Abstract:
The present invention provides a method and apparatus for increasing the number of articles processed. over a distance traveled in the machine direction of an assembly line. In particular, the orientation of the long dimension of the article is provided transverse to the machine direction, thus process rug the articles side-by-side instead of end-to-end.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 62/245,626, filed 23 Oct. 2015. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to processes and apparatus for applying discreet wings to traveling webs as the absorbent articles are oriented transverse to the machine direction. 
         [0003]    Generally, the absorbent articles have a long dimension and a short dimension, whereby the articles are oriented along an assembly line with the long dimension in line with the machine direction. As the articles are longer than they are wide, this orientation requires more assembly line space in the machine direction per processed article. The industry could benefit from an alternative approach that would reduce the amount of assembly line space required in the machine direction per processed article to increase the number of articles processed over the same distance traveled through the assembly line, as well as speed. 
         [0004]    In prior art sanitary napkin production, right and left wings are often formed of backsheet material, and the right and left wings are folded over the topsheet material and secured to one another for folding and packaging. One example of a prior art sanitary napkin is shown in U.S. Pat. No. 6,391,011. In that patent, a sanitary napkin is shown having flaps placed in a folded disposition prior to use. The flaps are formed of the backsheet material, and the flaps are unitary and coextensive on the product with the backsheet material, so that the backsheet material is folded about side edges of the product to present the flaps for usage and application to an undergarment. A bridge tape extending between the folded over flaps retains the flaps in their folded configuration until use, at which point the bridge tape is removed, exposing adhesive for releasably affixing the sanitary napkin to the undergarment of a wearer. 
         [0005]    In the prior art, again as demonstrated by U.S. Pat. No. 6,391,011, absorbent cores are placed on a chassis web with the longer dimension of the core processed and placed onto the chassis web in a machine direction orientation (see, e.g., FIG. 6, U.S. Pat. No. 6,391,011). 
       SUMMARY OF THE INVENTION 
       [0006]    Provided is a method and an apparatus for increasing the number of articles processed aver a distance traveled in the machine direction of an assembly line. In particular, the orientation of the long dimension of the core is provided transverse to the machine direction (cross-machine direction), thus processing the articles side-by-side instead of end-to-end. This results in efficiency of both speed and space. Wing material is placed onto a topsheet in a machine direction, and release papers are applied to the wing material in a relationship advantageous for processing and use, for instance by not requiring folding of the wings over the side edges of the product. 
         [0007]    A method of producing a disposable product is disclosed, the method comprising providing a topsheet web of material in a machine direction; coupling a first and a second wing component to said topsheet web on a first side of said topsheet web of material; coupling a first base release paper to said first wing component, coupling a second base release paper to said second wing component, coupling a secondary release paper to said first base release gaper and said second wing component, providing a backsheet web of material in said machine direction, providing an absorbent core having a length dimension and a width dimension, said length dimension greater than said width dimension, between said topsheet and backsheet webs, said length dimension of said core extending in a cross-machine direction, and coupling said topsheet and backsheet webs about said absorbent core. 
         [0008]    Said absorbent core is positioned underlying said first and said second wing components, and the method may further comprise severing said first and second wing components to create a first discrete disposable product. Backsheet release paper is releasably to an underside of said backsheet web. 
         [0009]    A method of producing disposable products, the method comprising coupling a plurality of wings to a top side of a topsheet web, said topsheet web traveling in a machine direction; releasably coupling a first release paper to a first edge portion of each of said wings; releasably coupling a second release paper to said first release caper and to a second portion of an adjacent wing; providing a series of spaced cores having a length dimension, and a width dimension less than said length dimension, said length dimension oriented transversely to said machine direction; sandwiching said cores between an underside of said topsheet and a top side of a backsheet traveling in said machine direction; bonding said topsheet, and said backsheet; severing said topsheet and said backsheet between spaced cores to produce an absorbent article. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a schematic of an apparatus according to the present invention. 
           [0011]      FIGS. 2-1 and 2-2  are a flow diagram of a process according to the present invention. 
           [0012]      FIGS. 2A-2E  show a flow diagram of sub-processes of the present invention,  FIG. 2A  shows wing material being provided,  FIG. 2B  shows firs wing-release paper web formation,  FIG. 2C  shows second wing release paper formation,  FIG. 2D  shows a backsheet web receiving adhesive and the combination supplied with cores formed, fluffed, debulked and embossed as shown in  FIG. 2E . 
           [0013]      FIG. 3  is a top plan view of an absorbent article according to the present invention a the location indicated in  FIG. 1  and  FIGS. 2-1 and 2-2 . 
           [0014]      FIG. 4  is a top plan view of the absorbent article according to the present invention at the location indicated in  FIGS. 2-1 and 2-2 . 
           [0015]      FIG. 5  is a cross sectional view of a preferred embodiment of the absorbent article shown in  FIG. 4 . 
           [0016]      FIG. 6  is a top view of an alternate wing arrangement for use on the absorbent article. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0017]    Referring now to  FIG. 1 , an illustration of an apparatus  10  according to the present invention is shown. The apparatus  10  preferably includes a first assembly line  12  comprising a wing die-cutter  14 , a first release-paper slip-cutter  16 , a second release-paper slip-cutter  18 , an anvil  20 , an ultrasonic horn  22 , and a plurality of adhesive applicators  24 , and a second assembly line  30  comprising a core forming drum  32 , a core applying drum  34 , and an adhesive applicator  24 . Adhesives used in the product could include garment adhesive, fugitive adhesive (or transport adhesive), and construction adhesive (for instance for bonding the core to the backsheet). Cores will be placed onto construction adhesive Placed on the backsheet. 
         [0018]    Although a first and a second release-paper slip-cutter  16 ,  18  are shown and discussed, it is contemplated that one release-paper slip-cutter could be provided to perform the steps of the first and the second release-paper slip-cutters  16   18 . 
         [0019]    Looking to  FIGS. 1 and 2  a process of forming an absorbent article  100  ( FIG. 4 ) according to the present invention is shown. A topsheet  40  is provided at the first assembly line  12  and travels along the first assembly line  12  in a machine direction  90 . Wing material  42  receives adhesive  26  (which can be a temporary, or fugitive adhesive indicated as  26 ′) from one of the adhesive applicators  24 . The wing material  42  is then processed through the wing die-cutter  14  to provide individual wing members  44  (as shown in  FIG. 2A ) having a first wing member portion  46  and a second wing member portion  48 , with the adhesive  26  dividing the first and second wing member portions  46 ,  48 . Each wing member  44  is then applied to the topsheet  40  as shown Preferably adhesive  26 ′ carried by wing  44  is a fugitive, or temporary bond, as ultrasonic bonding is used lamer in the process to couple wing  44  to topsheet  40 . Also preferably, adhesive  26 ′ on wing  44  is present outside of a region intended for ultrasonic bonding to topsheet  40 . Although fugitive adhesive  26 ′ is preferred, it is optional, as vacuum present on the assembly line  12  can in some instances provide holding force sufficient to retain wings  44  against web  40  during processing. 
         [0020]    As will be discussed later, in a preferred embodiment, first and second wing member portions  46 ,  48  of an individual wing member  44  ultimately end up on adjacent absorbent articles  100 ; that is, in a preferred embodiment, the wing members  44  preferably end up divided into two sections  46  and  48 ; first wing member portion  46  on one absorbent article  100 , and second wing member portion  48  on a different absorbent article  100 . Stated another way, in a preferred embodiment, portions of two individual wing members  44  can be used to form a single absorbent article  100 . In a preferred production technique, one wing member  44  bridges two adjacent products  100  during production. A center of wing patch  44  (in the cross direction) is region at which a future knife cut is placed when absorbent articles  100  are cut to discrete. During production, adjacent products  100  are made discrete, dividing each wing member  44  into two sections  46  and  48 , which will become left/right wings on adjacent products  100 . 
         [0021]    Still referring to  FIG. 1  and also to  FIG. 2B , a first wing-release paper web  60  is provided and adhesive  26  is applied by an adhesive applicator  24  in a predetermined pattern. Release paper typically has silicone coating so that adhesive cannot aggressively stick to it. In preferred embodiments, release paper as used in the present invention is used to prevent adherence of absorbent articles  100  in an unintended fashion. In use, absorbent articles  100  are provided with release papers which are removed, exposing adhesive surfaces for in-use adherence of absorbent articles  100  in desired places. As such, release papers  62  (and as later described, release papers  66 ) typically carry adhesive to wings  44 , and also serve to cover adhesive  26  until intended product use. The first wing-release paper we  60  is then processed through the first release-paper slip-cutter  16  to provide individual and spaced first wing-release paper members  62 . Preferably, each first wing-release paper member  62  is adhered to a respective wing member  44  on the first wing member portion  46  ( FIG. 3 ), at or near a trailing edge of wing member  44  when considered in the machine direction  90 . It should be noted that although reference is made to a trailing edge in the process, the process could easily be used to apply the release paper  62  to a leading edge of wing member  44  (to in effect, create right handed or left handed opening products in use). Also preferably, release paper  62  carries a single strip of adhesive  26  either from edge to edge or close-to-edge to close-to-edge of release paper  62  in the cross-machine direction. In use, release paper  62  can carry away adhesive  26  when removed from the article  100 . 
         [0022]    Still referring to  FIG. 1 , and also now to  FIG. 2C , a second wing-release paper web  64  is provided and adhesive  26  is applied by an adhesive applicator  24  in a predetermined pattern. The second wing-release paper web  64  is then processed through the second release-paper slip-cutter  18  to provide individual and spaced second wing-release paper members  66 . Preferably, each second wing-release paper member  66  is adhered to a respective wing member  44  onto the first wing-release paper member  62  (itself carried by first wing member portion  46  ( FIG. 3 ), at or near a trailing edge of wing member  44 ), and then second wing-release paper member  66  overlaps adjacent wing members  44 , and is carried by a leading edge of a trailing wing member  44  in the process, as can be seen in  FIGS. 3-5 . In such a configuration, second wing-release paper members  66  preferably carry adhesive  26  in two places of advancement in the machine direction, as see in cross-section in  FIG. 5 . In a preferred embodiment, adhesive  26  is carried by second wing-release paper member  66  toward a leading edge of second wing-release paper member  66  to facilitate coupling with first wing-release paper member  62  and toward a trailing edge to facilitate coupling with wing member  44  (see  FIG. 5 ). Again, also preferably, release paper  66  carries these strips of adhesive  26  either from edge to edge or close-to-edge to close-to-edge of release paper  66  in the cross-machine direction. 
         [0023]    The combination of topsheet  40 , wing members  44 , first wing-release paper members  62 , and second wing-release paper members  66  continue down the first assembly line  12 . The anvil  20  and ultrasonic horn  22  then combine to form an ultrasonic bond  28  of the wing members  44  and the topsheet  40  preferably at a location bisecting first and second wing member portions  46 ,  48  (see, e.g.,  FIG. 4 ). Additionally or alternatively, other forms of bonding now known or later developed may perform the step of bonding the wing members  44  to the topsheet  40  and still be within the purview of the present invention. 
         [0024]    Concurrently with the process occurring along the first assembly line  12 , a pulp core  70  is being formed and a backsheet  74  is provided along the second assembly line  30 . The core forming drum  32  receives pulp (not shown) and/or superabsorbent polymer, and in many instances a combination of both, and forms individual cores  70  each having a core longitudinal center line  72  (see  FIG. 3 ). Cores are produced as shown in  FIG. 2E , preferably first fluffed, second debulked, and third embossed. The cores  70  are spaced apart a predetermined distance. The absorbent articles  100  are oriented with the core center line  72  transverse, or perpendicular, to the machine direction  90 . This orientation increases the number of articles  100  processed over a distance traveled in the machine direction of an assembly line. It also increases the number of articles  100  produced over a given period of time at a given machine speed. 
         [0025]    Typically, absorbent cores nave an oblong shape designed to fit underneath a crotch section of a wearer, generally extending from the front of a body, under the body and to the rear of the body. Because of this configuration around the body of a wearer, rectangular, oblong, T-shaped or hourglass cores are commonly formed to be form fitting and comfortable. With respect to feminine hygiene products, cores are often hourglass shaped or elongated oval in shape. With regard to the present invention, a preferred core  70  is longer than it is wide, as depicted for example in  FIGS. 3 and 4 . 
         [0026]    Additionally or alternatively, the cores  70  may be formed in any other manner now known or later developed, including for example, through a die-cutting process (not shown). 
         [0027]    Still referring to  FIG. 1 , backsheet release paper web  92  is drawn past adhesive applicator  24  receiving adhesive  26 , severed into individual backsheet release papers  94 , and coupled to an underside of backsheet web  74 . This process is also shown in  FIG. 2D . 
         [0028]    As shown in  FIG. 1  the pulp cores  70  are adhered to the backsheet  74  with adhesive  26  from an adhesive applicator  24  prior to being combined with the topsheet  40 . In a preferred embodiment, construction adhesive can be applied in full coverage by adhesive spray means to hold core  70  to backsheet  74 . Additionally (and optionally and alternatively), as shown in  FIG. 2-1 , the pulp cores  70  may be adhered by adhesive, or other types of bonding to the topsheet  40  prior to combining the topsheet  40  and the backsheet  74 . In any event, the each core center line  72  is preferably aligned with a corresponding border line  50  separating neighboring wing members  44  as shown in  FIG. 3 . 
         [0029]    Referring now to  FIG. 2-1 , an additional plan process view of the process shown in  FIG. 1 , and processes occurring after those shown in  FIG. 1 , is shown. Continuing from  FIG. 1 , the combination of topsheet  40  and backsheet  74 , wings  44 , firs release papers  62 , second release papers  66 , backsheet release paper  94  and accompanying adhesives continue onward together as shown in  FIG. 2-1 . 
         [0030]    Referring now to  FIG. 2-2 , after the topsheet  74  (carrying its associated product components) and backsheet  70  (carrying its associated product components) are introduced to one another, preferably following the step of bonding the wings  44  to the topsheet  74  as shown in  FIG. 1 , a perimeter seal  80  is formed, preferably by at least one of a heat bond, a pressure bond and an ultrasonic bond, indicated at bond  80 . Referring now to  FIG. 4 , perimeter seal  80  forms a boundary about cores  70 . 
         [0031]    Still referring to  FIG. 2-2 , a final die-cut is provided to form a plurality of absorbent articles  100  according to the present invention as shown in  FIG. 4 . The absorbent articles  100  are then spaced apart, after which they preferably receive a web of pouch material for individual packaging. Individual products  100 , now carried by a couch web, are then folded along with the pouch web, and the pouch web is crimped about the products  100 . The pouch web is then itself cut to carry an individually packaged article  100 , and the individually packaged articles (now carried in a pouch) can be stacked packaged as desired. 
         [0032]    Referring now to  FIG. 5 , a cross-sectional view of a preferred embodiment of the absorbent article shown in  FIG. 4  is shown. Vertical dashed lines represent areas in which the final die cut of  FIG. 2-2  can be employed to sever wings  44  (into their left portion  48  and right portion  46 , see  FIG. 4 ), topsheet  44 , and backsheet  70 , resulting in individual and now distinct products  100 . 
         [0033]    Referring now to  FIG. 6 , a top view of an alternate wing  44  arrangement for use on the absorbent article  100  is shown. As can be seen, wings  44  are not necessarily rectangular (as shown for instance with reference to  FIGS. 2-4 ) but can be contoured, shaped or formed by die cutting or otherwise as desired. 
         [0034]    The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.