A PACKAGING UNIT FOR ABSORBENT ARTICLES AND A METHOD OF MANUFACTURING A PACKAGING UNIT

Abstract

A packaging unit for an absorbent article is formed from a sheet of material and includes a longitudinal center line, a transversal center line, a first longitudinal edge zone, a second longitudinal edge zone, a first transversal edge zone and a second transversal edge zone. At least one of the first longitudinal edge zone, the second longitudinal edge zone, the first transversal edge zone or the second transversal edge zone includes at least one zone provided with surface protrusions integrally formed from the material of the sheet of material. The sheet of material includes at least one landing zone able to engage with the surface protrusions to provide a fastening mechanism when said sheet of material is rolled or folded. A method of manufacturing a packaging unit and a method to close a packaging unit holding an absorbent article are also disclosed.

Claims

1. A packaging unit for an absorbent article, said packaging unit being formed from a sheet of material, said sheet of material, comprising an inner surface and an outer surface, said sheet of material having a longitudinal center line, a transversal center line, a first longitudinal edge zone, a second longitudinal edge zone, a first transversal edge zone and a second transversal edge zone, said first longitudinal edge zone and said second longitudinal edge zone extending along said longitudinal center line, said first transversal edge zone and said second transversal edge zone extending along said transversal center line, at least one of said first longitudinal edge zone, said second longitudinal edge zone, said first transversal edge zone or said second transversal edge zone comprise at least one zone provided with surface protrusions, said surface protrusions being integrally formed from said material of said sheet of material, said sheet of material comprising at least one landing zone able to engage with said surface protrusions to provide a fastening mechanism when said sheet of material is rolled or folded.

2. A packaging unit for an absorbent article according to claim 1, wherein said surface protrusions protrude from said inner surface and/or from said outer surface of said sheet of material.

3. A packaging unit for an absorbent article according to claim 1, wherein said first longitudinal edge zone and said second longitudinal edge zone have at least one zone provided with surface protrusions, said surface protrusions being integrally formed from said material of said sheet of material, said sheet of material comprising at least one landing zone able to engage with said surface protrusions to provide a fastening mechanism when said sheet is rolled or folded.

4. A packaging unit for an absorbent article according to claim 1, wherein said sheet of material is provided with at least one multilayered zone, said at least one multilayered zone being provided with said surface protrusions.

5. A packaging unit for an absorbent article according to claim 4, wherein said at least one multilayered zone is obtained by folding said sheet of material.

6. A packaging unit for an absorbent article according to claim 4, wherein said at least one multilayered zone is obtained by folding said sheet of material towards said longitudinal center line to form a longitudinal multilayered edge zone or by folding said sheet of material towards said transversal center line to form a transversal multilayered edge zone.

7. A packaging unit for an absorbent article according to claim 6, wherein said packaging unit comprises a first longitudinal multilayered edge zone and/or a second longitudinal multilayered edge zone and/or a first transversal multilayered edge zone and/or a second transversal multilayered edge zone.

8. A packaging unit for an absorbent article according to claim 4, wherein said at least one multilayered zone is obtained by applying an additional material along at least one of the first longitudinal edge zone, the second longitudinal edge zone, the first transversal edge zone or the second transversal edge zone.

9. A packaging unit for an absorbent article according to claim 1, wherein said sheet of material comprises a thermoplastic material, a woven structure or a non-woven structure.

10. A packaging unit for an absorbent article according to claim 1, wherein said surface protrusions comprise pins, straight pins, angled pins, curved pins, tapered pins, limbed or multi-limbed pins, hooks, limbed or multi-limbed hooks, mushroom shaped protrusions or -palm tree shaped protrusions.

11. A packaging unit for an absorbent article according to claim 1, wherein said at least one zone provided with surface protrusions and said at least one landing zone have a mechanical interaction providing a sealing strength ranging between 0.5 N and 3.5 N.

12. A packaging unit for an absorbent article according to claim 1, wherein said sheet has at least one folding axis, said folding axis dividing said sheet into a first region and a second region, both said first region and said second region having a first longitudinal edge zone and a second longitudinal edge zone, said first longitudinal edge zone and/or said second longitudinal edge zone of said first region being provided with at least one zone provided with said surface protrusions, said first longitudinal edge zone and/or said second longitudinal edge zone of said second region being provided with a landing zone able to engage with said surface protrusions of said first longitudinal edge zone and/or of said second longitudinal edge zone of said first region to provide a fastening mechanism when said sheet of material is rolled or folded.

13. A method of manufacturing a packaging unit for absorbent articles, said method comprising: bringing an inner surface or an outer surface of a sheet of material in contact with a first surface of a forming die; applying energy to said sheet of material to locally soften at least one of a first longitudinal edge zone, a second longitudinal edge zone, a first transversal edge zone or a second transversal edge zone, thereby forcing material of said sheet of material of at least one of said first longitudinal edge zone, said second longitudinal edge zone, said first transversal edge zone or said second transversal edge zone into cavities defined by the first surface of the forming die to form surface protrusions at said inner surface and/or at said outer surface of said sheet of material.

14. A method according to claim 13, wherein said energy is applied by a source selected from the group consisting of induction heating, ultrasonic vibrations, micro waves, radio waves, infrared waves, laser beams and electron beams.

15. A method to close a packaging unit holding an absorbent article, said method comprising: providing a sheet of material, said sheet of material having an inner surface and an outer surface, the sheet of material having a longitudinal center line, a transversal center line, a first longitudinal edge zone, a second longitudinal edge zone, a first transversal edge zone and a second transversal edge zone, said first longitudinal edge zone and said second longitudinal edge zone extending along said longitudinal center line, said first transversal edge zone and said second transversal edge zone extending along said transversal center line, at least one of said first longitudinal edge zone, said second longitudinal edge zone, said first transversal edge zone or said second transversal edge zone comprising at least one zone provided with surface protrusions extending from said inner surface and/or from said outer surface, said surface protrusions being integrally formed from said sheet of material, said sheet of material being provided with at least one landing zone; applying an absorbent article on said inner surface or said outer surface of said sheet of material, folding or rolling said sheet of material comprising said absorbent article applied on said sheet of material, thereby bringing said at least one zone provided with surface protrusions in contact with said at least one landing zone whereby said surface protrusions of said at least one zone provided with surface protrusions engage with said at least one landing zone.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Embodiments of the invention will now be described into more detail with reference to the accompanying drawings of which

[0068] FIG. 1A shows a first embodiment of a packing unit according to the present invention in its open state;

[0069] FIG. 1B shows the packaging unit of FIG. 1A in its folded state;

[0070] FIG. 1C shows the packaging unit of FIG. 1A in its rolled state;

[0071] FIG. 2A shows a second embodiment of a packing unit according to the present invention in its open state;

[0072] FIG. 2B shows the packaging unit of FIG. 2A in its folded state;

[0073] FIG. 2C shows the packaging unit of FIG. 2A in its rolled state;

[0074] FIG. 3A shows a third embodiment of a packing unit according to the present invention in its open state;

[0075] FIG. 3B shows the packaging unit of FIG. 3A in its folded state;

[0076] FIG. 4A shows a fourth embodiment of a packing unit according to the present invention having multilayered zones in its open state;

[0077] FIG. 4B shows the cross-section along a transversal line of a packing unit shown in FIG. 4A before subjected to a softening and forming operation;

[0078] FIG. 4C shows the folded packaging unit shown in FIG. 4B subjected to a softening and forming operation;

[0079] FIG. 5 shows a packing unit in its open state provided with an absorbent article;

[0080] FIG. 6 shows an embodiment how to provide a packaging unit as shown in FIGS. 1 to 5 with surface protrusions

DETAILED DESCRIPTION OF PARTICULAR EMBODIMENTS

[0081] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn to scale for illustrative purposes. The dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention.

[0082] FIG. 1A shows a packing unit 100 for an absorbent article according to the present invention in its open, unfolded state. FIG. 1B shows the packaging unit 100 shown in FIG. 1A in its folded state, FIG. 1C shows the packing unit 100 shown in FIG. 1A in its rolled state. The packaging unit 100 is formed from a sheet of material 102 and comprises an inner surface 104 and an outer surface 106. The sheet of material 102 has a longitudinal center line 108, a transversal center line 110, a first longitudinal edge zone 112, a second longitudinal edge zone 114, a first transversal edge zone 116 and a second transversal edge zone 118. The first longitudinal edge zone 112 and the second longitudinal edge zone 114 are extending parallel to the longitudinal center line 108. The first transversal edge zone 116 and the second transversal edge zone 118 are extending parallel to the transversal center line 110.

[0083] The sheet of material 102 comprises for example a non-woven material.

[0084] The packaging unit 100 has one folding axis 126. The folding axis 126 in the embodiment shown in FIG. 1A corresponds with the transversal center line 110. The folding axis 126 divides the sheet of material into a first region 122 and a second region 124.

[0085] The first region 122 has a first longitudinal edge zone 112 and a second longitudinal edge zone 114; the second region 124 has a first longitudinal edge zone 112 and a second longitudinal edge zone 114.

[0086] At least one of the first longitudinal edge zone 112 of the first region 122 or the second longitudinal edge zone 114 of the first region 122 is provided with at least one zone provided with surface protrusions 120. Preferably, as shown in FIG. 1A, both the first longitudinal edge zone 112 of the first region 122 and the second longitudinal edge zone 114 of the first region 122 are provided with at least one zone provided with surface protrusions 120. The surface protrusions 120 may for example comprise hooks. The surface protrusions 120 are integrally made of the sheet of material 102. The sheet of material 102 is subjected to a softening and forming process such that said surface protrusions 120 are being integrally made of said sheet of material 102.

[0087] The second region 124 is preferably provided with one or more landing zones so that when the sheet of material is folded as for example shown in FIG. 1B, the surface protrusions 120 of the first region 122 engage (preferably releasably engage) with the at least one landing zone of the second region 124.

[0088] The second region 124 in FIG. 1A is provided with two landing zones 129 for the surface protrusions 120 in the first longitudinal edge zone 112 of the first region 122 and the second longitudinal edge zone 114 of the first region 122. The non-woven material of the sheet of material 102 acts as a landing zone. Alternatively, loop patches or any other kind of landing zone material can be attached to the sheet of material 102. This may be advantageous, for example, if the sheet of material 102 is a plastic film. The loop patch or landing zone material is preferably arranged on at least one of the first longitudinal edge zone 112 of the second region 122 or the second longitudinal edge zone 114.

[0089] For the packaging function of a non-used absorbent article of a packaging unit 100 according to the present invention the sheet of material 102 is preferably folded as shown in FIG. 1B to wrap the non-used absorbent article. When folded the surface protrusions 120 engage with the landing zone 129.

[0090] For the disposal function of a used absorbent article of a packaging unit 100 according to the present invention the sheet of material 102 can be folded as shown in FIG. 1B or can be rolled as shown in FIG. 1C to wrap the used absorbent article dependent on the choice of the user. When rolled together the surface protrusions 120 engage with a further landing zone on the outer surface 106, which is the non-woven material of the sheet of material 102 or may be a separately attached landing zone.

[0091] FIG. 2A shows a second embodiment of a packing unit 100 according to the present invention in its open, unfolded state. FIG. 2B shows the packaging unit 100 shown in FIG. 2A in its folded state, FIG. 2C shows the packing unit 100 shown in FIG. 2A in its rolled state. The packaging unit 100 of FIG. 2A is similar to the first embodiment shown in FIG. 1A but is different from the packaging unit 100 shown in FIG. 1A in that the sheet of material 102 comprises a polymer material such as a polymer film and in that the first longitudinal edge zone 112 and the second longitudinal edge zone 114 comprise zones provided with surface protrusions 120 that are extending over the major part of the length of the first longitudinal edge zone 112 and the second longitudinal edge zone 114. The zones provided with surface protrusions 120 engage with corresponding surface protrusions 120 of the polymer film, when the packaging unit 100 is folded as in FIG. 2B. In the rolled configurations some of the surface protrusions 120 engage a landing zone 150 arranged on the outer surface 106 of the sheet of material 102. Alternatively, all surface protrusions 120 or substantially all surface protrusions 120 may engage a landing zone on the outer surface 106 of the sheet of material 102.

[0092] FIG. 3A shows a third embodiment of a packing unit 100 according to the present invention in its open, unfolded state. FIG. 3B shows the packaging unit 100 shown in FIG. 3A in its folded state. The packaging unit 100 has two folding axes 126, 126. The folding axes 126, 126 are parallel or substantially parallel with the transversal center line 110. The folding axis 126, 126 divide the sheet of material in a first region 122, a second region 124 and a third region 125. The first longitudinal edge zone 112 and the second longitudinal edge zone 114 comprise zones provided with surface protrusions 120 that are extending over the major part of the length of the first longitudinal edge zone 112 and the second longitudinal edge zone 114. One of the transversal edge zone, for example the second transversal edge zone 118 is provided with surface protrusions 120 that are extending over the major part of the length of the second transversal edge zone 118.

[0093] In addition the sheet of material can be provided with an additional means to fasten opposed surfaces for example by a fastening means 131 applied at the outer surface of the sheet of material 102. Such fastening means 131 comprises for example a loop patch or hook patch applied at the outer surface of the sheet of material 102. Alternatively, they are formed by the same softening and forming process as the surface protrusions 120.

[0094] Another example of the additional fastening means may comprise a sticky tape. The sticky tape may be arranged to the outer surface for example at one end of the sheet of material 102 and when the sheet of material 102 is rolled or folded together part of the sticky tape may be used to attach the end of the sheet of material 102 to the outer surface of the sheet of material which will be next to it, i.e. to help keeping the sheet of material in a rolled or folded state.

[0095] FIG. 4A shows a further embodiment of a packaging unit 100 according to the present invention in its open state. FIG. 4B shows the cross-section of the packaging unit 100 along a transversal line. The sheet of material 102 comprises at the first longitudinal edge zone 112 and at the second longitudinal edge zone 114 a multilayered zone obtained by folding a first portion 152 of the sheet of material 102 over the first longitudinal edge and the second longitudinal edge towards the longitudinal center line 108. FIG. 4c shows the folded portion of FIG. 4b once subjected to a softening and forming operation. By the softening and forming operation both layers are connected to each other and preferably form one layer of material. At least part of the double folded layer is provided with surface protrusions 120 by the same softening and forming operation. The dimensions and relative dimensions of the surface protrusions 120 are exaggerated and not drawn to scale for illustrative purposes. The height of the surface protrusions 120 typically range between 0.1 and 0.5 mm and is for example equal to 0.3 or 0.4 mm.

[0096] The folding can be any type of folding such as single folding, Z-shaped folding or double folding.

[0097] The multilayered zones are provided with surface protrusions 120, for example with hooks.

[0098] FIG. 5 shows a packaging unit 100 according to the present invention provided with an un-used absorbent article 101 as for example a sanitary napkin. The sheet of material 102 comprises at the first longitudinal edge zone 112 and at the second longitudinal edge zone 114 several zones provided with surface protrusions 120.

[0099] FIG. 6 shows one example how to provide the sheet of material 102 shown in FIGS. 1 to 5 with surface protrusions. FIG. 6 discloses a forming die 300, in form of a rotating moulding roll, which comprises a surface 301 provided a plurality of cavities 302, at least some of said cavities 302 comprise a shape to produce surface protrusions 120. The inner surface 104 of the sheet of material 102 is in contact with said surface 301 of said forming die 300. During operation a vibration source 303 is positioned in close proximity to the outer surface 301 of the rotating forming die 300. The vibration source 303 may be a vibrating ultrasonic horn. The vibration source 303 apply energy to the sheet of material 102. The material of the sheet of material 102 is softened and forced into said cavities 302 to provide said inner surface 104 of said sheet of material 102 with surface protrusions 120. If the sheet of material 102 is a folded portion, as for example shown in FIGS. 4a, 4b and 4c the energy from the vibration source 303 soften and form at least part of said sheet of material 102 in such a way that both layers connect and at the same time the material is forced into said cavities to provide said inner surface with surface protrusions 120.

[0100] While the present invention may be embodied in many different forms, a number of illustrative embodiments are described herein with the understanding that the present disclosure is to be considered as providing examples of the principles of the invention and such examples are not intended to limit the invention to preferred embodiments described herein and/or illustrated herein.