US20130211365A1 - Disposable Undergarment and Related Manufacturing Equipment and Processes - Google Patents
Disposable Undergarment and Related Manufacturing Equipment and Processes Download PDFInfo
- Publication number
- US20130211365A1 US20130211365A1 US13/835,296 US201313835296A US2013211365A1 US 20130211365 A1 US20130211365 A1 US 20130211365A1 US 201313835296 A US201313835296 A US 201313835296A US 2013211365 A1 US2013211365 A1 US 2013211365A1
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- US
- United States
- Prior art keywords
- crotch
- leg
- elastics
- elastic
- panty
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/45—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the shape
- A61F13/49—Absorbent articles specially adapted to be worn around the waist, e.g. diapers
- A61F13/494—Absorbent articles specially adapted to be worn around the waist, e.g. diapers characterised by edge leakage prevention means
- A61F13/49406—Absorbent articles specially adapted to be worn around the waist, e.g. diapers characterised by edge leakage prevention means the edge leakage prevention means being at the crotch region
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15585—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers
- A61F13/15593—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers having elastic ribbons fixed thereto; Devices for applying the ribbons
- A61F13/15601—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers having elastic ribbons fixed thereto; Devices for applying the ribbons the ribbons being applied transversely to the direction of the movement of the webs the diapers are being made of
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15585—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers
- A61F13/15593—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers having elastic ribbons fixed thereto; Devices for applying the ribbons
- A61F13/15609—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers having elastic ribbons fixed thereto; Devices for applying the ribbons the ribbons being applied in an irregular path
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/45—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the shape
- A61F13/49—Absorbent articles specially adapted to be worn around the waist, e.g. diapers
- A61F13/49007—Form-fitting, self-adjusting disposable diapers
- A61F13/49009—Form-fitting, self-adjusting disposable diapers with elastic means
- A61F13/49017—Form-fitting, self-adjusting disposable diapers with elastic means the elastic means being located at the crotch region
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/45—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the shape
- A61F13/49—Absorbent articles specially adapted to be worn around the waist, e.g. diapers
- A61F13/496—Absorbent articles specially adapted to be worn around the waist, e.g. diapers in the form of pants or briefs
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/505—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators with separable parts, e.g. combination of disposable and reusable parts
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
- A61F13/535—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes
- A61F13/536—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes having discontinuous areas of compression
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15203—Properties of the article, e.g. stiffness or absorbency
- A61F2013/15284—Properties of the article, e.g. stiffness or absorbency characterized by quantifiable properties
- A61F2013/15463—Absorbency
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1043—Subsequent to assembly
- Y10T156/1049—Folding only
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1062—Prior to assembly
Definitions
- Undergarments are made typically of cotton and/or synthetic materials.
- the cotton and synthetic panties typically do not offer barrier protection.
- the synthetic undergarments have a cotton lined crotch to absorb vaginal discharges or perspiration.
- the absorbent/barrier properties of regular undergarments are minimal such that any vaginal discharge and/or heavy perspiration may strike through onto outer clothing; i.e., liquid penetrates from the interior to the exterior of the panty.
- Panty liners and feminine care sanitary napkins or pads used with regular undergarments have polyethylene backings that provide some barrier properties inhibiting liquid strike through.
- the vaginal discharge extends to the sides or the ends of the pads, the discharge can leak or seep around an edge of the pad and onto the undergarment. Such leakage can stain the undergarment.
- liquid may strike through or go around the undergarment and stain outer clothing and/or bedding.
- Women with heavy liquid flows may often use one or more maxi pads, double pads and/or tampons alone, or in combination, and change these pads and tampons frequently to prevent embarrassing, messy leakage around the edges of the pads and/or staining of outer clothing. In some cases, during their heaviest flow days, some women will restrict their activities and stay home.
- the present invention broadly includes a three dimensional, disposable, discrete panty, subassemblies of the panty, and apparatus and methods for making the panty.
- a method for attaching elastic to a crotch area of an undergarment includes the steps of cutting an elastic thread into a plurality of elastic sections; providing a secondary absorbent for receipt of at least one of the elastic sections, the secondary absorbent defining an inner side and an opposing outer side; attaching the elastic sections to the inner side of the secondary absorbent as the elastic sections and the secondary absorbent move in a machine direction; maneuvering the secondary absorbent with the elastic sections attached thereto to a non-machine direction; and attaching the secondary absorbent to a garment web moving in the machine direction, the elastic sections of the inner side disposed against an inner crotch portion of the garment web, the opposing outer side visible in the crotch portion.
- each elastic section is from about one inch to about three inches in length.
- the elastic sections are attached to the inner side of the secondary absorbent by an adhesive.
- a disposable garment assembly includes a disposable garment defining a length and a width and including an outer cover having a front body portion and a back body portion, the front body portion and the back body portion being connected by a crotch portion, the outer cover, when laid out flat, having a length and a width, the front body portion and the back body portion being connected together to form a waist opening, a first leg opening and a second leg opening, the first and second leg openings having respective first and second front and back leg edge portions and corresponding first and second side leg edge portions connecting the front and back leg edge portions, the outer cover comprising a first layer, and a second layer having a front portion and a back portion, the second layer front portion disposed adjacent the front body portion of the outer cover, the second layer back portion disposed adjacent the back body portion of the outer cover; a first absorbent defining a length and a width, each respectively less than the length and the width of the disposable garment, the first absorbent further including a liquid impermeable
- the second absorbent capacity of the second absorbent is about one-half the absorbent capacity of the first absorbent.
- the second absorbent capacity of the second absorbent can be about 3 grams to about 6 grams, more particularly, about 4 grams to about 6 grams.
- the second absorbent is a stain shield.
- a disposable garment has a length and a width, and includes an outer cover having front and back body portions connected by a crotch portion, the outer cover, when laid out flat, having a length between first and second ends and a width between first and second sides, the front and back body portions being connected together to form a waist opening and first and second leg opening.
- the outer cover in this aspect includes a first layer; a second layer having front and back body portions overlying respective front and back body portions of the outer cover; and a stain shield incorporated into the disposable garment, the stain shield having a length and a width and a garment facing side, the garment facing side having a front portion, a back portion and a center portion therebetween, the garment facing side of the center portion having a plurality of extensible crotch elastic pieces attached thereto proximate the crotch portion, the extensible crotch elastic pieces being disposed between the garment facing side and the outer cover of the crotch portion, the stain shield affixed to the outer cover, each of the garment facing side front and back portions of the stain shield disposed adjacent one of the respective second layer front and back portions, at least a portion of the stain shield having an overall total absorbent capacity of about 3 grams to about 6 grams. Also in this aspect, at least a portion of the absorbent has an overall total absorbent capacity of about 4 grams to about 6 grams.
- FIG. 1 is a plan view of a garment subassembly according to an aspect of the invention
- FIG. 2 is a plan view of the garment subassembly of FIG. 1 , including a secondary absorbent in the crotch;
- FIG. 3 is a cross section of the garment subassembly taken along line 3 - 3 of FIG. 2 ;
- FIG. 4 is a cross section of the garment subassembly taken along line 4 - 4 of FIG. 2 ;
- FIG. 5 is a perspective view of a disposable panty according to another aspect of the invention.
- FIGS. 6 and 7 are enlarged cut-away views of a fragment of the subassembly of FIG. 1 , particularly showing cross-crotch elastics in detail;
- FIG. 8 is a side elevation view of an equipment layout for fabricating and processing subassemblies according to another aspect of the invention.
- FIGS. 9 and 10 are pictorial views of a nip area of the elevation shown in FIG. 8 ;
- FIG. 11 is a plan view showing transverse positioning of front and back leg elastics along an advancing web as an outer cover layer and a body side layer are being joined according to an aspect of the invention
- FIG. 12 is a plan view as in FIG. 10 , showing an alternate pattern for elastic threads.
- FIG. 13 is a perspective view showing steps in a method for cutting a plurality of elastics and attaching the elastics to a secondary absorbent according to another aspect of the invention.
- the panty subassembly 10 of FIG. 1 illustrates an embodiment of a two-layer panty subassembly prior to incorporation of the secondary absorbent.
- the panty subassembly of FIG. 2 illustrates the finished panty including all elements, but before the final steps of assembling the composite to form the panty structure.
- FIG. 5 shows the finally-assembled disposable panty structure.
- the panty subassembly 10 has an outer cover layer 12 generally defining the overall length “L 1 ” and width “W 1 ” of the subassembly, and a body side layer 14 secured to the outer cover layer.
- the panty subassembly 10 generally includes a front body portion 16 terminating at a front waist portion 18 as a first edge of the subassembly, a back body portion 20 terminating at a back waist portion 22 as a second edge of the subassembly, and a crotch portion 24 .
- the body side layer 14 includes a front layer element 19 generally overlying and secured to the outer cover layer 12 on the front body portion 16 , and a back layer element 21 generally overlying and secured to the outer cover layer 12 on the back body portion 20 .
- a space 23 separates the front layer element 19 from the back layer element 21 .
- a first side edge 26 of front body portion 16 is assembled with a first side edge 28 of the back body portion 20 to form a first side seal 30 .
- a second side edge 32 of the front body portion 16 is assembled with a second side edge 34 of the back body portion 20 to form a second side seal 36 .
- the waist portions 18 , 22 when assembled form a waist opening 38 for putting on and taking off the panty 25 .
- the waist opening 38 is surrounded at least in part by a waist elastic 40 .
- the waist elastic 40 is stretched and attached to the waist portions 18 , 22 in the stretched state.
- the waist elastic 40 is released after attachment to produce waist folds or pleats 42 to allow expansion of the waist opening 38 so that the panty 25 can fit various sizes of people.
- the front waist portion 18 preferably comes as high as the navel and is level around the wearer's waist. Having the panty at this height provides a snug fit.
- Alternative panty styles include bikini (e.g. regular leg cut or french leg cut) and hipster (e.g. regular leg cut or french leg cut).
- the front body portion 16 , the back body portion 20 , and the crotch portion 24 in combination, form left and right leg openings 44 and 46 , respectively, which are generally circular or oval in shape in the finally assembled panty 25 .
- the leg openings 44 and 46 are formed by cutting away portions of the outer cover layer 12 , and corresponding portions if any of body side layer 14 .
- Each leg opening 44 , 46 is surrounded at least in part by a back leg elastic 48 , a front leg elastic 50 , and a crotch elastic 51 between the back leg elastic and the front leg elastic.
- Each of the respective elastics 48 , 50 , 51 is adjacent the respective one of the edges 52 of the corresponding leg openings.
- the front and back leg elastics 48 , 50 are secured between the outer cover layer 12 and the body side layer 14 by adhesive 55 .
- the crotch elastics 51 are secured between outer cover layer 12 and a crotch elastic support sheet 53 , also by adhesive 55 .
- the elastics 48 , 50 , 51 are in the stretched state when secured to the outer cover layer 12 . Accordingly, when the elastics, the outer cover layer, the body side layer, and the support sheet 53 , are released after the elastics are secured to the outer cover layer, the elastics produce leg folds or pleats 54 at the edges of the leg openings 44 , 46 to allow expansion of the leg openings 44 , 46 to fit various sizes of legs.
- the front body portion 16 may be divided into a front upper portion 56 and a front lower portion 58 .
- the back body portion 20 may be divided into a back upper portion 60 and a back lower portion 62 .
- the upper portions 56 and 60 are preferably designed to include body elastics 64 which readily stretch to allow the wearer to put on the panty 25 and then readily contract to resume the normal release state of the body elastics. This ensures a close or snug fit to different body sizes and forms.
- a number of body elastics 64 are positioned on both the front and the back portions 56 , 60 , respectively, at positions between the waist opening 38 and the leg openings 44 , 46 , so that the panty 25 has a good fit, particularly around the body.
- the lower body portions 58 , 62 generally do not require the spaced elastics as in the upper body portions 56 , 60 , although the elastic threads may be used.
- the width of the crotch portion 24 between the left and right crotch elastics 51 should be wide enough to accommodate laying the primary absorbent 66 between the edges 52 without having the primary absorbent 66 obstruct the crotch elastics 51 . This allows the crotch elastics 51 to contract and draw up the sides of the crotch about the primary absorbent, to thus accommodate the thickness of the primary absorbent 66 , and to give surface area within the crotch portion 24 of the panty, adjacent edges 52 , to contain leakage from the primary absorbent 66 .
- the width of the crotch portion 24 between the elastics 51 should not be so wide as to seem bulky or uncomfortable.
- a suitable width is at least about 2.75 inches (70 mm) between the crotch elastics.
- Width of crotch portion 24 is advantageous from about 3 inches (76 mm) to about 3.5 inches (89 mm). Preferably, the width is about 3 inches (76 mm).
- the crotch elastics 51 are from about 0.375 inch (10 mm) to about 0.625 inch (16 mm) wide. More preferably, the width is about 0.5 inch (13 mm).
- ruffle material on the edge of the leg openings 44 , 46 outside the leg and crotch elastics 48 , 50 , 51 is less than about 0.25 (6 mm). More preferably, the ruffle material is less than about 0.125 inch (3 mm). It is most desirable to eliminate any ruffle material from the edges of the leg openings 44 , 46 .
- the overall width of the crotch portion 24 includes the width between the left and right crotch elastics 51 , the width of the crotch elastics, and any ruffle material outside the crotch elastics to the edges 52 of the leg openings.
- the overall width of the crotch portion 24 should be at least about 4 inches (102 mm).
- FIG. 2 shows the panty subassembly 10 of FIG. 1 with a secondary absorbent 68 secured in the crotch portion 24 , over the outer cover layer 12 and parts of the front and back layer elements 19 , 21 of the body side layer 14 .
- the width of the secondary absorbent 68 is sized in relation to the width of the crotch portion 24 .
- the width of the secondary absorbent 68 is at least the width of the crotch portion 24 between the crotch elastics 51 . More preferably, the width of the secondary absorbent is equivalent to the overall width of the crotch portion 24 .
- the secondary absorbent 68 should have sufficient capacity to absorb any flow or seepage of body fluid around or through the primary absorbent 66 .
- the secondary absorbent 68 should preferably have a capacity and thickness substantially less than that of the primary absorbent 66 , thus providing a nonbulky and flexible fit.
- the secondary absorbent 68 should have a total capacity of about one-half the capacity of the primary absorbent 66 .
- the secondary absorbent 68 should have a total capacity of at least about 3 grams and not more than 6 grams. More preferably, the total capacity of the secondary absorbent 68 should be from about 4 grams to about 6 grams.
- the basis weight of, or the type of, the secondary absorbent 68 should be selected to provide resistance to flexibility of less than around 400 grams, as measured by INDA Standard Test method IST 90.3-92 Standard Test Method for Handle-O-Meter Stiffness of Nonwoven Fabrics.
- the secondary absorbent has a low stiffness.
- the low stiffness allows the absorbent and its barrier to remain attached to the conformable outer cover layer 12 and the body side layer 14 which conform to a wide range of body sizes and shapes.
- the secondary absorbent has a stiffness of less than 400 grams along any axis tested, more preferably less than 300 grams along any axis and less than 100 grams along the axis parallel to the waist opening.
- the secondary absorbent alone will have a stiffness of less than 250 grams and preferably less than 100 grams along any axis and more preferably less than 75 grams along the axis parallel to the waist opening.
- the overall length of the secondary absorbent 68 should be adequate to extend beyond the ends of the primary absorbent 66 , in order to be properly positioned to receive liquid which flows or seeps around the edges of the primary absorbent 66 .
- This overall length is typically at least about 15 inches (382 mm) thus extending beyond the crotch portion 24 along the longitudinal centerline A-A of the subassembly 10 .
- the length should be in the range of about 15 inches (382 mm) to about 19 inches (484 mm).
- the length of the secondary absorbent 68 is about 17 inches (433 mm).
- the width of the secondary absorbent 68 beyond the crotch portion 24 should be at least as wide as the width of the crotch portion 24 .
- the width of the secondary absorbent 68 may be narrowed beyond the crotch portion 24 but may thus compromise the containment of liquid flowing or seeping from the primary absorbent. More preferably, the width outside the crotch portion is wider than in the crotch portion, and is from about 5 inches (127 mm) to about 12 inches (306 mm), alternatively from about 5.5 inches (140 mm) to about 7.5 inches (191 mm). Preferably, the width is about 6.5 inches (165 mm).
- the waist elastics 40 , the body elastics 64 , and the leg elastics 48 , 50 , 51 are generally covered by the front and back layer elements 19 , 21 of the body side layer 14 .
- Both outer cover layer 12 and body side layer 14 are compliant and soft feeling to the wearer.
- the following description of materials from which the outer cover layer 12 can be made applies equally to the material of the body side layer 14 .
- the outer cover layer 12 may be liquid pervious, permitting liquids to readily penetrate into its thickness, or impervious, resistant to the penetration of liquids into its thickness.
- Outer cover layer 12 may be made from a wide range of materials, such as natural fibers (e.g. wood or cotton fibers), synthetic fibers (e.g. polyester or polypropylene fibers) or from a combination of natural and synthetic fibers or reticulated foams and apertured plastic films.
- the outer cover layer 12 may be woven, nonwoven such as spunbonded, carded, or the like.
- a suitable outer cover layer 12 is carded, and thermally bonded by means well known to those skilled in the fabric art.
- the outer cover layer 12 is derived from a spunbonded web.
- the outer cover layer is spunbonded polypropylene nonwoven with a wireweave bond pattern having a grab tensile of 19 pounds as measured by ASTM D1682 and Do, a Taber 40 cycle abrasion rating of 3.0 as measured by ASTM Do and Handle-O-Meter MD value of 6.6 grams and CD value of 4.4 grams using TAPPI method To.
- spunbonded material is available from Kimberly-Clark Corporation, Roswell, Ga.
- the outer cover layer 12 has a weight of from about 0.3 ounce per square yard (osy) to about 2.0 osy, preferably about 0.7 osy.
- the position and shape of the leg openings 44 , 46 are important to avoid tightness in the crotch and groin area of the wearer, to obtain adequate buttocks coverage, and to prevent the panty 25 from tilting forward, e.g. tilting such that the front waist edge dips lower in relationship to the back waist edge.
- FIGS. 1 and 2 illustrate the most preferred design for leg fit and buttocks coverage.
- the shape of the curve across the top of the leg is important. If the curve is too deep, the panty 25 will shift downward and backward resulting in a short front waist, increased back length and bagginess in the seat of the panty. This would cause the panty 25 to appear tilted when worn as evidenced by an unevenness around the waist of the wearer.
- the majority of the edge 70 of the front portion of each leg opening 44 , 46 is defined by a straight section 72 having a length “L 2 ” at least about 70% of the length “L 3 ” of the entire edge 70 .
- the straight section 72 should form an angle with the centerline A-A of between about 75 degrees and about 100 degrees, and most preferably about 90 degrees.
- the majority of the edge 74 of the back portion of each leg is defined by a straight section 76 having a length “L 4 ” at least about 70% of the length “L 5 ” of the entire edge 74 .
- the straight section 76 forms an acute angle with the longitudinal centerline A-A of the subassembly 10 . More preferably, the straight section 76 of the edge 74 forms an acute angle ⁇ with the centerline A-A of the panty 25 of between about 50 degrees and 65 degrees and most preferably about 60 degrees.
- each leg opening 44 , 46 is defined by a straight section 80 having a length “L 6 .”
- the straight sections 80 are straight for at least about 70% of the entire lengths “L 7 ” of the respective edges 78 .
- Each back leg edge portion 74 includes an arcuate section “A 1 ” extending from one end 81 of the respective straight section 76 to a second end 82 connecting the respective back leg edge portion.
- Each front leg edge portion 70 includes an arcuate section “A 2 ” extending from one end 84 of the respective straight section 72 to a second end 86 connecting the respective front leg edge portion 70 to the front end of edge 78 of the respective crotch portion.
- the shape of the arcuate section “A 2 ” at the inner groin area is important. If the arc is too shallow, tightness may be experienced at the inner groin area.
- the preferred narrow crotch width reduces coverage of the buttocks.
- the arcuate section “A 1 ” is preferably adjusted toward back waist portion 22 , such that the end 82 of the arcuate section “A 1 ” should be positioned slightly forward of centerline B-B as shown in FIGS. 1 and 2 .
- the waist, leg, and body elastics 40 , 48 , 50 , 64 respectively are attached to the panty subassembly 10 , generally between the outer cover layer 12 and the body side layer 14 , using apparatus and processes described hereinafter.
- Materials suitable for elastics include a wide variety including but not limited to elastic strands, yarn rubber, flat rubber (e.g. as bands), elastic tape, film-type rubber, polyurethane, and, tape-like elastomer, or foam polyurethane or formed elastic scrim.
- Each elastic may be unitary, multipart, or composite in construction.
- Waist elastic 40 is typically about 0.5 inch (13 mm) wide.
- the elastic may comprise threads, ribbons, a film, or composite.
- the threads or ribbons may be multiple and may be applied as a composite.
- the waist elastic is threads, more preferably four threads are used as the elastic and the threads are spaced about 0.17 inch (4.3 mm) apart.
- the threads may be made of any suitable elastomeric material.
- One suitable material is spandex such as Lycra® threads available from Dupont located in Wilmington, Del.
- Suitable waist elastics include threads having a total decitex (g/1000 m) of about 3760 for 0.5 inch (13 mm) wide elastic.
- Adhesive 55 is used to bond the elastic between the outer cover layer 12 and the body side layer 14 .
- a suitable adhesive includes, for example Findley H2096 hot melt adhesive, available from Findley Adhesives, Milwaukee, Wis.
- the leg elastics 48 , 50 , and crotch elastic 51 are typically about 0.5 inch (13 mm) wide.
- the elastic may comprise threads, ribbons, a film or composite.
- the threads, ribbons, etc. may be multiple and may be applied as a composite.
- the front leg elastics and the crotch elastics may be threads, preferably numbering three threads which are spaced about 0.17 inch (4.3 mm) apart.
- Back leg elastics numbering up to six threads may have a width of about 0.75 inch (19 mm) and a spacing of about 0.15 inch (3.8 mm) apart.
- the threads may be made of any suitable elastomeric material.
- Suitable material is spandex such as Lycra® threads available from Dupont, Wilmington, Del.
- Suitable leg elastics include threads having a total decitex (g/1000 m) of about 3760 for a 0.5 inch (13 mm) wide elastic.
- Adhesive 55 is used to bond the several elastics 48 , 50 , and 51 to the outer cover layer 12 , the body side layer 14 , and the support sheet 53 .
- the leg elastics 48 , 50 , and the crotch elastics 51 are elongated when applied to the layers 12 and 14 respectively.
- the leg elastics 48 , 50 are applied in multiple segments, with the amount of elongation of each segment while being incorporated into the subassembly 10 being determined according to the position to be occupied by the respective segment. In the case of only front and back leg elastics, the front leg elastics are elongated less than the back elastics.
- the front and crotch elastics are elongated less than the back elastics.
- the front and crotch elastics are elongated to about 150% and the back elastics along the leg openings are elongated to about 250%.
- the differing tensions allow easier attachment of the primary absorbent pad 66 , less tightness in the groin area, and less bunching of the crotch portion 24 caused by high leg elastic retraction.
- the back leg elastic is under higher elongation to help keep the seat of the panty from creeping up with movement during use.
- the suggested six (back) and three (front) threads of elastic on the respective back and front leg elastics 48 and 50 are each represented as single threads 112 of elastic.
- the following description of the characteristics and use of the single threads applies to the usual multiple threads suggested above.
- the composite of the elastics extending about each of the leg openings 44 and 46 comprises a portion of the back leg elastics 48 , a portion of the front leg elastics 50 , and one of the left and right crotch elastics 51 .
- the back leg elastic 48 extends, as a first section 48 A, from a first locus 92 at or propinquant the edge 28 of the subassembly, width-wise across the subassembly at a substantially consistent acute angle ⁇ with the centerline A-A that takes it toward a first edge of the subassembly at front waist portion 18 , and generally following the back edge 74 of the leg opening 46 along the straight section 76 A and onto the first arcuate section “A 1 ” toward the crotch portion 24 , generally terminating in the first arcuate section “A 1 ,” at or near the crotch portion 24 .
- Back leg elastic 48 extends, as a second section 48 B, from the first arcuate section “A 1 ” across the crotch portion to the second arcuate section “A 1 .” From the second arcuate section “A 1 ,” the back leg elastic 48 extends, as a third section 48 C, at an acute angle ⁇ with the centerline A-A away from the front waist portion 18 , and generally following the back edge 74 of the leg opening 44 along the straight section 76 B to a second locus 94 at or propinquant edge 34 .
- sections 48 A and 48 C are elongated 250%, while section 48 B is relaxed, and under no substantial elongation.
- section 48 B includes a modest amount of slack in the elastic.
- the front leg elastic 50 extends, as a first section 50 A, from a third locus 96 at or propinquant the side edge 26 of the subassembly width-wise across the subassembly and generally following the front leg edge portion 70 along its longitudinal straight section 72 A, and onto the first arcuate section “A 2 ” toward the crotch portion 24 , generally terminating in the first arcuate section “A 2 ,” at or near the crotch portion 24 .
- Front leg elastic 50 extends, as a second section 50 B, from the first arcuate section “A 2 ” across the crotch portion to the second arcuate section “A 2 .” From the second arcuate section “A 2 ,” the front leg elastic 50 extends, as a third section 50 C, width-wise across the subassembly and generally following the front leg edge portion 70 along its longitudinal straight section 72 B to a fourth locus 98 at or propinquant side edge 32 .
- sections 50 A and 50 C are elongated 150%, while section 50 B is relaxed, and under no substantial elongation.
- section 50 B includes a modest amount of slack in the elastic.
- the front and rear leg elastics extend across the width W 1 of the subassembly 10 as one or more continuous threads.
- the crotch elastics 51 extend generally between the back and front leg elastics 48 and 50 , with respective ends of the crotch elastics generally being disposed at or near the arcuate sections “A 1 ” and “A 2 .” Accordingly, the elastic properties extant about each leg opening result from the combined contributions of the respective back leg section (e.g. 48 A), the respective front leg section (e.g. 50 A), and the respective crotch elastic 51 .
- the reason for providing leg elastics in multiple sections is at least two-fold.
- using multiple sections of elastics facilitates placing of the elastics on the outer cover layer 12 while maintaining advantageous production speeds.
- the subassembly of e.g. FIG. 1 is made as a sequence of such subassemblies in a continuous web 100 , with the width “W 1 ” of the subassembly disposed in the “with machine” direction of the processing apparatus.
- the front and back waist elastics 40 , the front and back body elastics 64 , and the front and back leg elastics 48 , 50 can all be assembled into the subassembly by appropriate continuous feeding of respective continuous threads of elastics into the processing apparatus in the “with machine” direction while the web 100 continuously advances in the “with machine” direction at a constant speed.
- the invention contemplates, rather, that the crotch elastics are placed in the subassembly 10 as a separate operation placing separate elastics segments, where the crotch elastics segments are first elongated and oriented transverse to the web 100 , and are then placed on the web as the web passes the appropriate operating station (not shown) subsequent to placing the leg, body and waist elastics in the subassembly, though the sequence of placing the elastics is not critical.
- a first continuous web which ultimately becomes cover layer 12
- a second continuous web which ultimately becomes body side layer 14
- Elastic threads 112 are fed from a continuous supply 114 of elastic thread through feed nip 116 , through thread guides 118 and sets of guide fingers 120 A and 120 B, and between cover layer 12 and body side layer 14 at the nip formed by assembly roll 102 and turning roll 110 .
- thread guides 118 and corresponding sets of guide fingers 120 A and 120 B are elements of lateral guides 122 A and 122 B respectively.
- Each of the lateral guides 122 A and 122 B is mounted on a transverse slide bar 124 for sliding transverse to the with machine direction of travel of the webs.
- Each lateral guide 122 is connected to a transverse drive mechanism 126 including linkage arms 128 and 130 , vertical drive shaft 132 , and a cam follower. The cam followers follow the corresponding cams inside the respective cam housings. The cams are linked to the machine drive shaft 140 by drive belt 142 .
- the cams and correspondingly the thread guides and the sets of guide fingers, move transversely with respect to the with machine direction of the webs as the drive shaft turns.
- rotation of the processing line drive shaft 140 effects transverse motion of the thread guides and the sets of guide fingers, as indicated by the arrows in FIG. 10 , in cooperation with the design of the cams and cam followers.
- the guide fingers 120 are positioned close to the nip 144 so that they closely control the transverse positions of the elastics with respect to the webs 12 and 14 as the webs 12 and 14 enter the nip 144 and correspondingly trap the elastics between them, fixing the position of the elastics between them by means of adhesive 55 .
- the guide fingers 120 are preferably physically positioned, and provide guidance to the threads of elastic, within one inch of the nip 144 . To the extent the fingers can be placed closer to the nip 144 , they provide more positive guidance to the elastic.
- the guide fingers 120 can be advantageously positioned within 0.5 inch of the line of contact defined at the nip between roll 102 and 108 .
- the limitation on how close the guide fingers 120 can be placed to the nip is controlled by the ability to design fingers which can affirmatively guide the threads of elastic while avoiding having the fingers themselves drawn into the nip.
- the criticality of urging the fingers as ultimately close as possible to the nip can be attenuated by directing the threads 112 onto the adhesive-coated layer 14 ahead of nip 144 , preferably instantaneously ahead of the nip 144 , as suggested by the depiction in FIG. 8 .
- the open distance spanned by the threads between the fingers 120 and the adhesive-coated layer 14 is minimized, being held to less than 0.5 inch, for example 0.25-0.375 inch (6 mm to 10 mm).
- FIG. 11 shows the pattern of transverse movement of the sets of guide fingers 120 A and 120 B relative to the movement of the web in the with machine direction, along the processing line.
- the sets of fingers 120 A and 120 B are depicted at several locations along the front and back edges of the leg openings 44 , 46 , to indicate that it is the positioning of the sets of fingers 120 A and 120 B, and the dynamic changing of that positioning by the drive mechanism 126 , that determines the instantaneous transverse location of the elastics in the web at any point and time while the elastics are being placed in the web at nip 144 as shown in FIGS. 8-11 . Comparing FIGS.
- the set of fingers 120 A generally places the threads of the back leg elastics generally parallel to each other in the web
- the set of fingers 120 B generally places the threads of the front leg elastics generally parallel to each other in the web, both along their respective portions of the designed paths defining the front 70 and back 74 edges of the leg openings 44 and 46 .
- the threads of elastic deviate slightly from their parallel relationships with each other as the elastic threads traverse paths that deviate from the with machine direction, the distance between the threads 90 being generally constant as they emerge from the fingers 120 .
- Such deviations from the parallel, resulting from the cross machine traverse of the elastics are included herein within the phrase “generally parallel” as respects the relationships of the threads of elastic to each other.
- FIG. 11 represents only one panty in the continuous sequence of panty subassemblies 10 contained in the web 100 passing through nip 144 . It will also be understood that the web passing through the nip 144 is further acted upon at cutter 146 to cut away material from the web 100 in creating the leg openings 44 and 46 .
- webs 12 and 14 are provided as substantially endless rolls from unwind stands (not shown).
- Web 14 is typically provided as front and back layer elements 19 and 21 .
- Space 23 separates the elements 19 and 21 , and generally corresponds with the crotch portion and the portion of the web 12 which is cut out to form leg openings 44 and 46 .
- Adhesive 55 is applied to the front and back elements 19 and 21 of web 14 by adhesive applicator 106 .
- Webs 12 and 14 are joined adhesively, with elastic threads being interposed between webs 12 and 14 at nip 144 , and with space 23 interposed between the front and back elements 19 , 21 of the body side layer 14 .
- the transverse positions of the elastics change according to a pre-set path of transverse movements, driven by the drive shaft 140 which drives and times the several operations along the processing line.
- the threads of elastic 112 as placed by the guide fingers 120 , traverse respective paths that ultimately follow the front and back edges of the leg openings 44 and 46 , as defined at cutter 146 , in registration with the advance of the web, and accordingly, with the advance of the series of panty subassemblies 10 being defined in the web at nip 144 and cutter 146 .
- the portions of the threads of elastic located along the front and back edges of the leg openings are stretched.
- the portions traversing the crotch portion are relaxed.
- the crotch portions of the elastic are separately placed in the subassembly 10 at a later processing station, preferably downstream from the cutter 146 .
- FIG. 12 A second embodiment of the subassembly is illustrated in FIG. 12 .
- the front edge 148 of back layer element 21 is disposed rearwardly of that same edge 148 as depicted in the embodiment of FIG. 10 , while the guide fingers 120 A traverse the same path as in FIG. 10 . Accordingly, as the threads of elastic 112 extend across the crotch portion 24 , the threads 112 are guided forwardly of edge 148 , into space 23 , and are thus not held between the layers 12 and 14 , and thus are not controlled by the adhesive on layer 14 .
- the tension is maintained on the threads of elastic 112 across the crotch portion 24 , such that the threads retract along the edge 148 of the layer element 21 in a configuration that loosely resembles a rope under tension.
- the rope is subsequently cut such that the cut portions of the threads retract to positions generally defined by the intersection of the edge 148 of the back layer element 21 and the path of the threads adhesively held between layer 12 and the back layer element 21 .
- the threads 112 generally include loose intermediate ends 150 after being cut, as shown in FIG. 7 .
- Body elastics 64 and waist elastics 40 can be incorporated at nip 144 in the conventional manner of providing stationary feeds and guides at the nip.
- a section of web processing equipment 297 is shown including a drive side DS and an operator side OS.
- a plurality of elastic threads 212 are attached to a stain shield or secondary absorbent web 267 , and the secondary absorbent 267 and attached elastic threads 212 are cut to create a plurality of stain shields 268 having respective elastic pieces or sections 251 A attached thereto.
- the elasticized stain shields 268 are maneuvered as shown and attached to a garment web 201 to form a garment blank subassembly.
- the processing equipment 297 supplies the plurality of elastic threads 212 from an elastic thread roll 214 generally in a machine direction MD.
- the elastic threads 212 are routed by a series of guide rollers G in a known manner and are attached in a stretched condition in a non-machine direction (NMD) in this example to the secondary absorbent web 267 using an adhesive 255 A.
- NMD non-machine direction
- the adhesive 255 A is applied intermittently to the elastic threads 212 by a plurality of applicators 206 A to form a plurality of adhesive gaps 213 along the elastic threads 212 .
- the cutter 246 cuts the secondary absorbent web 267 into the stain shields 268 at each adhesive gap 213 .
- the stain shield 268 the resultant sections 251 A are attached to a first or inner side 268 B, which opposes a second or outer side 268 A discussed further below.
- the exemplary cutter 246 shown in FIG. 13 is a roller cutter having a plurality of blades 246 A,B attached thereto for cutting the elastic sections 251 A at the adhesive gaps 213 as discussed above.
- the cutter 246 is controlled by a controller 299 disposed on the operator side OS of the processing equipment 297 in this example.
- the controller 299 can be a computer or a programmable logic controller, which can be programmed to cut the elastic threads 212 at the adhesive gaps 213 based on a passage of time or a sensed length of passing elastic threads 212 to create the sections 251 A.
- each end of each section 251 A which formed the gaps 213 in the elastic threads 212 before the elastic threads 212 were cut, retract after being cut to create a retraction area 268 C on the outer side 268 B.
- the sections 251 A are from about one (1) inch to about three (3) inches in length.
- a second adhesive applicator 206 B applies a second amount of adhesive 255 B to the outer sides 268 B of the stain shields 268 .
- a plurality of applicator assembly segments 297 A-D subsequently maneuver or rotate the adhesive coated stain shields 268 transverse to the machine direction MD.
- the applicator assembly segments 297 A-D affix the adhesive coated outer sides 268 B and the underlying elastic sections 251 A to the garment web 201 with the inner sides 268 A facing upward or outward from within a crotch area or portion 224 .
- the inner sides 268 A are located between a plurality of garment elastics 251 B.
- the individual elastic sections 251 A are rapidly manipulated, positioned and attached to the crotch area 224 without having to maneuver the entire garment web 201 and/or cut the elastic threads 212 and apply the elastic sections 251 A to the crotch portions 224 through acute angles at high machine speeds.
Abstract
This invention pertains to a three dimensional disposable panty, subassemblies of the panty, and an apparatus and methods for making the panty and subassemblies. The panty is designed to hold a primary absorbent sanitary pad. The panty may have elasticized leg and waist openings and be stretchable about the hip and stomach regions of a user. the panty provides backup protection to control egress of fluids that leak or seep around or through the primary sanitary pad. The panty includes a secondary absorbent positioned in the crotch area and extending into the body of the disposable panty, front and back, and preferably over the leg elastics to trap, inside the panty, leakage from the primary absorbent, and to prevent strike through onto e.g. outer clothing and bed linen. The apparatus and methods facilitate assembling leg elastics and crotch elastics into the panty subassemblies while assembling a series of panty subassemblies in a continuous web structure at a constant, or relatively constant, continuous and efficient speed.
Description
- The present application is a divisional application of Ser. No. 12/913,362, filed Oct. 27, 2010, which is a continuation application of and claims priority to U.S. patent application Ser. No. 11/240,262, filed Sep. 30, 2005, now abandoned, which is a continuation-in-part application of U.S. patent application Ser. No. 09/548,231, filed Apr. 12, 2000, now abandoned, which is a continuation of prior U.S. patent application Ser. No. 08/937,225, filed Sep. 11, 1997, now U.S. Pat. No. 6,049,916, which is a divisional of prior U.S. patent application Ser. No. 08/382,108 filed on Jan. 31, 1995, now U.S. Pat. No. 5,745,922, each of which are incorporated herein by reference in their entirety.
- Undergarments are made typically of cotton and/or synthetic materials. The cotton and synthetic panties typically do not offer barrier protection. Often the synthetic undergarments have a cotton lined crotch to absorb vaginal discharges or perspiration. The absorbent/barrier properties of regular undergarments are minimal such that any vaginal discharge and/or heavy perspiration may strike through onto outer clothing; i.e., liquid penetrates from the interior to the exterior of the panty.
- Panty liners and feminine care sanitary napkins or pads used with regular undergarments have polyethylene backings that provide some barrier properties inhibiting liquid strike through. However, if the vaginal discharge extends to the sides or the ends of the pads, the discharge can leak or seep around an edge of the pad and onto the undergarment. Such leakage can stain the undergarment. Depending upon the amount of leakage, liquid may strike through or go around the undergarment and stain outer clothing and/or bedding. Women with heavy liquid flows may often use one or more maxi pads, double pads and/or tampons alone, or in combination, and change these pads and tampons frequently to prevent embarrassing, messy leakage around the edges of the pads and/or staining of outer clothing. In some cases, during their heaviest flow days, some women will restrict their activities and stay home.
- Many women experience some leakage of menses from their pads to their undergarments. This varies from being limited to a small number of pads leaking onto only the undergarment during light flow to more prevalent leakage onto the wearer's outer clothing on pads worn during heavy flow. Normally this leakage occurs at the side of the pad, although end leakage is also a problem. Placement of maxi pads and overnight pads in the crotch of regular undergarments shows that, at best, the pads lay on the leg elastic and, at worst, overhang the leg elastics. This causes side leakage onto the undergarment and possibly onto outer clothing. Typical leakage from the pads is caused by poor fit of the pad to the body, improper positioning of the pad by the user and lack of absorbency. Leakage from the undergarment onto the outer clothing is typically due to incompatibility between the pad width and the panty crotch width and/or lack of barrier properties in the panty material around the edge portion of the pad.
- The present invention broadly includes a three dimensional, disposable, discrete panty, subassemblies of the panty, and apparatus and methods for making the panty.
- In one aspect of the invention, a method for attaching elastic to a crotch area of an undergarment includes the steps of cutting an elastic thread into a plurality of elastic sections; providing a secondary absorbent for receipt of at least one of the elastic sections, the secondary absorbent defining an inner side and an opposing outer side; attaching the elastic sections to the inner side of the secondary absorbent as the elastic sections and the secondary absorbent move in a machine direction; maneuvering the secondary absorbent with the elastic sections attached thereto to a non-machine direction; and attaching the secondary absorbent to a garment web moving in the machine direction, the elastic sections of the inner side disposed against an inner crotch portion of the garment web, the opposing outer side visible in the crotch portion. In this aspect, each elastic section is from about one inch to about three inches in length. Also in this aspect, the elastic sections are attached to the inner side of the secondary absorbent by an adhesive.
- According to a further aspect of the invention, a disposable garment assembly includes a disposable garment defining a length and a width and including an outer cover having a front body portion and a back body portion, the front body portion and the back body portion being connected by a crotch portion, the outer cover, when laid out flat, having a length and a width, the front body portion and the back body portion being connected together to form a waist opening, a first leg opening and a second leg opening, the first and second leg openings having respective first and second front and back leg edge portions and corresponding first and second side leg edge portions connecting the front and back leg edge portions, the outer cover comprising a first layer, and a second layer having a front portion and a back portion, the second layer front portion disposed adjacent the front body portion of the outer cover, the second layer back portion disposed adjacent the back body portion of the outer cover; a first absorbent defining a length and a width, each respectively less than the length and the width of the disposable garment, the first absorbent further including a liquid impermeable outer sheet and a liquid permeable inner sheet, the liquid impermeable outer sheet having a front portion and a back portion, and a center portion therebetween, each of the liquid impermeable outer sheet front and back portions of the first absorbent disposed adjacent one of the respective second layer front and back body portions of the outer cover, the first absorbent having a first absorbent capacity; a second absorbent including a first side and a second side and having a second absorbent capacity, the second absorbent attached in the crotch portion and covering the width of the first absorbent, the second absorbent underlying the first absorbent on the liquid impermeable outer sheet of the first absorbent, the first side of the second absorbent disposed facing the liquid impermeable outer sheet, the first absorbent capacity of the first absorbent being greater than the second absorbent capacity of the second absorbent; and a plurality of crotch elastics extendably affixed between the outer cover and the second side of the second absorbent proximate the crotch portion, the second absorbent affixed to the outer cover.
- In this aspect of the invention, the second absorbent capacity of the second absorbent is about one-half the absorbent capacity of the first absorbent. For instance, the second absorbent capacity of the second absorbent can be about 3 grams to about 6 grams, more particularly, about 4 grams to about 6 grams. Also in this aspect of the invention, the second absorbent is a stain shield.
- In a further aspect of the invention, a disposable garment has a length and a width, and includes an outer cover having front and back body portions connected by a crotch portion, the outer cover, when laid out flat, having a length between first and second ends and a width between first and second sides, the front and back body portions being connected together to form a waist opening and first and second leg opening. The outer cover in this aspect includes a first layer; a second layer having front and back body portions overlying respective front and back body portions of the outer cover; and a stain shield incorporated into the disposable garment, the stain shield having a length and a width and a garment facing side, the garment facing side having a front portion, a back portion and a center portion therebetween, the garment facing side of the center portion having a plurality of extensible crotch elastic pieces attached thereto proximate the crotch portion, the extensible crotch elastic pieces being disposed between the garment facing side and the outer cover of the crotch portion, the stain shield affixed to the outer cover, each of the garment facing side front and back portions of the stain shield disposed adjacent one of the respective second layer front and back portions, at least a portion of the stain shield having an overall total absorbent capacity of about 3 grams to about 6 grams. Also in this aspect, at least a portion of the absorbent has an overall total absorbent capacity of about 4 grams to about 6 grams.
- The present invention will be more fully understood and further advantages will become apparent when reference is made to the following detailed description of the invention and the drawings, in which:
-
FIG. 1 is a plan view of a garment subassembly according to an aspect of the invention; -
FIG. 2 is a plan view of the garment subassembly ofFIG. 1 , including a secondary absorbent in the crotch; -
FIG. 3 is a cross section of the garment subassembly taken along line 3-3 ofFIG. 2 ; -
FIG. 4 is a cross section of the garment subassembly taken along line 4-4 ofFIG. 2 ; -
FIG. 5 is a perspective view of a disposable panty according to another aspect of the invention; -
FIGS. 6 and 7 are enlarged cut-away views of a fragment of the subassembly ofFIG. 1 , particularly showing cross-crotch elastics in detail; -
FIG. 8 is a side elevation view of an equipment layout for fabricating and processing subassemblies according to another aspect of the invention; -
FIGS. 9 and 10 are pictorial views of a nip area of the elevation shown inFIG. 8 ; -
FIG. 11 is a plan view showing transverse positioning of front and back leg elastics along an advancing web as an outer cover layer and a body side layer are being joined according to an aspect of the invention; -
FIG. 12 is a plan view as inFIG. 10 , showing an alternate pattern for elastic threads; and -
FIG. 13 is a perspective view showing steps in a method for cutting a plurality of elastics and attaching the elastics to a secondary absorbent according to another aspect of the invention. - The following detailed description is made in the context of an article including a disposable panty, and corresponding panty subassemblies, for holding a sanitary pad in place as a primary absorbent during use of the panty. It is readily apparent, however, that the present invention can be employed with other disposable sanitary articles, such as feminine tampons, incontinent garments and the like.
- The panty subassembly 10 of
FIG. 1 illustrates an embodiment of a two-layer panty subassembly prior to incorporation of the secondary absorbent. The panty subassembly ofFIG. 2 illustrates the finished panty including all elements, but before the final steps of assembling the composite to form the panty structure.FIG. 5 shows the finally-assembled disposable panty structure. - Referring to
FIGS. 1-3 , the panty subassembly 10 has anouter cover layer 12 generally defining the overall length “L1” and width “W1” of the subassembly, and abody side layer 14 secured to the outer cover layer. The panty subassembly 10 generally includes afront body portion 16 terminating at afront waist portion 18 as a first edge of the subassembly, aback body portion 20 terminating at aback waist portion 22 as a second edge of the subassembly, and acrotch portion 24. - The
body side layer 14 includes afront layer element 19 generally overlying and secured to theouter cover layer 12 on thefront body portion 16, and aback layer element 21 generally overlying and secured to theouter cover layer 12 on theback body portion 20. Aspace 23 separates thefront layer element 19 from theback layer element 21. - Referring to
FIGS. 2 and 5 , for assembling the subassembly ofFIG. 2 to form apanty 25 as inFIG. 5 , afirst side edge 26 offront body portion 16 is assembled with afirst side edge 28 of theback body portion 20 to form afirst side seal 30. Similarly, asecond side edge 32 of thefront body portion 16 is assembled with asecond side edge 34 of theback body portion 20 to form asecond side seal 36. Thewaist portions panty 25. Thewaist opening 38 is surrounded at least in part by a waist elastic 40. The waist elastic 40 is stretched and attached to thewaist portions pleats 42 to allow expansion of thewaist opening 38 so that thepanty 25 can fit various sizes of people. Because users of this invention generally prefer a brief style panty, thefront waist portion 18 preferably comes as high as the navel and is level around the wearer's waist. Having the panty at this height provides a snug fit. Alternative panty styles include bikini (e.g. regular leg cut or french leg cut) and hipster (e.g. regular leg cut or french leg cut). - Referring to
FIGS. 1 and 5 , thefront body portion 16, theback body portion 20, and thecrotch portion 24, in combination, form left andright leg openings panty 25. Theleg openings outer cover layer 12, and corresponding portions if any ofbody side layer 14. Eachleg opening edges 52 of the corresponding leg openings. The front and back leg elastics 48, 50 are secured between theouter cover layer 12 and thebody side layer 14 by adhesive 55. The crotch elastics 51 are secured betweenouter cover layer 12 and a crotchelastic support sheet 53, also by adhesive 55. The elastics 48, 50, 51 are in the stretched state when secured to theouter cover layer 12. Accordingly, when the elastics, the outer cover layer, the body side layer, and thesupport sheet 53, are released after the elastics are secured to the outer cover layer, the elastics produce leg folds or pleats 54 at the edges of theleg openings leg openings - The
front body portion 16 may be divided into a frontupper portion 56 and a frontlower portion 58. Similarly, theback body portion 20 may be divided into a backupper portion 60 and a backlower portion 62. Theupper portions panty 25 and then readily contract to resume the normal release state of the body elastics. This ensures a close or snug fit to different body sizes and forms. A number of body elastics 64 are positioned on both the front and theback portions waist opening 38 and theleg openings panty 25 has a good fit, particularly around the body. - The
lower body portions upper body portions - The width of the
crotch portion 24 between the left and right crotch elastics 51 should be wide enough to accommodate laying the primary absorbent 66 between theedges 52 without having the primary absorbent 66 obstruct the crotch elastics 51. This allows the crotch elastics 51 to contract and draw up the sides of the crotch about the primary absorbent, to thus accommodate the thickness of the primary absorbent 66, and to give surface area within thecrotch portion 24 of the panty,adjacent edges 52, to contain leakage from the primary absorbent 66. - The width of the
crotch portion 24 between the elastics 51 should not be so wide as to seem bulky or uncomfortable. A suitable width is at least about 2.75 inches (70 mm) between the crotch elastics. Width ofcrotch portion 24 is advantageous from about 3 inches (76 mm) to about 3.5 inches (89 mm). Preferably, the width is about 3 inches (76 mm). - Preferably, the crotch elastics 51 are from about 0.375 inch (10 mm) to about 0.625 inch (16 mm) wide. More preferably, the width is about 0.5 inch (13 mm). Preferably, ruffle material on the edge of the
leg openings leg openings - The overall width of the
crotch portion 24 includes the width between the left and right crotch elastics 51, the width of the crotch elastics, and any ruffle material outside the crotch elastics to theedges 52 of the leg openings. Preferably, the overall width of thecrotch portion 24 should be at least about 4 inches (102 mm). -
FIG. 2 shows the panty subassembly 10 ofFIG. 1 with asecondary absorbent 68 secured in thecrotch portion 24, over theouter cover layer 12 and parts of the front and backlayer elements body side layer 14. The width of thesecondary absorbent 68 is sized in relation to the width of thecrotch portion 24. Preferably, the width of thesecondary absorbent 68 is at least the width of thecrotch portion 24 between the crotch elastics 51. More preferably, the width of the secondary absorbent is equivalent to the overall width of thecrotch portion 24. - The
secondary absorbent 68 should have sufficient capacity to absorb any flow or seepage of body fluid around or through the primary absorbent 66. Thesecondary absorbent 68 should preferably have a capacity and thickness substantially less than that of the primary absorbent 66, thus providing a nonbulky and flexible fit. Thesecondary absorbent 68 should have a total capacity of about one-half the capacity of the primary absorbent 66. Preferably, thesecondary absorbent 68 should have a total capacity of at least about 3 grams and not more than 6 grams. More preferably, the total capacity of thesecondary absorbent 68 should be from about 4 grams to about 6 grams. However, the basis weight of, or the type of, thesecondary absorbent 68 should be selected to provide resistance to flexibility of less than around 400 grams, as measured by INDA Standard Test method IST 90.3-92 Standard Test Method for Handle-O-Meter Stiffness of Nonwoven Fabrics. - The secondary absorbent has a low stiffness. The low stiffness allows the absorbent and its barrier to remain attached to the conformable
outer cover layer 12 and thebody side layer 14 which conform to a wide range of body sizes and shapes. Preferably, the secondary absorbent has a stiffness of less than 400 grams along any axis tested, more preferably less than 300 grams along any axis and less than 100 grams along the axis parallel to the waist opening. The secondary absorbent alone will have a stiffness of less than 250 grams and preferably less than 100 grams along any axis and more preferably less than 75 grams along the axis parallel to the waist opening. - The overall length of the
secondary absorbent 68 should be adequate to extend beyond the ends of the primary absorbent 66, in order to be properly positioned to receive liquid which flows or seeps around the edges of the primary absorbent 66. This overall length is typically at least about 15 inches (382 mm) thus extending beyond thecrotch portion 24 along the longitudinal centerline A-A of the subassembly 10. The length should be in the range of about 15 inches (382 mm) to about 19 inches (484 mm). Preferably, the length of thesecondary absorbent 68 is about 17 inches (433 mm). - The width of the
secondary absorbent 68 beyond thecrotch portion 24 should be at least as wide as the width of thecrotch portion 24. The width of thesecondary absorbent 68 may be narrowed beyond thecrotch portion 24 but may thus compromise the containment of liquid flowing or seeping from the primary absorbent. More preferably, the width outside the crotch portion is wider than in the crotch portion, and is from about 5 inches (127 mm) to about 12 inches (306 mm), alternatively from about 5.5 inches (140 mm) to about 7.5 inches (191 mm). Preferably, the width is about 6.5 inches (165 mm). - Referring to
FIGS. 2 , 3, and 4, the waist elastics 40, the body elastics 64, and the leg elastics 48, 50, 51 are generally covered by the front and backlayer elements body side layer 14. - Both
outer cover layer 12 andbody side layer 14 are compliant and soft feeling to the wearer. The following description of materials from which theouter cover layer 12 can be made applies equally to the material of thebody side layer 14. - The
outer cover layer 12 may be liquid pervious, permitting liquids to readily penetrate into its thickness, or impervious, resistant to the penetration of liquids into its thickness.Outer cover layer 12 may be made from a wide range of materials, such as natural fibers (e.g. wood or cotton fibers), synthetic fibers (e.g. polyester or polypropylene fibers) or from a combination of natural and synthetic fibers or reticulated foams and apertured plastic films. Theouter cover layer 12 may be woven, nonwoven such as spunbonded, carded, or the like. A suitableouter cover layer 12 is carded, and thermally bonded by means well known to those skilled in the fabric art. Alternatively, theouter cover layer 12 is derived from a spunbonded web. In preferred embodiments, the outer cover layer is spunbonded polypropylene nonwoven with a wireweave bond pattern having a grab tensile of 19 pounds as measured by ASTM D1682 and Do, aTaber 40 cycle abrasion rating of 3.0 as measured by ASTM Do and Handle-O-Meter MD value of 6.6 grams and CD value of 4.4 grams using TAPPI method To. Such spunbonded material is available from Kimberly-Clark Corporation, Roswell, Ga. Theouter cover layer 12 has a weight of from about 0.3 ounce per square yard (osy) to about 2.0 osy, preferably about 0.7 osy. - The position and shape of the
leg openings panty 25 from tilting forward, e.g. tilting such that the front waist edge dips lower in relationship to the back waist edge.FIGS. 1 and 2 illustrate the most preferred design for leg fit and buttocks coverage. The shape of the curve across the top of the leg is important. If the curve is too deep, thepanty 25 will shift downward and backward resulting in a short front waist, increased back length and bagginess in the seat of the panty. This would cause thepanty 25 to appear tilted when worn as evidenced by an unevenness around the waist of the wearer. - Thus, the majority of the
edge 70 of the front portion of eachleg opening entire edge 70. The straight section 72 should form an angle with the centerline A-A of between about 75 degrees and about 100 degrees, and most preferably about 90 degrees. - With the panty subassembly 10 laid out flat as in
FIG. 1 , the majority of theedge 74 of the back portion of each leg is defined by astraight section 76 having a length “L4” at least about 70% of the length “L5” of theentire edge 74. Thestraight section 76 forms an acute angle with the longitudinal centerline A-A of the subassembly 10. More preferably, thestraight section 76 of theedge 74 forms an acute angle α with the centerline A-A of thepanty 25 of between about 50 degrees and 65 degrees and most preferably about 60 degrees. - The majority of the edge 78 of the crotch portion of each
leg opening straight section 80 having a length “L6.” Preferably, thestraight sections 80 are straight for at least about 70% of the entire lengths “L7” of the respective edges 78. - Each back
leg edge portion 74 includes an arcuate section “A1” extending from oneend 81 of the respectivestraight section 76 to asecond end 82 connecting the respective back leg edge portion. - Each front
leg edge portion 70 includes an arcuate section “A2” extending from oneend 84 of the respective straight section 72 to a second end 86 connecting the respective frontleg edge portion 70 to the front end of edge 78 of the respective crotch portion. - The shape of the arcuate section “A2” at the inner groin area is important. If the arc is too shallow, tightness may be experienced at the inner groin area.
- The preferred narrow crotch width reduces coverage of the buttocks. To compensate for such reduction, the arcuate section “A1” is preferably adjusted toward
back waist portion 22, such that theend 82 of the arcuate section “A1” should be positioned slightly forward of centerline B-B as shown inFIGS. 1 and 2 . - The waist, leg, and body elastics 40, 48, 50, 64 respectively are attached to the panty subassembly 10, generally between the
outer cover layer 12 and thebody side layer 14, using apparatus and processes described hereinafter. - Materials suitable for elastics include a wide variety including but not limited to elastic strands, yarn rubber, flat rubber (e.g. as bands), elastic tape, film-type rubber, polyurethane, and, tape-like elastomer, or foam polyurethane or formed elastic scrim. Each elastic may be unitary, multipart, or composite in construction.
- Waist elastic 40 is typically about 0.5 inch (13 mm) wide. The elastic may comprise threads, ribbons, a film, or composite. The threads or ribbons may be multiple and may be applied as a composite. Preferably, the waist elastic is threads, more preferably four threads are used as the elastic and the threads are spaced about 0.17 inch (4.3 mm) apart. The threads may be made of any suitable elastomeric material. One suitable material is spandex such as Lycra® threads available from Dupont located in Wilmington, Del. Suitable waist elastics include threads having a total decitex (g/1000 m) of about 3760 for 0.5 inch (13 mm) wide elastic. Adhesive 55 is used to bond the elastic between the
outer cover layer 12 and thebody side layer 14. A suitable adhesive includes, for example Findley H2096 hot melt adhesive, available from Findley Adhesives, Milwaukee, Wis. - The leg elastics 48, 50, and crotch elastic 51, including multiple threads in each, are typically about 0.5 inch (13 mm) wide. The elastic may comprise threads, ribbons, a film or composite. The threads, ribbons, etc., may be multiple and may be applied as a composite. The front leg elastics and the crotch elastics may be threads, preferably numbering three threads which are spaced about 0.17 inch (4.3 mm) apart. Back leg elastics numbering up to six threads may have a width of about 0.75 inch (19 mm) and a spacing of about 0.15 inch (3.8 mm) apart. The threads may be made of any suitable elastomeric material. One suitable material is spandex such as Lycra® threads available from Dupont, Wilmington, Del. Suitable leg elastics include threads having a total decitex (g/1000 m) of about 3760 for a 0.5 inch (13 mm) wide elastic. Adhesive 55 is used to bond the several elastics 48, 50, and 51 to the
outer cover layer 12, thebody side layer 14, and thesupport sheet 53. - To provide a snug leg fit and to draw up the sides of the
crotch portion 24 to a cradle to receive the primary absorbent, the leg elastics 48, 50, and the crotch elastics 51, are elongated when applied to thelayers crotch portion 24 caused by high leg elastic retraction. The back leg elastic is under higher elongation to help keep the seat of the panty from creeping up with movement during use. - Referring now to
FIGS. 1 , 6, and 7, the suggested six (back) and three (front) threads of elastic on the respective back and front leg elastics 48 and 50 are each represented assingle threads 112 of elastic. The following description of the characteristics and use of the single threads applies to the usual multiple threads suggested above. - The composite of the elastics extending about each of the
leg openings FIGS. 1 , 6, and 7, the back leg elastic 48 extends, as afirst section 48A, from afirst locus 92 at or propinquant theedge 28 of the subassembly, width-wise across the subassembly at a substantially consistent acute angle α with the centerline A-A that takes it toward a first edge of the subassembly atfront waist portion 18, and generally following theback edge 74 of theleg opening 46 along thestraight section 76A and onto the first arcuate section “A1” toward thecrotch portion 24, generally terminating in the first arcuate section “A1,” at or near thecrotch portion 24. Back leg elastic 48 extends, as asecond section 48B, from the first arcuate section “A1” across the crotch portion to the second arcuate section “A1.” From the second arcuate section “A1,” the back leg elastic 48 extends, as athird section 48C, at an acute angle α with the centerline A-A away from thefront waist portion 18, and generally following theback edge 74 of theleg opening 44 along the straight section 76B to asecond locus 94 at orpropinquant edge 34. In the flat configuration shown for the subassembly inFIGS. 1 , 6, and 7,sections section 48B is relaxed, and under no substantial elongation. Preferably,section 48B includes a modest amount of slack in the elastic. - The front leg elastic 50 extends, as a
first section 50A, from athird locus 96 at or propinquant theside edge 26 of the subassembly width-wise across the subassembly and generally following the frontleg edge portion 70 along its longitudinalstraight section 72A, and onto the first arcuate section “A2” toward thecrotch portion 24, generally terminating in the first arcuate section “A2,” at or near thecrotch portion 24. Front leg elastic 50 extends, as asecond section 50B, from the first arcuate section “A2” across the crotch portion to the second arcuate section “A2.” From the second arcuate section “A2,” the front leg elastic 50 extends, as athird section 50C, width-wise across the subassembly and generally following the frontleg edge portion 70 along its longitudinal straight section 72B to afourth locus 98 at orpropinquant side edge 32. In the flat configuration shown for the subassembly inFIGS. 1 , 6, and 7,sections section 50B is relaxed, and under no substantial elongation. Preferably,section 50B includes a modest amount of slack in the elastic. - Thus, in the embodiment seen in
FIGS. 1 , 2, 6, and 11, the front and rear leg elastics extend across the width W1 of the subassembly 10 as one or more continuous threads. - The crotch elastics 51 extend generally between the back and front leg elastics 48 and 50, with respective ends of the crotch elastics generally being disposed at or near the arcuate sections “A1” and “A2.” Accordingly, the elastic properties extant about each leg opening result from the combined contributions of the respective back leg section (e.g. 48A), the respective front leg section (e.g. 50A), and the respective crotch elastic 51.
- The reason for providing leg elastics in multiple sections is at least two-fold. First, using multiple sections of elastics facilitates placing of the elastics on the
outer cover layer 12 while maintaining advantageous production speeds. As suggested inFIGS. 1 , 8, and 9, the subassembly of e.g.FIG. 1 is made as a sequence of such subassemblies in acontinuous web 100, with the width “W1” of the subassembly disposed in the “with machine” direction of the processing apparatus. In such arrangement, the front and back waist elastics 40, the front and back body elastics 64, and the front and back leg elastics 48, 50 can all be assembled into the subassembly by appropriate continuous feeding of respective continuous threads of elastics into the processing apparatus in the “with machine” direction while theweb 100 continuously advances in the “with machine” direction at a constant speed. - Given the orientation of the crotch elastics at essentially 90 degrees to the direction of advance of the
web 100, placing the crotch elastics as a portion of a continuous element of either the front or back leg elastics would suggest either (1) momentarily and regularly stopping the advance of theweb 100 while the crotch elastic is fed into place, or (2) severely slowing theweb 100 and severely driving an elastics guide, in a direction transverse to the web in order to apply the crotch elastic while the web was thus slowed. In either scenario, severe stresses would be placed on the respective drive apparatus, as well as on the web. The invention contemplates, rather, that the crotch elastics are placed in the subassembly 10 as a separate operation placing separate elastics segments, where the crotch elastics segments are first elongated and oriented transverse to theweb 100, and are then placed on the web as the web passes the appropriate operating station (not shown) subsequent to placing the leg, body and waist elastics in the subassembly, though the sequence of placing the elastics is not critical. - Referring now to
FIGS. 8 and 9 , a first continuous web, which ultimately becomescover layer 12, is pressed against theassembly roll 102 by turning roll 104. A second continuous web, which ultimately becomesbody side layer 14, passes under adhesive applicator 106 and over turning rolls 108 and 110, and is pressed against theassembly roll 102 by turningroll 110.Elastic threads 112 are fed from acontinuous supply 114 of elastic thread through feed nip 116, through thread guides 118 and sets ofguide fingers 120A and 120B, and betweencover layer 12 andbody side layer 14 at the nip formed byassembly roll 102 and turningroll 110. - Referring especially to
FIGS. 10 and 11 , thread guides 118 and corresponding sets ofguide fingers 120A and 120B are elements oflateral guides 122A and 122B respectively. Each of the lateral guides 122A and 122B is mounted on atransverse slide bar 124 for sliding transverse to the with machine direction of travel of the webs. Eachlateral guide 122 is connected to atransverse drive mechanism 126 includinglinkage arms vertical drive shaft 132, and a cam follower. The cam followers follow the corresponding cams inside the respective cam housings. The cams are linked to themachine drive shaft 140 bydrive belt 142. Thus, the cams, and correspondingly the thread guides and the sets of guide fingers, move transversely with respect to the with machine direction of the webs as the drive shaft turns. The end result is that rotation of the processingline drive shaft 140 effects transverse motion of the thread guides and the sets of guide fingers, as indicated by the arrows inFIG. 10 , in cooperation with the design of the cams and cam followers. - Referring to
FIG. 8 , theguide fingers 120 are positioned close to the nip 144 so that they closely control the transverse positions of the elastics with respect to thewebs webs guide fingers 120 are preferably physically positioned, and provide guidance to the threads of elastic, within one inch of the nip 144. To the extent the fingers can be placed closer to the nip 144, they provide more positive guidance to the elastic. By careful design of theguide fingers 120, and by careful control of the positioning of theguide fingers 120 with respect to nip 144, theguide fingers 120 can be advantageously positioned within 0.5 inch of the line of contact defined at the nip betweenroll 102 and 108. - The limitation on how close the
guide fingers 120 can be placed to the nip is controlled by the ability to design fingers which can affirmatively guide the threads of elastic while avoiding having the fingers themselves drawn into the nip. The criticality of urging the fingers as ultimately close as possible to the nip can be attenuated by directing thethreads 112 onto the adhesive-coatedlayer 14 ahead of nip 144, preferably instantaneously ahead of the nip 144, as suggested by the depiction inFIG. 8 . By directing the threads of elastic ontolayer 14 ahead of the nip, the open distance spanned by the threads between thefingers 120 and the adhesive-coatedlayer 14 is minimized, being held to less than 0.5 inch, for example 0.25-0.375 inch (6 mm to 10 mm). - The transverse movement of the lateral guides 122, and thus
fingers 120, as the webs advance along the processing line, creates transverse positioning of theelastics threads 112 with respect to the with machine direction of the advancingwebs FIG. 11 shows the pattern of transverse movement of the sets ofguide fingers 120A and 120B relative to the movement of the web in the with machine direction, along the processing line. InFIG. 11 , the sets offingers 120A and 120B are depicted at several locations along the front and back edges of theleg openings fingers 120A and 120B, and the dynamic changing of that positioning by thedrive mechanism 126, that determines the instantaneous transverse location of the elastics in the web at any point and time while the elastics are being placed in the web at nip 144 as shown inFIGS. 8-11 . ComparingFIGS. 1 , 10, and 11, it is seen that the set offingers 120A generally places the threads of the back leg elastics generally parallel to each other in the web, while the set of fingers 120B generally places the threads of the front leg elastics generally parallel to each other in the web, both along their respective portions of the designed paths defining the front 70 and back 74 edges of theleg openings fingers 120. Such deviations from the parallel, resulting from the cross machine traverse of the elastics, are included herein within the phrase “generally parallel” as respects the relationships of the threads of elastic to each other. - It will be understood that
FIG. 11 represents only one panty in the continuous sequence of panty subassemblies 10 contained in theweb 100 passing through nip 144. It will also be understood that the web passing through the nip 144 is further acted upon atcutter 146 to cut away material from theweb 100 in creating theleg openings - In general, then,
webs Web 14 is typically provided as front and backlayer elements Space 23 separates theelements web 12 which is cut out to formleg openings back elements web 14 by adhesive applicator 106.Webs webs space 23 interposed between the front andback elements body side layer 14. The transverse positions of the elastics change according to a pre-set path of transverse movements, driven by thedrive shaft 140 which drives and times the several operations along the processing line. The threads of elastic 112, as placed by theguide fingers 120, traverse respective paths that ultimately follow the front and back edges of theleg openings cutter 146, in registration with the advance of the web, and accordingly, with the advance of the series of panty subassemblies 10 being defined in the web at nip 144 andcutter 146. The portions of the threads of elastic located along the front and back edges of the leg openings are stretched. The portions traversing the crotch portion are relaxed. The crotch portions of the elastic are separately placed in the subassembly 10 at a later processing station, preferably downstream from thecutter 146. - A second embodiment of the subassembly is illustrated in
FIG. 12 . In the second embodiment, thefront edge 148 ofback layer element 21 is disposed rearwardly of thatsame edge 148 as depicted in the embodiment ofFIG. 10 , while theguide fingers 120A traverse the same path as inFIG. 10 . Accordingly, as the threads of elastic 112 extend across thecrotch portion 24, thethreads 112 are guided forwardly ofedge 148, intospace 23, and are thus not held between thelayers layer 14. Rather, the tension is maintained on the threads of elastic 112 across thecrotch portion 24, such that the threads retract along theedge 148 of thelayer element 21 in a configuration that loosely resembles a rope under tension. The rope is subsequently cut such that the cut portions of the threads retract to positions generally defined by the intersection of theedge 148 of theback layer element 21 and the path of the threads adhesively held betweenlayer 12 and theback layer element 21. Thus, thethreads 112 generally include loose intermediate ends 150 after being cut, as shown inFIG. 7 . -
Body elastics 64 and waist elastics 40 can be incorporated at nip 144 in the conventional manner of providing stationary feeds and guides at the nip. - In another embodiment of the invention shown in
FIG. 13 , a section ofweb processing equipment 297 is shown including a drive side DS and an operator side OS. As generally shown, a plurality ofelastic threads 212 are attached to a stain shield or secondaryabsorbent web 267, and thesecondary absorbent 267 and attachedelastic threads 212 are cut to create a plurality of stain shields 268 having respective elastic pieces orsections 251A attached thereto. The elasticized stain shields 268 are maneuvered as shown and attached to agarment web 201 to form a garment blank subassembly. This garment blank subassembly is similar in many ways to the embodiments described above; therefore, only certain features of this embodiment are described below for the sake of brevity and reference is made to the foregoing descriptions for like or similar components of the garment blank subassembly to enable this aspect of the invention. - With more particular reference to
FIG. 13 , theprocessing equipment 297 supplies the plurality ofelastic threads 212 from anelastic thread roll 214 generally in a machine direction MD. Theelastic threads 212 are routed by a series of guide rollers G in a known manner and are attached in a stretched condition in a non-machine direction (NMD) in this example to the secondaryabsorbent web 267 using an adhesive 255A. As shown, the adhesive 255A is applied intermittently to theelastic threads 212 by a plurality ofapplicators 206A to form a plurality ofadhesive gaps 213 along theelastic threads 212. Thecutter 246 cuts the secondaryabsorbent web 267 into the stain shields 268 at eachadhesive gap 213. As further shown, thestain shield 268 theresultant sections 251A are attached to a first orinner side 268B, which opposes a second orouter side 268A discussed further below. - The
exemplary cutter 246 shown inFIG. 13 is a roller cutter having a plurality of blades 246A,B attached thereto for cutting theelastic sections 251A at theadhesive gaps 213 as discussed above. Thecutter 246 is controlled by acontroller 299 disposed on the operator side OS of theprocessing equipment 297 in this example. Those skilled in the art will instantly recognize that thecontroller 299 can be a computer or a programmable logic controller, which can be programmed to cut theelastic threads 212 at theadhesive gaps 213 based on a passage of time or a sensed length of passingelastic threads 212 to create thesections 251A. As shown, each end of eachsection 251A, which formed thegaps 213 in theelastic threads 212 before theelastic threads 212 were cut, retract after being cut to create a retraction area 268C on theouter side 268B. In this example, thesections 251A are from about one (1) inch to about three (3) inches in length. - As further shown in
FIG. 13 , a secondadhesive applicator 206B applies a second amount of adhesive 255B to theouter sides 268B of the stain shields 268. As shown, a plurality of applicator assembly segments 297A-D subsequently maneuver or rotate the adhesive coated stain shields 268 transverse to the machine direction MD. As further shown, the applicator assembly segments 297A-D affix the adhesive coatedouter sides 268B and the underlyingelastic sections 251A to thegarment web 201 with theinner sides 268A facing upward or outward from within a crotch area orportion 224. As shown, theinner sides 268A are located between a plurality ofgarment elastics 251B. In this manner, the individualelastic sections 251A are rapidly manipulated, positioned and attached to thecrotch area 224 without having to maneuver theentire garment web 201 and/or cut theelastic threads 212 and apply theelastic sections 251A to thecrotch portions 224 through acute angles at high machine speeds. - Wherever herein this teaching refers to “multiple” elements, e.g. multiple threads of elastic or multiple paths of traverse, any two or more such elements are included.
- Having thus described the invention in full detail, it will be readily apparent that various changes and modifications may be made without departing from the spirit of the invention. All such changes and modifications are contemplated as being within the scope of the present invention, as defined by the following claims.
Claims (16)
1. A disposable garment comprising:
a front body portion, a back body portion, and a crotch portion in between the front body portion and the back body portion, the front body portion and the back body portion being connected together to form a waist opening, a first leg opening, and a second leg opening, the first leg opening being surrounded by a first front leg edge portion, a first back leg edge portion, and a first crotch leg edge portion positioned in between the first front leg edge portion and the first back leg edge portion, the second leg opening being surrounded by a second front leg edge portion, a second back leg edge portion, and second crotch leg edge portion positioned in between the second front leg edge portion and the second back leg edge portion;
an absorbent located at least within the crotch portion;
an elastic having a first end near a first outer edge of one of the body portions and extending along the first leg edge portion and the second leg edge portion to a second end near a second outer edge of the same body portion, the elastic having been cut to form a first intermediate end spaced from a second intermediate end; and
a plurality of opposing crotch elastics extendably affixed to opposing edges of the crotch portion on each side of the crotch portion.
2. The disposable garment of claim 1 , having a second elastic having a first end near a first outer edge of the body portion free of the first elastic and extending along the first leg edge portion and the second leg edge portion to a second end near a second outer edge of the same body portion, the second elastic having been cut to form a first intermediate end spaced from a second intermediate end.
3. A disposable garment as in claim 1 , wherein the intermediate ends are retracted.
4. A disposable garment as in claim 3 , wherein the retracted intermediate ends are free from adhesive.
5. A disposable garment as in claim 2 , wherein the first and second elastics have been cut into a plurality of elastic sections.
6. A disposable garment as in claim 1 , wherein the waist opening is surrounded at least in part by a waist elastic.
7. A disposable garment as in claim 6 , wherein the waist elastic comprises threads, ribbons, a film, or a composite.
8. A disposable garment as in claim 1 , wherein the front body portion and the back body portion include body elastics positioned between the waist opening and the leg openings.
9. A disposable garment as in claim 1 , wherein the garment defines a length direction and a width direction transverse to the length direction, wherein the crotch elastics extendably affixed to opposing edges of the crotch portion extend in the length direction of the garment.
10. A disposable garment as in claim 1 , wherein the garment defines a length direction and a width direction transverse to the length direction, wherein the crotch portion is free from continuous elastics spanning the width direction of the garment.
11. A disposable garment as in claim 1 , wherein the opposing crotch elastics and the first and second elastics overlap.
12. A disposable garment as in claim 1 , wherein the garment has a body side liner positioned to face the wearer.
13. A disposable garment as in claim 12 , wherein the body side liner comprises a front body portion element and a back body portion element which are separate from one another.
14. A disposable garment as in claim 1 , wherein the intermediate ends are adjacent the crotch portion.
15. A disposable garment as in claim 1 , wherein the intermediate ends extend over the crotch portion.
16. A disposable garment as in claim 2 , wherein at least one of the first or second elastic is angled with respect to a longitudinal centerline of the disposable garment.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/835,296 US20130211365A1 (en) | 1995-01-31 | 2013-03-15 | Disposable Undergarment and Related Manufacturing Equipment and Processes |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
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US08/382,108 US5745922A (en) | 1995-01-31 | 1995-01-31 | Disposable garment and related manufacturing equipment and methods |
US08/937,225 US6049916A (en) | 1995-01-31 | 1997-09-11 | Disposable garment |
US54823100A | 2000-04-12 | 2000-04-12 | |
US11/240,262 US20060064069A1 (en) | 2000-04-12 | 2005-09-30 | Disposable undergarment and related manufacturing equipment and processes |
US12/913,362 US8622984B2 (en) | 1995-01-31 | 2010-10-27 | Disposable undergarment and related manufacturing equipment and processes |
US13/835,296 US20130211365A1 (en) | 1995-01-31 | 2013-03-15 | Disposable Undergarment and Related Manufacturing Equipment and Processes |
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Application Number | Title | Priority Date | Filing Date |
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US12/913,362 Division US8622984B2 (en) | 1995-01-31 | 2010-10-27 | Disposable undergarment and related manufacturing equipment and processes |
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US20130211365A1 true US20130211365A1 (en) | 2013-08-15 |
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Application Number | Title | Priority Date | Filing Date |
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US11/240,262 Abandoned US20060064069A1 (en) | 1995-01-31 | 2005-09-30 | Disposable undergarment and related manufacturing equipment and processes |
US12/913,362 Expired - Fee Related US8622984B2 (en) | 1995-01-31 | 2010-10-27 | Disposable undergarment and related manufacturing equipment and processes |
US12/913,334 Expired - Fee Related US8142590B2 (en) | 1995-01-31 | 2010-10-27 | Method of manufacturing a disposable undergarment |
US13/835,296 Abandoned US20130211365A1 (en) | 1995-01-31 | 2013-03-15 | Disposable Undergarment and Related Manufacturing Equipment and Processes |
Family Applications Before (3)
Application Number | Title | Priority Date | Filing Date |
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US11/240,262 Abandoned US20060064069A1 (en) | 1995-01-31 | 2005-09-30 | Disposable undergarment and related manufacturing equipment and processes |
US12/913,362 Expired - Fee Related US8622984B2 (en) | 1995-01-31 | 2010-10-27 | Disposable undergarment and related manufacturing equipment and processes |
US12/913,334 Expired - Fee Related US8142590B2 (en) | 1995-01-31 | 2010-10-27 | Method of manufacturing a disposable undergarment |
Country Status (2)
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WO (1) | WO2007040895A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
US8622984B2 (en) | 2014-01-07 |
US20110036487A1 (en) | 2011-02-17 |
US8142590B2 (en) | 2012-03-27 |
WO2007040895A1 (en) | 2007-04-12 |
US20110040277A1 (en) | 2011-02-17 |
US20060064069A1 (en) | 2006-03-23 |
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