AN ARRAY OF PANT-TYPE ARTICLES, AND A METHOD OF PRODUCING PANT-TYPE ARTICLES IN AN ARRAY OF PANT-TYPE ARTICLES
20210307969 · 2021-10-07
Assignee
Inventors
Cpc classification
A61F13/15699
HUMAN NECESSITIES
A61F13/15747
HUMAN NECESSITIES
International classification
Abstract
A method for producing an array of disposable pant-type articles, the array including at least a first and a second pant-type article having different sizes. The method includes a number of different processes corresponding to the number of pant-type articles in the array wherein all processes involve forming a stretchbonded laminate web comprising a continuous elastic web and a non-elastic or less elastic web, forming a composite web of precursor articles including the stretchbonded laminate web and separating individual pant-type articles from the composite web by severing the composite web at side joins formed between the precursor articles. In the different processes, the continuous elastic web differs between the different processes with regard to elastic properties while a pitch length of the stretchbonded elastic laminate web is the same in all continuous processes of the method. Also, an array of pant-type articles which may be produced by the method.
Claims
1. An array of pant-type articles, such as an array of absorbent pant-type articles including an absorbent core, said array of pant-type articles including a first pant-type article and a second pant-type article, each said first pant-type article and said second pant-type article comprising a chassis, said chassis comprising a front panel, a back panel and a crotch portion between said front and back panels, said front panel having a waist edge and a pair of side edges, and said back panel having a waist edge and a pair of side edges, said side edges of said front and back panels being joined in a first and a second side seam, whereby said pant-type article has a waist opening and a first and a second leg opening, wherein each said first pant-type article and said second pant-type article comprises a stretchbonded elastic laminate web comprising an elastic web and an in-elastic or less elastic web, said elastic web of said first pant-type article differing from said elastic web of said second pant-type article in at least one or more aspects selected from: physical structure; polymer composition; basis weight; thickness; permanent set; degree of orientation in a machine direction of said elastic web, said stretchbonded elastic laminate web extending from said first side seam to said second side seam over at least a part of said front panel and/or of said back panel of said chassis, wherein: a body portion circumference at 10 Newton of said first pant-type article in said array is at least 20% larger than a body portion circumference of said second pant-type article in said array at 10 Newton, a body portion circumference at 30 Newton of said first pant-type article in said array is at least 20% larger than a body portion circumference of said second pant-type article in said array at 30 Newton, and a body portion circumference at 90 Newton of said first pant-type article in said array is less than 10% larger than a body portion circumference of said second pant-type article in said array at 90 Newton as measured by the body portion circumference test as disclosed herein.
2. The array of pant-type articles according to claim 1, wherein said stretchbonded elastic laminate web constitutes a sole component of said chassis in in 20%-100% of a total surface area of said pant-type article, as seen in a flat state.
3. The array of pant-type articles according to claim 1, wherein each said first pant-type article and said second pant-type article comprises a two-piece chassis.
4. The array of pant-type articles according to claim 1, wherein each said first pant-type article and said second pant-type article comprises a unitary chassis.
5. A method for producing pant-type articles for an array of pant-type articles, said array of pant-type articles comprising a first pant-type article and a second pant-type article, said first and second pant-type articles differing in size, wherein said method comprises a first continuous process for producing said first pant-type article and a second continuous process for producing said second pant-type article, each said first and second continuous process including: providing a continuous elastic web and moving said continuous elastic web in a machine direction, said continuous elastic web being elastically stretchable in said machine direction; stretching said continuous elastic web in said machine direction; bonding said stretched continuous elastic web while held in said stretched state to a non-elastic or less elastic web to form a stretchbonded elastic laminate web; forming a composite web of article components, said composite web constituting a continuous web having leg openings arranged therein and consisting of interconnected precursor articles, said composite web comprising said stretchbonded elastic laminate web as a chassis component; folding said composite web along a fold line extending along said composite web in said machine direction; forming side joins in said folded composite web; and separating individual pant-type articles from said composite web by severing said composite web at said side joins, wherein said continuous elastic web in said first continuous process is different from said continuous elastic web in said second continuous process in one or more aspects selected from: physical structure polymer composition; basis weight; thickness; permanent set; degree of orientation in said machine direction of said elastic web; and wherein a pitch length of said stretchbonded elastic laminate web is the same in said first continuous process and said second continuous process.
6. The method according to claim 5, wherein forming said composite web of article components comprises: moving said stretchbonded elastic laminate web as a first continuous web in said machine direction alongside a second continuous web arranged at a distance from said first continuous web in a cross machine direction perpendicular to said machine direction with a gap between said first continuous web and said second continuous web; intermittently connecting said first continuous web with said second continuous web by attaching a crotch material to said first continuous web and to said second continuous web, said crotch material bridging said gap between said first continuous web and said second continuous web, wherein said second continuous web is a non-elastic or elastic web.
7. The method according to claim 5, wherein forming said composite web of article components comprises: moving said stretchbonded elastic laminate web in said machine direction; intermittently cutting out leg openings in said stretchbonded elastic laminate web.
8. The method according to claim 5, wherein said elastic web is stretched in said machine direction by at least 90% of an initial non-stretched length during stretch-bonding.
9. The method according to claim 5, wherein said stretched elastic web is bonded to said non-elastic or less elastic web by means of adhesive that is applied to one or both webs by means of coating, spraying, extrusion or meltblowing, or that said stretched elastic web is bonded to said non-elastic or less elastic web by means of ultrasonic welding or thermobonding.
10. The method according to claim 5, wherein said article components include one or more of: an absorbent core or core insert; a waist elastic member; a leg elastic member; an inner liner; an acquisition layer; a barrier layer; a barrier cuff; and a fastener element.
11. The method according to claim 5, wherein said continuous elastic web comprises an elastic film, and/or wherein said non-elastic or less elastic web is a nonwoven web.
12. The method according to claim 11, wherein said continuous elastic web is a laminate comprising an elastic film and a nonwoven web.
13. An array of pant-type articles, such as an array of absorbent pant-type articles including an absorbent core, said array of pant-type articles including a first pant-type article and a second pant-type article, wherein said array of pant-type articles is produced according to the method of claim 5 and wherein said first pant-type article differs in size from that of said second pant-type article.
14. The array of pant-type articles according to claim 13, wherein: a body portion circumference at 10 Newton of said first pant-type article in said array is at least 20% larger than a body portion circumference of said second pant-type article in said array at 10 Newton, a body portion circumference at 30 Newton of said first pant-type article in said array is at least 20% larger than a body portion circumference of said second pant-type article in said array at 30 Newton, and a body portion circumference at 90 Newton of said first pant-type article in said array is less than 10% larger than a body portion circumference of said second pant-type article in said array at 90 Newton as measured by the body portion circumference test as disclosed herein.
15. The array of pant-type articles according to claim 1, wherein a body portion circumference at 90 Newton of said first pant-type article in said array is less than 5% larger than a body portion circumference of said second pant-type article in said array at 90 Newton as measured by the body portion circumference test as disclosed herein.
16. The array of pant-type articles according to claim 1, wherein said stretchbonded elastic laminate web constitutes a sole component of said chassis in in 40%-100% of a total surface area of said pant-type article, as seen in a flat state.
17. The array of pant-type articles according to claim 1, wherein the first pants-type article and the second pants-type article are each produced with a pitch length of said stretchbonded elastic laminate web that is the same.
18. The method according to claim 5, wherein said elastic web is stretched in said machine direction by at least 300% of an initial non-stretched length during stretch-bonding.
19. The method according to claim 5, wherein said continuous elastic web consists of a breathable elastic film, and wherein said non-elastic or less elastic web is a nonwoven web.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0081] The present invention will be further explained hereinafter by means of non-limiting examples and with reference to the appended drawings wherein:
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DETAILED DESCRIPTION
[0089] It is to be understood that the drawings are schematic and that individual components, such as layers of material are not necessarily drawn to scale. The disposable pant-type absorbent article shown in the figures is provided as an example only and should not be considered limiting to the invention as disclosed herein. As set out herein, the method of producing different sized pant type articles is applicable also to non-absorbent articles and reusable pant-type articles or articles which can be laundered and reused a limited number of times. Reusable articles which may withstand laundering may be non-absorbent pant-type articles e.g. pant-type articles which are adapted for use together sin an absorbent insert.
[0090] Furthermore, the construction of the pant-type articles may be different from those shown in connection with the figures. As set out herein, an alternative construction of a unitary chassis may comprise a single continuous outer cover sheet, and/or a continuous inner liner and an elastic panel webs joined to one or both of the front and back part of the chassis to form an elastic front or back panel, respectively.
[0091] The pant-type articles shown in the figures are simplified articles, and it should be understood that they may be enhanced with elastic elements arranged at the leg openings on one or more of the front panel, the back panel and in the crotch portion. Further elastification may be provided e.g. in the form of barrier cuffs. It is also to be understood that the waist elastic disclosed in connection with
[0092] The pant-type absorbent article 1 shown in
[0093] The pant-type absorbent article 1 which is schematically shown in
[0094] At least one of the front panel 3 and the back panel 4, and preferably both the front panel 3 and the back panel 4 are formed from a stretch bonded laminate as produced in the continuous processes of the method for forming an array of pant-type articles as disclosed herein.
[0095] In
[0096] The unitary chassis 9″ including the front panel 3, the back panel 4 and the interconnecting crotch portion 10 is fully or partly formed from a stretch bonded laminate as produced in the continuous processes of the method for forming an array of pant-type articles as disclosed herein.
[0097] At least one and preferably both of the front panel 3 and the back panel 4 in the example of
[0098] The material in the front and back panels 3, 4 in the unitary chassis in the article in
[0099] The shape of the front and back panels 3, 4 may be varied to fit a particular category of user. For example, one or both of the front panel and the back panels 3, 4 may have a substantially rectangular shape. Moreover, a leg edge region of the front and/or back panels 3, 4 may have a curved shape adapted to provide better conformance to a leg. As is illustrated in
[0100] As described herein, an objective with the present disclosure is to provide an array of absorbent articles in at least two sizes, for the purpose of providing absorbent articles with increased comfort and fit as well as discrete underwear-like visual appearance, while taking into account anatomical and size differences between different users, and while also maintaining a low manufacturing cost.
[0101] The method as disclosed herein is a method for producing an array of disposable pant-type articles comprising at least a first pant-type article and a second pant-type article having different size. The method comprises a number of different processes corresponding to the number of pant-type articles in the array, all processes involving forming a stretchbonded laminate web comprising a continuous elastic web and at least one non-elastic or less elastic web, forming a composite web of interconnected precursor articles comprising the stretchbonded laminate web and separating individual pant-type articles from the composite web by severing the composite web at side joins formed between the precursor articles.
[0102] In the different processes comprised in the method, the continuous elastic web differs between the different processes with regard to elastic properties while a pitch length of the stretchbonded elastic laminate web (31) is the same in all continuous processes of the method.
[0103] With reference to
[0104] The stretchbonded elastic laminate web may be composed of first and second outer layers of fibrous material and an elastic film located between the fibrous layers. The stretchbonded elastic laminate web may comprise one or more additional fibrous layers laminated to one or both of the first and second fibrous layers. Such additional fibrous layers may be present only in parts of the elastic laminate. Thus the elastic laminate need not be identical all over its area, but may comprise different layers in different areas.
[0105] It may be preferred that a continuous elastic web in the form of an elastic film is provided with fibrous nonwoven webs on both surfaces of the film. As disclosed herein, a stretchbonded nonwoven-film-nonwoven laminate web may alternatively be produced e.g. by stretchbonding a nonwoven web to an elastically stretchable bi-laminate of a nonwoven web and an elastic film which has been produced by other methods than stretchbonding, e.g. involving incremental stretching.
[0106] A stretchbonded elastic laminate web 31 having outer fibrous nonwoven layers is highly suitable for being arranged as an outside coversheet material as well as an inner coversheet material over at least part of the front panel, the back panel and the crotch portion of the chassis of the pant-type articles as disclosed herein. The stretchbonded elastic laminate web may constitute the sole component of the chassis in at least 20%, preferably at least 25%, more preferably at least 30% and most preferably at least 40% of the total surface area of the pant-type article, as seen in a flat state.
[0107] The elastic laminate may be absent in all or a substantial part of the crotch portion of the article. A crotch panel material may underlie at least part of the absorbent assembly on the garment-side thereof. The crotch panel material may be of a non-elastic web material, although elastic materials may also be used. Suitably, the crotch panel material is a nonwoven material. The crotch panel material is joined to the elastic laminate.
[0108] With reference to
[0109] Depending on the desired shape of the leg openings of the final pant-type article the web material may be cut and shaped to provide a more underwear-like appearance when assembled into a pant configuration.
[0110] The separately fabricated core insert 2 is placed in the gap between the strips 31′, 31″ of stretchbonded elastic laminate web while the strips 31′, 31″ are still in a tensioned state, such that the core insert 2 partly overlaps with the both strips 31′, 31″ of stretchbonded elastic laminate web. The absorbent insert 2 is secured to the strips 31′, 31″ by any suitable method, as set out herein.
[0111] In this manner a composite web 35 of article components is formed, the composite web 35 constituting a continuous web having leg openings 8 arranged therein and consisting of interconnected precursor articles 36. As set out herein, the composite web 35 comprises a stretchbonded elastic laminate web 31′, 31″ as a chassis component. As shown in the right-hand part of
[0112] After the composite web 35 has been folded, side joins are formed in the folded composite web 35 and individual pant-type articles 1 are separated from the composite web 35 by severing the composite web at the side joins 6a, 6b.
[0113] As illustrated by
[0114] When the individual pant-type articles 1 have been separated from the composite web 35, the laminated elastic web of the front and back panels 3, 4 is no longer held in a stretched state. Thereby, the stretchbonded elastic web material in the front and back panels will cause the web material to gather, i.e. to contract and form rugosities or wrinkles in the non-elastic or less elastic web material which is bonded to the elastic web material.
[0115] The process which is schematically illustrated in
[0116] After the composite web 35 has been folded, side joins are formed in the folded composite web 35 and individual pant-type articles 1 are separated from the composite web 35 by severing the composite web at the side joins 6a, 6b as illustrated by the right-hand part of
[0117] Although the process in
[0118] The method as disclosed herein comprises the production of an array of pant-type articles, the array comprising at least two articles differing in size. In the method the differently sized articles in the array are produced by different processes, each process involving stretchbonding of a continuous elastic web to a non-elastic or less elastic web. In each different continuous process the continuous elastic web is different from the continuous elastic web in every other continuous process used for manufacturing the different size pant-type articles of the array. The continuous elastic webs of the different processes in the method differ from each other with regard to elastic properties although the pitch length of the stretchbonded elastic laminate web is the same in all the different continuous processes.
DESCRIPTION OF TEST METHODS
Elasticity Test
[0119] The method measures how an elastic material behaves at cycles of repeated load and unload. The sample is stretched to a predetermined elongation and a cyclic movement between 0 and said predetermined elongation is performed. Desired load and unload forces are recorded. The permanent, i.e. remaining, elongation of the relaxed material is measured.
[0120] A tensile tester, Lloyd LRX, able to perform cyclic movements and equipped with a printer/plotter or software presentation is used. The sample is prepared by cutting it to a width of 25 mm and a length that is preferably 20 mm longer than the distance between the clamps in the tensile tester.
[0121] The tensile tester is calibrated according to the apparatus instructions. The parameters needed for the test (load and unload forces) are adjusted to: [0122] Crosshead speed: 500 mm/min [0123] Clamp distance: 50 mm [0124] Preload: 0.05 N
[0125] The sample is placed in the clamps according to the marks and it is made sure that the sample I centred and fastened perpendicularly in the clamps. The tensile tester is started and three cycles between 0 and the predetermined elongation equal to the highest defined 1.sup.st load are performed. Before the last cycle, the sample is relaxed for 1 minute, then the permanent elongation is measured by stretching the sample until a force of 0.1 N is detected and the elongation is read.
[0126] An elastic material is defined as a material having a permanent elongation after relaxation of less than 10% after the material has been subjected to an elongation of 30% in the test above. An elongation of 30% means an elongation to a length that is 30% longer than the initial length of the sample.
[0127] A non-elastic material has a permanent elongation after relaxation of more than 10% after having been subjected to an elongation of 30%.
Body Portion Circumference Test
[0128]
[0129] Measurements of the circumference of the body portion 43 in an extended state of the pant-type article 1 may be performed by using any suitable tensile tester. The tensile tester that were used for obtaining the experimental data below was an Instron, model 4464, being equipped with parallel upper and lower tube-formed cylinders 91 having a diameter of 60 millimetres and being oriented in the longitudinal direction Y of the pant-type article 1. The tube-formed cylinders are made of blank polished SS2333 stainless steel with a smooth surface to provide low friction such that the pant-type articles do not stick to the surface of the tube-formed cylinders. The distance 92 between the cylinders 91 are initially set to correspond to the natural relaxed width of the pant-type article 1 such that the pant-type article can be mounted on the cylinders 91 in a non-extended state with the cylinders 91 placed inside the pant-type article 1 and with the cylinders 91 extending at least over the entire length of the side seams 6a, 6b. The cylinders 91 are subsequently pulled apart in the transverse direction X. The test is performed with a constant speed of 200 mm/minute up to 90 Newton tension force in which the tensile tester has been programmed to plot and/or sample data at least at 3, 10, 30 and 90 Newton.
[0130] For the measurements, new products were taken from a package and unfolded. The test result is based on an average result of 5 tested products. The distance 92 between the centres of the cylinders 91 was measured when applying a specified force in opposite directions 93. The circumference of the body portion 43 in an extended state of the absorbent article 1 corresponds to twice the distance 92 between the centre of the cylinders 91 plus the diameter 60 millimetres of the cylinders 91 multiplied with n. The circumference of the body portion 43 is measured at 3, 10, 30 and 90 Newton.
[0131] Comparison between the circumferences at different extension of the body portion of the pant-type articles in the array of pant-type articles should be made at 3 N, at 10 N, at 30 N and at 90 N in accordance with the described test method. Any waist elastic should be cut away before the measurements of the body portion circumference are carried out.
Example
[0132] Two different pant-type articles, A and B, were produced and tested according to the body portion circumference test disclosed herein. The tested article A is suitable for use as a medium-size article and the tested article B is suitable for use as a small size article.
[0133] Both tested articles had the same construction with a chassis having a front panel and a back panel made from a stretchbonded laminate of an elastic film which had been stretchbonded between two spunbond nonwoven webs. The only difference between the tested articles was that the elastic film in test article A was Extretch MD which is a coextruded film with elastic polyolefin core and polyolefin skin layers provided by Exten S.A. and the elastic film in test article B was CEX-614 which is a coextruded film with elastic core comprising SBC and polyolefin elastomers and polyolefin skin layers, provided by Tredegar Corporation.
[0134] The results of the tests are shown in the diagram in