Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
2002-01-03
2003-11-11
Sells, James (Department: 1734)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S209000, C156S359000, C156S580200
Reexamination Certificate
active
06645330
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to disposable absorbent articles, and more particularly to disposable absorbent articles having graphics thereon. The invention also relates to processes and apparatus for making absorbent articles having graphics thereon whereby the graphics are made using ultrasonic thermal imaging methods.
2. Description of Related Art
Absorbent articles, and in particular disposable absorbent articles such as infant diapers or training pants, adult incontinence products and other such products, typically are constructed with a moisture-impervious outer backing sheet (or “backsheet”), a moisture-pervious body-contacting inner liner sheet (or “topsheet”), and a moisture-absorbent core (or “absorbent core”) sandwiched between the liner sheet and the backing sheets. These disposable absorbent articles oftentimes include additional features such as elastic waist bands, elastic leg bands, and stretchable side panels. Further, decorative graphics can be incorporated into the disposable absorbent article for aesthetic and functional purposes.
Disposable absorbent articles generally are assembled on an automated production line by separately supplying the individual components of the absorbent article to the production line at predetermined locations along the machine direction, and layering the individual components to form an integrated absorbent article. Various methods are available for bringing these individual components together so that the components in the integrated product are in a desired relation with respect to each other. In bringing these individual components together, various known methods have been used to sense the position of a particular component, and then to adjust the placement of subsequent components in order to properly position them with respect to the previously sensed component. Proper placement of the components is even more important when one or more component(s) have graphics or other identifying marks printed or embossed thereon.
U.S. Pat. Nos. 5,286,543 and 5,235,515 to Ungpiyakul et al. disclose a system for selectively providing predetermined segments of web material that have printed graphics to an absorbent article production line using a reference marker that is incorporated into the final assembled absorbent article. Generally stated, the method includes supplying the web material at a web speed and sensing a reference mark on the web material to generate at least one reference mark datum which is associated with a selected web segment. The '543 Patent discloses that the predetermined segments of web material comprise discrete graphic patches corresponding to the tape landing zone of the diaper. The patch is said to have a predetermined set of graphics which are “congruously entire.” The patches are also said to abruptly change from graphics set to graphics set and, therefore, from diaper to diaper because there is no modulating transition between the adjacent compositions formed on the original supply roll of web material. The patches are said to be provided with reference markers delineating the boundaries between individual web or patch segments. The reference markers comprise any signaling mechanism which is recognizable by a machine.
U.S. Pat. No. 5,766,389 to Brandon et al. discloses a process for controllably registering a plurality of components of a continuously moving first layer with a plurality of reference marks on a continuously moving second layer with pre-printed graphics. Brandon is said to controllably register a graphic within a designated area of the absorbent article. The '543 patent and Brandon both require transfer of a graphic from one supply of web material to the absorbent garment by cutting and placing the supply of web material including the graphic(s) on the absorbent garment.
Embossed plastic films are known in the art and are used as a substitute for textiles. Embossed films may be used for many different purposes such as diaper liners, panty liners and sanitary napkins. Examples of embossed films are disclosed in U.S. Pat. Nos. 3,911,187, 4,518,643, and 5,229,186, the disclosures of each of which are incorporated by reference herein in their entirety, and in a manner consistent with this disclosure. Embossing typically is used to alter the “feel” or “hand” of the fabric, and to add a decorative design. Different methods for embossing non-woven fabrics and films are known, some of which are designed primarily to alter the strength properties of the fabric, as disclosed in U.S. Pat. No. 4,592,943, the disclosure of which is incorporated by reference herein in its entirety. The '943 patent discloses heating a non-woven web as it passes between two grids so that the grids impart a pattern of rectangular densified areas to the web. Another method referred to as pattern roll embossing is disclosed in U.S. Pat. No. 4,774,124, the disclosure of which is incorporated by reference herein in its entirety, which discloses using a pair of pattern rollers to emboss non-woven fabric. Patterned and embossed non-woven materials also are described in U.S. Pat. No. 5,599,420, the disclosure of which is incorporated by reference herein in its entirety, and in a manner consistent with this disclosure. The '420 patent discloses a non-woven fabric comprising continuous polymeric filaments extending continuously along the length of the fabric that are bonded together with a heat-activated adhesive. Upon embossing, the fabric is said to have a pattern of densified areas separated by high loft areas.
Thermoplastic films have been bonded to one another with ultrasonic energy using embossed patterns or pins. Ultrasonic bonding and embossing techniques are disclosed in, for example, U.S. Pat. No. 3,562,041 (ultrasonic joining of materials according to a pattern), U.S. Pat. No. 3,733,238 (vibration welding of sheet materials), U.S. Pat. No. 4,668,316 (welding thin thermoplastic film by ultrasonic energy), U.S. Pat. No. 5,096,532 (ultrasonic rotary horn), U.S. Pat. No. 5,110,403 (high efficiency ultrasonic rotary horn), U.S. Pat. No. 5,846,377 (welding thermoplastic work pieces using ultrasonic energy), U.S. Pat. No. 6,036,796 (ultrasonic welding apparatus and method), U.S. Pat. No. 6,165,298 (patterned anvil roll to effect bonding, cutting, embossing, perforating), and U.S. Pat. No. 6,277,224 (ultrasonic perforator), the disclosures of each of which are incorporated by reference herein in their entirety. It also is known to use heated rolls to thermally emboss a web of material, as disclosed, for example, in U.S. Pat. Nos. 5,229,186 and 6,041,701, the disclosures of each of which are incorporated by reference herein in their entirety.
It also is common to use inks, e.g., adhesive inks, to form an image on a non-woven fabric. U.S. Pat. No. 5,503,076, the disclosures of which is incorporated by reference herein in its entirety, and in a manner consistent with this disclosure, discloses laminating a non-woven web facing layer and a substrate layer with colored adhesive inks that are applied in a discrete bond pattern. Thermal imaging techniques useful in forming images on various substrates are disclosed in, for example, U.S. Pat. Nos. 5,716,477 and 6,117,562, the disclosures of each of which are incorporated by reference herein in their entirety, and in a manner consistent with this disclosure.
SUMMARY OF THE INVENTION
It would be desirable to provide an absorbent garment having a graphic formed thereon, whereby the image can be formed on the backsheet or outer liner in-line during manufacture of the article. It also would be desirable to provide a method of forming a viewable image on an absorbent article that is cost efficient and easy to carry out. It would further be desirable to provide a method of forming an image on a moving web of material that is efficient, can operate at high line speeds, does not damage the moving web when the system shuts down, and that enables a more precise application of heat.
Accordingly, it is a feature of an embodiment
Pargass Sunita
Vergona Joseph
Hunton & Williams
Paragon Trade Brands, Inc.
Sells James
LandOfFree
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