Method for production of disposable absorbent articles

Abstract

A method for production of disposable hygienic absorbent articles, the method comprising advancing in a first direction a continuous length of a substantially homogeneous elastic laminate web having a maximum elastic extensibility in the first direction of at least 40% under a peak load F.sub.p; maintaining said substantially homogeneous elastic laminate web under a tensioning load F.sub.t in the first direction during the advancing, the tensioning load F.sub.t satisfying the condition: 0.03 F.sub.pF.sub.t0.25 F.sub.p; attaching individual absorbent cores to the substantially homogeneous elastic laminate web while maintaining said substantially homogeneous elastic laminate web under the tensioning load F.sub.t; and severing the substantially homogenous elastic laminate web into individual disposable hygienic absorbent articles.

Claims

1. A method for production of disposable hygienic absorbent articles, the method comprising: advancing in a first direction a continuous length of a substantially homogeneous elastic laminate web having a maximum elastic extensibility in the first direction of at least 40% under a peak load F.sub.p; maintaining said substantially homogeneous elastic laminate web under a tensioning load F.sub.t in the first direction during the advancing, the tensioning load F.sub.t satisfying the condition: 0.03 F.sub.pF.sub.t0.25 F.sub.p; attaching individual absorbent cores to the substantially homogeneous elastic laminate web while maintaining said substantially homogeneous elastic laminate web under the tensioning load F.sub.t; and severing the substantially homogenous elastic laminate web into individual disposable hygienic absorbent articles.

2. The method as claimed in claim 1, further comprising welding said substantially homogeneous elastic laminate web to define weld lines intermittently transverse to the first direction.

3. The method as claimed in claim 1, wherein: said substantially homogenous elastic laminate web includes two layers having respective levels of elasticity different from one another, and said substantially homogenous elastic laminate web exhibits a non-linear load-strain curve relationship.

4. The method as claimed in claim 1, wherein the individual disposable hygienic absorbent articles are pull-up pant diapers.

5. The method as claimed in claim 1, wherein the individual absorbent cores include a plastic film, an absorbent core, and a nonwoven surface layer.

6. The method as claimed in claim 5, wherein the individual absorbent cores further include a crotch elastic.

7. The method as claimed in claim 1, wherein the absorbent cores are attached to the substantially homogenous elastic web and the substantially homogenous elastic web is severed such that the substantially homogenous elastic web is arranged on a side of the absorbent cores such that the substantially homogenous elastic web forms an outer cover for the individual disposable hygienic absorbent articles and the substantially homogeneous elastic laminate web does not cover an entire outer surface of the individual disposable hygienic absorbent articles.

8. The method as claimed in claim 7, wherein the absorbent cores are attached to the substantially homogenous elastic web and the substantially homogenous elastic web is severed such that the substantially homogenous elastic web is arranged on a side of the absorbent cores such that the substantially homogenous elastic web forms an outer cover for the individual disposable hygienic absorbent articles and the outer cover of the individual disposable hygienic absorbent articles has a non-elastic region.

9. The method as claimed in claim 1, wherein the absorbent cores are attached to the substantially homogenous elastic web and the substantially homogenous elastic web is severed such that the substantially homogenous elastic web is arranged on a side of the absorbent cores such that the substantially homogenous elastic web forms an outer cover for the individual disposable hygienic absorbent articles.

10. The method as claimed in claim 1, wherein: the substantially homogenous elastic laminate web comprises at least one nonwoven layer affixed to a film layer.

11. The method as claimed in claim 10, wherein: said substantially homogenous elastic laminate web exhibits a non-linear load-strain curve relationship.

12. The method as claimed in claim 1, wherein: said substantially homogenous elastic laminate web exhibits a non-linear load-strain curve relationship.

13. The method as claimed in claim 1, wherein: the tensioning load F.sub.t satisfies the condition: 0.05 F.sub.pF.sub.t0.25 F.sub.p.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Embodiments of the invention will be described in the following in greater detail by way of example only and with reference to the attached drawings, in which:

(2) FIG. 1 is a schematic perspective view of a length of a production line for the production of a disposable hygienic absorbent article in accordance with an embodiment of the present invention;

(3) FIG. 2 is a schematic graphic representation showing load vs. strain for an elastic laminate;

(4) FIG. 3 is a graph showing load vs. strain for an elastic laminate comprising 25 gsm nonwoven material;

(5) FIG. 4 is a graph showing load vs. strain for an elastic laminate comprising 20 gsm nonwoven material;

(6) FIG. 5 is a graph showing load vs. strain for an elastic laminate comprising 18 gsm nonwoven material, and

(7) FIG. 6 is a cross-sectional view through an elastic laminate web for use in an embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(8) In FIG. 1, reference numeral 10 generally denotes length of a production line for the production of a disposable hygienic absorbent article 12. In the present example, the absorbent article is a pull-up pants-type diaper.

(9) The various components of the absorbent article are united on a (not shown) continuous conveyor belt running in a direction of travel denoted by arrow A. In the broadest form of the invention, a continuous length of a substantially homogenous elastic laminate web 14 is placed on the conveyor belt and maintained under a tensioning load F.sub.t. The elastic laminate web has a maximum extensibility in a first direction corresponding to the direction of travel denoted by arrow A of at least 40%, preferably at least 60%, and most preferably at least 80%, under a peak load F.sub.p. The continuous length of the elastic laminate web 14 is advanced in the direction of travel A to a station at which individual absorbent cores 16 are attached to the continuous length of the elastic laminate web 14 at spaced intervals. Individual articles 12, in this case pull-up pants-type diapers, are thereafter formed from the thus assembled individual absorbent cores 16 and the continuous length of the elastic laminate web.

(10) The continuous length of the elastic laminate web 14 is maintained under a tensioning load F.sub.t in the direction of travel during the advancing, with the tensioning load F.sub.t satisfying the condition: 0.03 F.sub.pF.sub.t0.25 F.sub.p.

(11) In order to carry out the above described method, it is necessary to determine the peak load F.sub.p, i.e. the load under which the elastic laminate web displays elastic extensibility. The peak load is determined using the ASTM D 882 tensile strength test method. The tensile strength and elongation of a well-defined test piece is tested by means of a tensile tester.

(12) Apparatus: Instron 4301

(13) Tensile tester connected to a computer

(14) Crosshead speed: 500 mm/min

(15) Clamp distance: 50 mm

(16) Sample preparation: Test samples are cut from the entire width of the material. The width of the sample shall be 25.4 mm and the length at least 50 mm longer than the clamp distance if possible. It is of importance that the edges of the sample are even and without break notches. The samples are conditioned for at least 4 h in 50% RH5% RH and 23 C.2 C. before testing.

(17) Procedure: The tensile tester is calibrated according to the apparatus instructions and set to zero. The sample is mounted and it is ensured that it is not obliquely or unevenly fastened. The material is prevented from slipping by using clamps covered with galloon or similar material. The tensile tester is started, and stopped after the material has broken (if not automatically controlled). Measurements resulting from premature failures (i.e. the sample breaks at the clamp, or is damaged during preparation) are ignored if possible.

(18) The following results are expressed by the tensile tester/computer:

(19) Maximum force, N/25.4 mm

(20) Elongation at maximum force, %

(21) Break force, N/25.4 mm

(22) Elongation at break force, %

(23) Knee point, N/%

(24) FIG. 2 is a schematic representation of the behaviour of an elastic laminate web for use in the method according to the present invention under stretching at a constant strain. The laminate web comprises 25 gsm Sofspan NW from BBA on both sides of a 40 gsm apertured elastic film, where one face is glue-laminated with approximately 5 gsm glue.

(25) From zero strain, the elastic laminate web exhibits substantially elastic behaviour in region (A) up to around a knee point (B), after which, the load increases rapidly through region (C). The knee point (B) is defined as the first point on the load-strain curve at which the gradient becomes greater than 0.3N/%. The laminate web shown is elastic up to about 80% strain. The applied load eventually reaches a maximum (the peak load) at point (D), at which the gradient of the load-strain curve is zero. The load then drops through region (E) as the material fails. Complete failure of the laminate web occurs at point (F).

(26) The peak load F.sub.p is the applied load at point D. In the embodiment of the present invention, the elastic laminate web is maintained under a tensioning load F.sub.t which satisfies the condition: 0.03 F.sub.pF.sub.t0.25 F.sub.p.

(27) FIGS. 3 to 5 show the actual behaviour of elastic laminate webs having a 40 gsm apertured elastic film, though glue-laminated with approximately 3 gsm glue to Sofspan NW of different basis weights. Thus, in FIG. 3 the basis weight of the nowwoven webs is 25 gsm, in FIG. 4 it is 20 gsm and in FIG. 5 it is 18 gsm. In all cases, the knee point (B) lies within the range 0.03 F.sub.pF.sub.t0.25 F.sub.p.

(28) Under certain circumstances, it may be preferable to increase the elongation of the laminate during production. As such, in a preferred embodiment, the tensioning load F.sub.t may be selected so as to satisfy the condition 0.05 F.sub.pF.sub.t0.25 F.sub.p. Similarly, where it is desirable to keep the load on the laminate as low as possible, F.sub.t may be selected so as to satisfy the condition 0.03 F.sub.pF.sub.t0.20 F.sub.p. In a further preferred embodiment, F.sub.t may be selected so as to satisfy the condition 0.05 F.sub.pF.sub.t0.20 F.sub.p.

(29) FIG. 6 is a cross-section through an elastic laminate web 14 for use in an embodiment of the present invention. The elastic laminate web comprises a first nonwoven layer 26 affixed to a first surface 28 of a film layer 30. Advantageously, the elastic laminate web further comprises a second nonwoven layer 32 affixed to a second surface 34 of the film layer 30.

(30) Preferably, the film layer comprises an elastic film having a basis weight from about 20 g/m.sup.2 to about 100 g/m.sup.2, preferably between 20 and 60 g/m.sup.2. The film layer may be selected from the group consisting of low crystallinity polyethylenes, metallocene-catalyzed low crystallinity polyethylene, ethylene vinyl acetate copolymers (EVA), polyurethane, polyisoprene, butadiene-styrene copolymers, styrene block polymers such as styrene/isoprene/styrene (SIS), styrene/butadiene/styrene (SBS), styrene/ethylene-butadiene/styrene (SEBS) block copolymer and blends thereof.

(31) To increase the breathability of the elastic laminate web, the film layer 30 may be provided with apertures 37. In a preferred embodiment, the film is an apertured three-layer PE/styrene-based film/PE elastomeric film.

(32) Each of the first and second nonwoven layers may have a basis weight of from about 10 g/m.sup.2 to about 40 g/m.sup.2, preferably from about 12 g/m.sup.2 to about 30 g/m.sup.2, most preferably from about 15 g/m.sup.2 to about 25 g/m.sup.2, and may comprise a spunbond or carded material selected from the group consisting of: polypropylene, polyethylene, polyester and other polyolefin homopolymers and copolymers.

(33) In order to provide the individual articles 12 with desirable properties, the basic production method outlined above may be complemented by one or more of the following steps.

(34) In the production of a pants-type diaper, adhesive 36 may be applied, for example by spraying or coating, to the elastic laminate web 14, after which elastic members 38 in the form of continuous elastic bands or threads are secured in a curved pattern across the laminate web. These elastic members 38 will form elasticised leg openings in the completed article 12. Alternatively, the adhesive may be applied directly to the elastic members themselves.

(35) A second material web 40 of liquid barrier material, such as an elastic plastic film, may thereafter be applied over the elastic laminate web 14 and the elastic members 38. The second material web may be provided with adhesive on its surface facing the first web 14 to ensure its adequate adhesion thereto.

(36) In the illustrated embodiment a third material web 42 is placed over the elastic laminate web 14 and the second material web 40 and secured over the absorbent cores 16. The third elastic material web will constitute the topsheet of the completed absorbent article. As such, it can consist of a nonwoven material, e g spunbond, meltblown, carded, hydroentangled, wetlaid etc. Suitable nonwoven materials can be composed of natural fibers, such as woodpulp or cotton fibres, manmade fibres, such as polyester, polyethylene, polypropylene, viscose etc. or from a mixture of natural and manmade fibres. The topsheet material may further be composed of tow fibres, which may be bonded to each other in a bonding pattern, as e.g. disclosed in EP-A-1 035 818. Further examples of topsheet materials are porous foams, apertured plastic films etc. The materials suited as topsheet materials should be soft and non-irritating to the skin and intended to be readily penetrated by body fluid, e.g. urine or menstrual fluid. Advantageously, the third material web will have elastic properties. Before the third material web is applied to the second material web, the third elastic web may be coated with an adhesive on its surface directed towards the second material web.

(37) In an alternative production method, the second material web 40 of liquid barrier material may be omitted. Instead, nonwoven material may be placed over the elastic members 38. Liquid barrier material may then be incorporated in an absorbent packet comprising a plastic film, an absorbent core and a nowoven surface layer. Although in FIG. 1 the elastic members 38 as laid out on the elastic laminate web comprise crotch elastic, it is to be understood that the crotch elastic may be incorporated in the thus-described absorbent packet instead.

(38) The above-described assembly of components forms a production web 44. Leg openings 46 are cut out from the production web and the production web is then folded double in the production direction so that a fold edge 48 and an open edge 50 are formed. The folded production web 44 is then welded intermittently transverse to the production direction along weld lines 52 extending from the open edge 50 to the edge at each leg opening 46. The welded production web 44 is then divided by being severed along each weld line 52 so that individual pants-type diapers 12 are separated from the production web 44. The individual diapers can then be subjected to further processing steps such as folding and packing.

(39) The elastic laminate web 14 of the thus-produced pants-type diapers 12 constitutes the outer cover of the diapers. In a similar manner, the elastic laminate web may also constitute the outer cover of many types of disposable hygienic absorbent articles, such as conventional diapers, incontinence garments, sanitary napkins and panty liners. It is to be understood that the elastic laminate web 14 need not cover the entire outer surface of such articles. Instead, in certain circumstances it may be desirable to have a non-elastic region of the outer cover. Thus, for example, the crotch region of a diaper may have an outer cover region which is constituted by a strip of non-elastic nonwoven material bounded on either side by an elastic laminate web. In this manner, front and rear panels of the diaper will enjoy elastic properties.