COMPOSITE WEB

Abstract

A composite web including: a first continuous web; at least one molded segment having at least one protrusion and a base portion at least partly delimiting the protrusion, the molded segment being obtained from a second continuous web; the molded segment being joined to the first continuous web by the base portion, the first continuous web and the molded segment delimiting at least one cavity at the protrusion.

Claims

1. A composite web comprising: a first continuous web, at least one molded segment having at least one protrusion and a base portion at least partly delimiting the protrusion, the molded segment being obtained from a second continuous web; the molded segment being joined to the first continuous web by the base portion, the first continuous web and the molded segment delimiting at least one cavity at the protrusion.

2. The composite web according to claim 1, wherein the molded segment comprises a multiplicity of protrusions, the protrusions being delimited by a multiplicity of base portions, the molded segment being joined to the first continuous web by the base portions, the first continuous web and the molded segment delimiting a multiplicity of cavities at the protrusions.

3. The composite web according to claim 2, wherein the multiplicity of protrusions defines a pattern on the molded segment.

4. The composite web according to claim 1, comprising a multiplicity of molded segments, the molded segments being joined to the first continuous web.

5. The composite web according to claim 1, wherein the molded segment comprises a protrusion having a bubble shape.

6. The composite web according to claim 1, wherein the molded segment comprises a protrusion having a wave shape.

7. The composite web according to claim 1, comprising at least one weld, preferably a thermal weld or a thermomechanical weld or an ultrasonic weld, the base portion and the first continuous web being joined by the weld.

8. The composite web according to claim 1, comprising at least one adhesive layer, the adhesive layer being disposed between the base portion of the molded segment and the first continuous web.

9. The composite according to claim 1, wherein the base portion is outside the protrusion.

10. An absorbent article comprising: a topsheet, an impermeable backsheet, an absorbent core disposed between the topsheet and the backsheet, wherein the topsheet comprises a segment of a composite web according to claim 1, the first continuous web being disposed between the molded segment and the absorbent core.

11. A method for the production of a composite web, specifically for making absorbent sanitary articles, comprising the following steps: feeding a first continuous web, feeding at least one molded segment of a second continuous web, the molded segment having at least one protrusion) delimited at least partly by a base portion, joining the molded segment to the first continuous web at the base portion to delimit at least one cavity between the first continuous web and the molded segment at the protrusion.

12. The production method according to claim 11, comprising a step of molding a segment of the second continuous web to obtain the molded segment.

13. The production method according to claim 12, further comprising the following steps: feeding the second continuous web, cutting and spacing the second continuous web to obtain the segment of the second continuous web.

14. The production method according to claim 11, wherein the step of joining the molded segment to the first continuous web comprises a step of welding the molded segment to the first continuous web at least at the base portion.

15. The production method according to claim 11, wherein the step of joining the molded segment to the first continuous web comprises a step of disposing a layer of adhesive between the molded segment and the first continuous web.

16. The production method according to claim 11, wherein the step of joining the molded segment to the first continuous web comprises a step of joining a discrete succession of molded segments to the first continuous web.

17. A forming unit for making a composite web, the forming unit comprising: an applicator device configured to join a molded segment, provided with a pattern that comprises at least one protrusion, and a base portion to a first continuous web; a production device for making the molded segment, the production device comprising a molding device for molding the pattern and a cutting and spacing device configured to cut and space a second continuous web to make at least one segment or a plurality of segments of the second continuous web, wherein the molding device is disposed downstream of the cutting and spacing device in a feed direction of the second continuous web in order to mold the pattern on the segment or wherein the molding device is disposed upstream of the cutting and spacing device in a feed direction of the second continuous web in order to mold the pattern on the second continuous web, the molding device comprising a first drum and a second drum positioned relative to each other to define a through-gap for passage of the segment of second web or of the second continuous web; the applicator device being configured to join the molded segment to the first continuous web at the base portion, the applicator device being disposed downstream of the production device in a feed direction of the molded segment.

18. The forming unit according to claim 17, wherein the cutting and spacing device comprises an anvil and a rotary knife acting in conjunction with the anvil.

19. The forming unit according to claim 17, wherein the cutting and spacing device, specifically the anvil, is configured to space the segments of second web.

20. The forming unit according to claim 17, wherein the applicator device comprises at least one applicator drum that is tangent to the first drum or to the second drum.

21. The forming unit according to claim 17, wherein the applicator device comprises a welder for welding the molded segment to the first continuous web.

22. The forming unit according to claim 17, wherein the applicator device comprises an adhesive dispenser, the adhesive dispenser being disposed downstream of the production device in the feed direction of the molded segment.

23. The forming unit according to claim 17, wherein the first drum and the second drum comprise male and female portions, respectively, the male and female portions being shaped to match each other so as to mold the pattern on the molded segment.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0100] The main features of the invention are more apparent from the detailed description which follows, with reference to the accompanying drawings which illustrate a preferred, non-limiting embodiment of the invention, and in which:

[0101] FIG. 1 illustrates a detail of a composite web according to the description in a schematic cross sectional view;

[0102] FIG. 2 illustrates a detail of a composite web according to the disclosure in a schematic perspective view;

[0103] FIG. 3 illustrates a detail of a composite web according to the disclosure in a schematic perspective view;

[0104] FIG. 4 illustrates an absorbent article according to the description in a schematic plan view;

[0105] FIG. 5 illustrates a unit for forming a composite web according to the description in a schematic front view;

[0106] FIG. 6 illustrates a detail of a unit for forming a composite web according to the description in a schematic view;

[0107] FIG. 7 illustrates a detail of a unit for forming a composite web according to the description in a schematic view;

[0108] FIG. 8 illustrates an absorbent article according to the description in a schematic cross sectional view.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0109] With reference to the accompanying drawings and, in particular, FIG. 1, the numeral 1 denotes a composite web according to the description.

[0110] The composite web 1 is preferably intended for the production of absorbent sanitary articles such as diapers, an example of which, labelled 200, is illustrated in FIG. 4.

[0111] The composite web 1, as explained in more detail below, allows making what are known as three-dimensional or 3D topsheets for diapers.

[0112] The composite web 1 comprises a first continuous web 11 and a molded segment 12S, that is to say, a segment with a pattern M stamped on it.

[0113] The molded segment 12S is obtained from a segment 12L of a second continuous web 12. The segment 12S has a first face 12A and a second face 12B.

[0114] Basically, the molded segment 12S has at least one protrusion 4 which is at least partly delimited by a base portion 5, outside the protrusion 4.

[0115] The protrusion 4 protrudes from the first face 12A relative to the base portion 5.

[0116] With reference to the accompanying drawings, the cross section of the composite web 1 is greatly scaled up in the illustrations so as to make it easier to understand this description.

[0117] The molded segment 12S defines what is known as the 3D part of the topsheet, made to improve the comfort of the diaper, thanks to the protrusions 4.

[0118] The segment 12S thus defines a molded portion 3 for the composite web 1.

[0119] The first continuous web 11 has a first face 11A and a second face 11B.

[0120] The first face 11A is joined to the second face 12B of the segment 12S by the base portions 5.

[0121] The second face 11B is in contact preferably with the absorbent core 203 of the absorbent sanitary product 200 or with an ADL, if any.

[0122] The composite web 1 has at least one cavity 7 which is delimited by the molded segment 12S and by the web 11 at the protrusions 4.

[0123] In other words, the cavity 7 is delimited by the second face 12B of the segment 12S at the protrusion 4 and by the first face 11A of the first continuous web 11.

[0124] In an embodiment, the segment 12S, on its first face 12A, has a multiplicity of protrusions 4, delimited by a respective multiplicity of base portions 5 surrounding the protrusions 4.

[0125] In this embodiment, the composite web 1 has a multiplicity of cavities 7 delimited by the segment 12S and by the first continuous web 11 (at the multiplicity of protrusions 4).

[0126] The multiplicity of protrusions 4 defines the motif M, that is, a pattern that will constitute the three-dimensional portion of the topsheet.

[0127] The wearer, when wearing an absorbent sanitary product 200 that comprises the composite web 1, is in contact with the protrusions present on the first face 12A of the segment 12S.

[0128] Advantageously, the protrusions 4 improve the comfort for the wearer who is wearing the product and comes into contact with the protrusions.

[0129] In an embodiment, the molded segment 12S comprises non-woven fabric.

[0130] In an embodiment, the molded segment 12S comprises polymer fibers.

[0131] In an embodiment, the first continuous web 11 comprises non-woven fabric.

[0132] In an embodiment, the first continuous web 11 is a liquid acquisition and distribution layer (ADL).

[0133] The shape imparted to the segment 12S by molding is maintained by gluing the segment 12S to the first continuous web 11.

[0134] In an embodiment, the composite web 1 comprises a discrete succession of segments 12S joined to the first web 11.

[0135] The composite web 1 has a succession of molded portions 3 (at the segments 12S), kept in the required shape by the first continuous web 11.

[0136] In an absorbent article 200 that uses a segment of the web 1 as topsheet, the segment will have a molded portion 3, enhancing the comfort of the wearer, at the molded segment 12S.

[0137] In an embodiment, the protrusions 4 of the segment 12S have a bubble shape, illustrated, for example, in FIG. 3.

[0138] In an embodiment, the protrusions 4 of the segment 12S have a wavy shape, illustrated, for example, in FIG. 2.

[0139] In an embodiment, the waves molded on the segment 12S comprise waves with crests 4A that are parallel to the main direction of extension of the segment 12S.

[0140] In an embodiment, the waves molded on the segment 12S comprise waves with crests 4A that are transverse to the main direction of extension of the segment 12S.

[0141] The protrusions 4 may have different shapes: for example, diamond, heart, oval, teardrop, elliptic, shamrock and others.

[0142] The segments 12S and the first web 11 are joined, for example, by a weld 9, shown in FIG. 1, and/or by a layer of adhesive 8, illustrated in FIG. 2.

[0143] In an embodiment, the segments 12S and the web 11 are joined by welding, in particular thermal welding.

[0144] In an embodiment, the segments 12S and the web 11 are joined by ultrasonic welding.

[0145] The layer of adhesive 8 is disposed between the segment 12S and the continuous web 11, preferably between the base portions 5 that delimit the protrusions 4 and the web 11.

[0146] This description relates to an absorbent article illustrated, for example, in FIG. 4 and denoted by the reference numeral 200.

[0147] The absorbent article 200, described only insofar as necessary for understanding this invention, essentially comprises: a topsheet 201, an impermeable backsheet 202 and an absorbent core 203 disposed between the topsheet 201 and the backsheet 202.

[0148] The topsheet 201 is the part of the article 200 which, in use, is in contact with the wearer.

[0149] The topsheet 201 comprises a segment of a composite web 1 according to one or more of the features described above.

[0150] The composite web 1 is cut to make a segment of composite web to be assembled in the article 200.

[0151] The segment of composite web comprises at least one molded segment 12S and one segment 11S of the first continuous web 11.

[0152] In an embodiment, the molded segment 12S is smaller in length than the segment 11S.

[0153] In an embodiment, the molded segment 12S is smaller in width than the segment 11S.

[0154] As illustrated, for example, in FIG. 8, the segment 11S included in the composite web 1, is disposed between the molded segment 12S (also included in the composite web 1) and the absorbent core 203.

[0155] In an embodiment, not illustrated, the absorbent article 200 comprises an ADL (that is, a liquid acquisition and distribution layer) disposed between the segment 11S and the absorbent core 203. Preferably, the ADL is discrete and disposed at the molded segment 12S.

[0156] Advantageously, the presence of an ADL allows acquiring the liquids and directing them towards an absorbent core, thereby increasing the efficiency of the absorbent sanitary product 200.

[0157] This description relates to a method for the production of a composite web 1. The composite web 1 is preferably used for making absorbent sanitary articles such as, for example, the article 200.

[0158] The method essentially comprises the following steps: [0159] feeding a first continuous web 11, [0160] feeding at least one molded segment 12S of a second continuous web 12, where the segment 12S has at least one protrusion 4 delimited at least partly by a base portion 5, [0161] joining the segment 12S to the first web 11 at the base portion 5 to delimit at least one cavity 7 between the web 11 and the segment 12S at the protrusions 4.

[0162] In an embodiment, the method comprises a step of molding a segment 12L of second continuous web 12 to obtain the molded segment 12S.

[0163] Preferably, the method, in particular the step of molding, comprises a step of embossing the segment 12L, that is, stamping or molding a 3D pattern on it.

[0164] The method used to mold the segment is commonly known as embossing.

[0165] For example, the step of molding can basically be performed using a first roller that is peripherally provided with a plurality of suction hollows, and a second roller that is peripherally provided with a plurality of teeth that are substantially shaped to match the suction hollows.

[0166] In an embodiment, the method comprises the step of feeding the second continuous web 12.

[0167] In an embodiment the method comprises a step of cutting and spacing the second continuous web 12 to obtain segments 12L of second web 12.

[0168] The segments 12L are subsequently molded to obtain segments 12S provided with protrusions 4 delimited by base portions 5.

[0169] The step of cutting and spacing can be carried out, for example, using a method known as slip and cut, that is to say, a method of cutting and sliding whereby (discrete) segments are cut from the web and then spaced apart.

[0170] In an embodiment, the step of joining at least one molded segment 12S to the first continuous web 11 comprises a step of welding the segments 12S to the web 11 at the base portion 5.

[0171] In an embodiment, the step of welding the segments 12S to the web 11 is carried out by ultrasonic welding or thermomechanical welding.

[0172] In an embodiment, the step of joining the segments 12S to the continuous web 11 comprises a step of disposing a layer of adhesive 8 between the segments 12S and the web 11.

[0173] Joining the segments 12S to the web 11 allows fixing and keeping the 3D pattern imparted to the segment 12S by molding.

[0174] In an embodiment, a succession of suitably sized and spaced segments 12S is applied to the web 11.

[0175] In an embodiment, the step of joining the segment 12S to the web 11 comprises a step of joining a discrete succession of segments 12S to the first continuous web 11.

[0176] The first continuous web 11 is joined at the base portions 5 of the molded segment 12S, in particular, it is joined on the side opposite the protrusions 4, defining the molded portion 3 for the composite web 1.

[0177] In an embodiment, the method comprises the steps of molding the continuous web 12 and cutting and spacing the continuous web 12 to obtain segments 12S.

[0178] This description relates to a forming unit 100 for making composite webs, for example of the type like the composite web 1.

[0179] The unit 100 essentially comprises a production device 101 and an applicator device 110.

[0180] The applicator device 110 is configured to join a molded segment 12S, provided with a pattern M that comprises at least one protrusion 4 and one base portion 5, to a first continuous web 11.

[0181] The production device 101 for making the segment 12S comprises a molding device 102 for molding the pattern M and a cutting and spacing device 103 configured to cut and space a second continuous web 12 to make at least one segment or a plurality of segments 12L of the second continuous web 12.

[0182] The device 102 is of a type known in the trade and is also called embossing device.

[0183] In an embodiment, the device 102 is disposed downstream of the device 103 in a feed direction V12 of the second web 12 so as to mold the pattern M on the segment 12L.

[0184] In an embodiment not illustrated, the device 102 is disposed upstream of the device 103 in the feed direction V12 to mold the pattern M on the web 12. That way, the segments 12S that are cut and spaced are already molded.

[0185] The device 102 comprises a first drum 104 and a second drum 105 positioned relative to each other to define a through-gap 106 for passage of the segment 12L or of the web 12.

[0186] In the example illustrated in FIG. 5, the first drum 104 is rotatable clockwise about an axis a4, while the second drum 105 is rotatable anticlockwise about an axis a5, parallel to a4. For simplicity, the drums 104 and 105 are considered to be substantially tangent.

[0187] In an embodiment, the first drum 104 and the second drum 105 are provided, respectively, with the male portions and the female portions, which are shaped to match each other and to mold the pattern M (formed of the protrusions 4).

[0188] The male-female portions present on the drums 104 and 105 allow making the protrusions 4 on the segment 12S.

[0189] The male and female portions are shaped according to the shape which the protrusion 4 is intended to have.

[0190] In an embodiment, the segment 12S is thus molded by conveying it between the drums 104, 105.

[0191] The drums 104, 105 shown in FIG. 6, for example, are shaped to make wavy protrusions 4.

[0192] In an embodiment, the drum 104 is patterned and the drum 105 acts as anvil.

[0193] The segment 12L advances and passes through the gap 106 so that the outside surfaces of the drums 104, 105 act in conjunction to engage the segment 12L to impart the 3D pattern to it.

[0194] The device 110 is configured to join the segment 12S to the web 11 at the base portion 5.

[0195] In an embodiment, the device 110 is located downstream of the production device 101 in a feed direction V12S of the molded segment.

[0196] In an embodiment, as illustrated in the example of FIG. 5, the device 103 comprises an anvil 107, preferably in the form of a drum that is rotatable clockwise about an axis a7, and a rotary knife 108 that is rotatable anticlockwise about an axis a8, and acts in conjunction with the anvil 107.

[0197] The knife 108 cuts the continuous web 12 to form the segments which are suitably spaced, for example on the anvil 107 itself with a known slip and cut method not further described.

[0198] In an embodiment, the device 103, in particular the anvil 107, is configured to space the segments 12L.

[0199] The device 110 comprises at least one applicator drum 111 that is tangent to the first drum 104 or to the second drum 105.

[0200] The applicator drum 111 is rotatable about an axis all clockwise in the example illustrated in FIG. 5 and is located downstream of the drum 105 in the feed direction V12S.

[0201] In an embodiment, the drum 111 is tangent to the drum 105 and allows carrying out the step of joining the segments 12S to the web 11, that is to say, joining the web 11 to the base portions 5 of the segments 12S, as illustrated schematically in FIG. 7.

[0202] In an embodiment, the device 110 comprises a welder 112 for welding the molded segment 12S to the first continuous web 11.

[0203] In an embodiment, the drum 112 and the drum 105 are configured to weld the segments 12S to the first web 11.

[0204] In an embodiment, the device 110 comprises an adhesive dispenser 113 located downstream of the production device 101 in a feed direction V12S of the molded segment. The dispenser 113 dispenses at least one layer of adhesive 8 so that the segments 12S can be joined to the continuous web 11 by the adhesive. For example, the dispenser 113 dispenses the adhesive to the web 11 and/or to the segments 12S.