectional area smaller than a cross-sectional area of the elastic thread in a non-tensioned state.
According to another embodiment of the invention, a method of manufacturing an elastic composite structure includes positioning at least one tensioned elastic thread between a first web layer and a second web layer and bonding the first web layer to the second web layer via a bond pattern comprising at least one bond line having at least one pair of adjacent bonds. The method also includes anchoring the at least one elastic thread within a passage formed between the first web layer, the second web layer, and facing edges of the at least one pair of adjacent bonds, wherein the passage has a cross-sectional area that is smaller than a cross-sectional area of the at least one elastic thread in a non-tensioned state.
According to yet another embodiment of the invention, an elastic composite structure includes a first web layer, a second web layer coupled to the first web layer by a bond pattern comprising at least one bond line having at least one pair of adjacent bonds, and at least one elastic thread extending through a passage defined by facing edges of the at least one pair of adjacent bonds. The passage has a cross-sectional area that is smaller than a cross-sectional area of the at least one elastic thread in a non-tensioned state.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
The present invention claims priority to U.S. Provisional Patent Application Ser. No. 62/789,058 filed Jan. 7, 2019, the disclosure of which is incorporated herein by reference in its entirety.
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