Metal working – Method of mechanical manufacture – Assembling or joining
Reexamination Certificate
2001-05-15
2002-12-24
Ball, Michael W. (Department: 1733)
Metal working
Method of mechanical manufacture
Assembling or joining
C156S226000, C156S227000
Reexamination Certificate
active
06497032
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention pertains to processes and apparatus for making garments, and more particularly to processes and apparatus for folding and bonding disposable absorbent garments.
Garments such as disposable absorbent garments have numerous applications including diapers, training pants, feminine care products, and adult incontinence products. The typical disposable absorbent garment is formed as a composite structure including an absorbent assembly disposed between a liquid permeable bodyside liner and a liquid impermeable outer cover. These components can be combined with other materials and features such as elastic materials and containment structures to form a product that is specifically suited to its intended purposes.
One form of disposable absorbent garment is a two-dimensional product that has open sides. Two-dimensional products, such as conventional diapers and some adult incontinence products, are generally flat and provided in an unfastened configuration. These garments have typically included fasteners such as adhesive tape fasteners or hook and loop type fasteners that releasably connect the front and back waist portions to secure the product about the wearer. Two-dimensional product can be easily applied or removed while the wearer is lying down.
Another form of disposable absorbent garment is a three-dimensional product with closed sides so that the product has a unitary waist opening and two leg openings. The wearer raises and lowers the garment to apply the product. Three-dimensional products are particularly appealing because the pant has a very garment-like look. Children for instance identify diaper products with babies, and most children do not like being identified with or as babies. Consequently, these children do not want to wear baby diapers, and instead prefer to wear training pants that look like adult underwear. Thus, the switch from a traditional diaper to a more garment-like or underwear-like training pant can be an important step in the toilet training process. Similarly, adults seeking the protection of incontinence products prefer the normalcy of a pant product rather than an incontinence product that must be applied in another fashion. Three-dimensional garments have been designed such that they can be torn to remove the garment from the wearer after it has been soiled.
Recently, prefastened and refastenable disposable absorbent garments have been proposed to provide the advantages of both two-dimensional and three-dimensional products. Prefastened and refastenable products can be applied and/or removed either like a conventional diaper or like a conventional training pant. For use as training pants, for example, there may be times when it would be useful to apply the product like a diaper. For instance, it might be more convenient to apply the product like a diaper when there is a desire not to remove the child's shoes. Because it is difficult to know when a particular mode of applying the garment will be needed, it is beneficial to have a garment that is adaptable to being used either as a diaper or as a pant. This is preferable to keeping both types of garments available. A product that can be applied like either a diaper or a pant permits the interior of the product to be easily checked without having to pull the product downward.
Disposable absorbent products present many manufacturing challenges. In part, this is due to the high speed that is necessary to economically produce relatively low cost disposable absorbent products. Further, prefastened and refastenable garments present new challenges for high speed manufacturing. Such products must incorporate refastenable fasteners that are properly aligned and engaged. Improperly attached or aligned fasteners can lead to many product deficiencies, including machine waste and/or delay, improper fit, fastener delamination during use, fastener disengagement during use, skin irritation, or the like.
Thus, what is lacking and needed in the art are improved processes and apparatus for folding and bonding disposable absorbent garments, including prefastened disposable absorbent garments.
SUMMARY OF THE INVENTION
In response to the above-referenced unfulfilled need in the art, new processes and apparatus for folding and bonding disposable absorbent garments, including prefastened disposable absorbent garments, have been discovered. One aspect of the invention concerns a process for making a prefastened and refastenable garment. The process comprises transporting a discrete article in a primary direction of movement. The discrete article defines a leading half comprising first fastening components, a trailing half comprising second fastening components releasably engageable with the first fastening components, and an interconnecting region disposed between and interconnecting the leading and trailing halves. The leading half is temporarily diverted from the primary direction of movement while continuing to transport the interconnecting region and the trailing half in the primary direction of movement. Movement of the leading half in the primary direction of movement is reestablished. The method also comprises contacting the leading half with a contoured surface, such that the first fastening components are transversely displaced toward one another. The transversely displaced first fastening components can be moved into contact with the second fastening components.
In another embodiment, the process for making a prefastened and refastenable garment comprises: transporting a discrete article on a primary transport surface in a primary direction of movement; drawing the leading half onto a secondary transport surface traveling in a secondary direction of movement divergent from the primary direction of movement while continuing to transport the interconnecting region and the trailing half in the primary direction of movement; releasing the leading half from the secondary transport surface; contacting the leading half with a contoured surface, wherein the first fastening components are transversely displaced toward one another; and pressing the leading and trailing halves together with the transversely displaced first fastening components releasably engaging the second fastening components.
In another embodiment, a process for making prefastened and refastenable garments comprises: providing main and secondary folding drums in close proximity to one another and defining a tangent point therebetween; rotating the main and secondary folding drums in opposite directions; introducing a plurality of discrete articles onto the main folding drum, each discrete article defining a leading half comprising first fastening components, a trailing half comprising second fastening components releasably engageable with the first fastening components, and an interconnecting region disposed between and interconnecting the leading and trailing halves; drawing the leading half of a discrete article onto the secondary folding drum as the leading half passes the tangent point, and continuing to transport the interconnecting region and the trailing half on the main folding drum; releasing the leading half from the secondary folding drum such that the interconnecting region remains on the main folding drum; contacting the leading half with a contoured surface, wherein the first fastening components are transversely displaced toward one another; and pressing the leading and trailing halves together with the transversely displaced first fastening components releasably engaging the second fastening components.
Through contact with the contoured surface, the distance between the first fastening components can be reduced from an initial distance to a post displacement distance. The post displacement distance can correspond to the distance between the second fastening components. In particular embodiments, side panels of the trailing half can be folded to invert the second fastening components and reduce the distance between the second fastening components to a post inversion distance. The post
Clemmensen Megan Elizabeth
Maxton David Albert
Pettit Chris Alan
Shimon Steven John
Ball Michael W.
Gage Thomas M.
Kimberly--Clark Worldwide, Inc.
Musser Barbara J
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