Method of producing incontinence articles in the form of pants

A continuous method for producing incontinence articles in the form of pants for receiving body excrements utilizes crotch sections comprising absorbent bodies and having leg cut-outs formed by a first contour cut. Two partial webs are joined to the crotch sections in such a fashion that one end of the crotch sections overlaps one partial web in a longitudinal direction transversely to the machine direction, and the other end thereof overlaps the other partial web, and the crotch sections are disposed at a separation from each other in the machine direction. A second contour cut is performed that includes the partial webs on their mutually facing edge sections for forming substantially curved leg cut-outs. The article is then folded and the partial webs are joined transversely to the machine direction at a separation from each other for forming side seam areas of the incontinence article to be produced.

BACKGROUND OF THE INVENTION

The invention concerns a continuous method for producing incontinence articles in the form of pants for receiving body excrements, comprising a front belly section and a rear back section, which are connected to each other at side seam areas on both sides during production to form a belly and back band, which is continuous in the transverse or peripheral hip direction and has a hip opening that is closed in the peripheral hip direction, and a crotch section which has an absorbent body and extends in a longitudinal direction between the belly section and the back section, and is permanently attached to the belly section and to the back section, wherein the crotch section as well as the belly section and the back section define the leg openings of the incontinence article, wherein first elastification means are provided in the belly section and the back section, which extend in the transverse or peripheral hip direction at a separation from each other and parallel to each other to extensively elastify the belly area and the back area, wherein second elastification means are provided in an area of the belly section and the back section on the crotch side facing the leg openings (i.e. remote from the hip), which extend starting from the two side seam areas towards a longitudinal center axis of the incontinence article in a curved shape, thereby fanning out with increasing separation from each other.

A three-component incontinence article of this type is disclosed e.g. in the German patent application DE 10 2007 055524.7 of the Assignee, which has not been previously published.

In this specific product concept, an H-shaped basic structure of the incontinence article is realized by joining the crotch section, which extends in the longitudinal direction, to the belly section, which extends substantially in the transverse or peripheral hip direction, and to the correspondingly extending back section when these three components are flatly extended. The incontinence article is then modularly designed from the components crotch section, belly section and back section. These components are advantageously initially connected to each other via the crotch section, and preferably after that, the side seam areas of the belly section are connected to those of the back section on both sides. This connection is realized by the manufacturer to obtain the shape of pants. This connection is typically permanent. However, it may also be provided that the pants can be opened, in particular, along a breaking line which may extend, in particular, in the side seam area, e.g. for removing a used incontinence article from a person who is in need of care.

Incontinence articles in the form of pants differ, in principle, from incontinence articles of normal diaper shape that can be opened and closed in that the hip size is generally predetermined and the article can be adjusted to different body sizes by providing a number of different basic sizes that can be elastically stretched. Towards this end, elastification means, in particular, in the form of bands or threads, often called LYCRA® (elastane) threads, are generally connected in a prestrained state (stretch-bond method) to chassis materials of the incontinence article, i.e. they are fixed in the prestrained state to the chassis materials e.g. by means of glue. Due to their pretension, these elastification means gather the chassis materials to thereby form crimps. The incontinence article or the elasticised chassis materials of the incontinence article can be elastically stretched again when the incontinence article is applied, like pants, to the user. Several incontinence articles in the form of pants comprising elasticised chassis materials of this type have been disclosed and are also discussed e.g. in the above-mentioned document WO 2004/052260 A1.

It is difficult to produce an optimum contour of the leg openings, in particular, when working at high machine speed, in particular in a range of several 100 m/min, which is normal during production of modern incontinence articles, since both the crotch section and the belly and back section of the incontinence article define the leg openings.

It is the underlying purpose of the present invention to provide a continuous method for producing an incontinence article in the form of pants having the above-mentioned features, which takes into account, in particular, the above-mentioned aspects of providing the leg opening contour and which can be economically performed.

SUMMARY OF THE INVENTION

In accordance with the invention, this object is achieved by a method comprising the following method steps:supplying crotch sections which comprise absorbent bodies and leg cut-outs formed by a first contour cut;supplying two partial webs based on non-woven material, which form the subsequent belly section and the subsequent back section of the incontinence article;supplying and applying the second elastification means to both partial webs and fixing them thereto;joining the crotch sections with the two partial webs in such a fashion that one end of the crotch sections overlaps one partial web in a longitudinal direction transversely to the machine direction, and the other end thereof overlaps the other partial web, and that the crotch sections are disposed at a separation from each other in the machine direction, fixing the crotch sections and partial webs in the overlapping areas, and forwarding in the machine direction;supplying, applying and fixing the first elastification means to the partial webs in the machine direction;performing a second contour cut that includes the partial webs on their mutually facing edge sections for forming substantially curved leg cut-outs;folding about a folding line that extends in the machine direction in such a fashion that one partial web comes to rest on top of the other partial web;joining the partial webs, which are disposed on top of each other, transversely to the machine direction at a separation from each other for forming side seam areas of the incontinence article to be produced, and obtaining products that comprise a belly section, a back section and an intermediate crotch section;performing a separating cut in a direction transversely to the machine direction and obtaining separated finished incontinence articles.

Since the leg cut-outs are realized in two steps, i.e. by a first contour cut, which is performed on the crotch section of the hygiene article, and a second contour cut, which is performed on both partial webs which form the belly section or the back section of the incontinence article, shaping can be optimized. In this fashion, the respective single contour cut is also shorter.

Moreover, one single cut can be better adjusted to the machine direction. The cutting devices for the contour cut can also be optimized with respect to the materials to be cut, e.g. different cutting knifes can be used for different materials.

In accordance with a preferred embodiment of the inventive method, a non-woven material cover layer that extends over the second elastification means is supplied to and disposed on each partial web after supplying, applying, and fixing the second elastification means to the partial webs, and the two partial webs are further supplied in the machine direction at a separation from each other and parallel to each other.

In accordance with another preferred embodiment of the inventive method, a non-woven material cover layer that extends over the first elastification means is applied to each partial web after supplying, applying and fixing the first elastification means in the machine direction to the partial webs, and the two partial webs are further supplied in the machine direction at a separation from and parallel to each other.

It is basically feasible to previously configure the crotch sections of the incontinence article, which are to be supplied, in such a fashion that they are supplied in an endless fashion, in particular, from a roll, and already have the first contour cut for forming the leg cut-outs on the crotch section. In accordance with a further embodiment of the inventive method, it may be advantageous for the crotch sections to be supplied to have, in particular, a uniform width, and to perform the first contour cut for forming the leg cut-outs of the crotch section within the continuous method.

In accordance with a further method variant, it may be advantageous for the crotch sections to be formed within the continuous method and not before, by supplying an endless topsheet material web, an endless backsheet material web and absorbent bodies in a machine direction, disposing the absorbent bodies at a separation from each other between the topsheet material web and the backsheet material web, and securing the composite formed in this fashion. The first contour cut is then performed in the composite formed in this fashion, in order to form the leg cut-outs of the subsequent crotch sections of the incontinence article.

In another advantageous fashion, leg elastification means are supplied between the cover materials of the crotch section, i.e. between the topsheet material web and the backsheet material web. The leg elastification means are moreover advantageously supplied in such a fashion that they extend at a varying separation from the absorbent body and have, at their longitudinal ends, a larger separation from the absorbent body than in the center. The leg elastification means are preferentially supplied in a curved shape. In a particularly advantageous fashion, the leg elastification means are supplied in such a fashion that the leg elastification means substantially follow the curved leg cut-outs of the subsequent crotch section.

In a preferred embodiment of the method, the first contour cut is performed in such a fashion that it substantially forms curved leg sections of the subsequent crotch sections of the incontinence article.

In a particularly preferred embodiment, the first contour cut is performed by means of a cutting roller pair, i.e. a rotating knife with an anvil roller.

The present invention is particularly advantageous exactly for the production of incontinence articles of this type, in which the crotch section has leg elastification means that are associated with the leg openings. If, in this case, the respective crotch sections are provided with leg elastification means and then separated, the leg elastification means exert strong tensile forces on the materials of the respective crotch section and try to pull the crotch section together. This is difficult to control by means of production technology, and it is even more difficult to provide the leg openings with a contour when the crotch sections are separated. In accordance with the present invention, that part of the leg openings, which is defined by the crotch section, is already produced during performance of the first contour cut, at a time at which the crotch sections are not yet separated, i.e. are still endlessly supplied. With this endless supply, the above explained forces, which are caused by the leg elastification means, can be better controlled, leading to a better result with respect to accuracy of contour of the leg openings with reduced technical effort.

It is basically feasible to supply the topsheet material web, backsheet material web and absorbent body components in the subsequent longitudinal direction of the crotch section or the hygiene article. Supply in the transverse direction is also feasible. In the first case, a 90° deflection is required in the course of the endless production method, since further production is preferably performed in the transverse direction of the incontinence article. In any event, the crotch sections must be separated, i.e. singled, in a direction transversely to the machine direction, and then be further supplied at a separation from each other in order to be connected to the endless partial webs.

The backsheet material web can be supplied in the form of a liquid-impermeable foil sheet, which is provided with a non-woven material coating prior to or during the continuous method, which can provide the outer side of the incontinence article facing away from the body with a textile impression. It may also be advantageous to provide a reinforcing coating of the backsheet material web in some areas. The reinforcing coating preferably consists of a non-woven material, in particular, a spunbonded non-woven material of polypropylene, in particular, having a surface density of 10 to 20 g/m2, in particular of 12 to 17 g/m2.

The backsheet material web comprises, in particular, a foil, in particular of a surface density of 18 to 40 g/m2. The backsheet material web comprises, in particular, a foil, which is liquid-tight but at the same time breathable during use, i.e. a water vapor-permeable, in particular, microporous foil. The water vapor permeability of the backsheet material web, measured according to DIN 53 122-1 (Edition: 2001-08), is, in particular, at least 300 g/m2/24 h, moreover, in particular at least 1000 g/m2/24 h, moreover, in particular at least 2000 g/m2/24 h, moreover, in particular at least 3000 g/m2/24 h, moreover, in particular at least 4000 g/m2/24 h, moreover, in particular at most 6000 g/m2/24 h.

The absorbent body comprises materials that absorb body liquids, such as natural or synthetic fibers, in particular, cellulose fibers, preferably in the form of cellulose fluff. The absorbent body moreover preferably comprises super-absorbent materials (SAP), in particular, on the basis of surface-cross-linked, partially neutralized polyacrylates.

Thread-shaped or band-shaped elastification means, such as rubber or polyetherpolyurethane or polyesterpolyurethane threads, preferably elastic threads such as LYCRA® or SPANDEX® (elastane) threads are preferably used as leg elastification means. The leg elastification means preferably have a thickness of 300 to 1500 dtex, in particular 500 to 1200 dtex, moreover in particular 500 to 900 dtex.

The leg elastification means are advantageously fixed to the cover materials of the crotch section with a pretension of 1.5 to 6.0, in particular of 2.5 to 4.5.

The two partial webs that form the subsequent belly section and the subsequent back section may e.g. be supplied in that each partial web is unrolled from its own roll and supplied to the production process. In accordance with a preferred method variant, an endless non-woven material web may initially be supplied which is then separated along the machine direction to form the two partial webs. The machine thereby requires only one roll.

The partial webs on the basis of non-woven material for the subsequent belly section and/or the subsequent back section are preferably selected from the group of spunbonded non-woven materials, meltblown non-woven materials, SM non-woven materials, SMS non-woven materials, SMMS non-woven materials, card webs or Through Air bonded card webs. With particular preference, the partial webs for the subsequent belly section and/or the subsequent back section are produced from a spunbonded non-woven material. The non-woven materials that are used for the partial webs for the subsequent belly section and/or the subsequent back section advantageously have a surface density of 10 to 30 g/m2, moreover preferably 15 to 25 g/m2. A spunbonded non-woven material of polypropylene, in particular, with a surface density of 15 to 25 g/m2, is preferentially used for the partial webs for the subsequent belly section and the subsequent back section.

The first and/or second elastification means are advantageously endlessly supplied to the partial webs in the machine direction. The first and the second elastification means are preferentially endlessly supplied to the partial webs in the machine direction.

The above-mentioned first elastification means that extend in the peripheral hip direction are advantageously introduced at a separation from each other of 4 to 10 mm, in particular 4 to 8 mm, in particular 4 to 6 mm.

The second elastification means that fan out in a curved shape in the direction towards the longitudinal center axis of the incontinence article are correspondingly introduced at a varying separation from each other (separation of directly neighboring elastification means) of between 3 mm and 35 mm. Guiding instruments that can be driven in an oscillating fashion are advantageously used for introducing the elastification means.

The second elastification means are advantageously introduced in such a fashion that a minimum separation between the second elastification means (i.e. the separation between directly neighboring second elastification means) in the subsequent side seam areas is 3 to 8 mm, in particular 3 to 7 mm, and moreover in particular 3 to 6 mm.

The second elastification means are moreover advantageously introduced in such a fashion that a maximum separation between the second elastification means (i.e. the separation between directly neighboring elastification means) on a subsequent absorbent body edge or on a subsequent longitudinal edge of the crotch section is 7 to 35 mm, in particular 10 to 32 mm, and moreover in particular 12 to 30 mm.

The separations between the second elastification means in the subsequent back section advantageously differ from the separations between the second elastification means in the subsequent belly section. The maximum separation between the second elastification means in the subsequent back section is advantageously larger than the maximum separation between the second elastification means in the subsequent belly section.

The second elastification means advantageously also have a fanning-out degree of
F=(A−B)/B*100%
of 50 to 900%, in particular 100 to 700%, and moreover, in particular 150 to 550%.

The fanning-out degree F. is thereby defined as the ratio between the separation increase (A−B) and the minimum separation (B) in percent. The values A and B are thereby defined as the separation between the outermost second elastification means in the longitudinal direction of the subsequent incontinence article and the innermost second elastification means in the longitudinal direction (i.e. not the separation between directly neighboring second elastification means), i.a. A as the maximum separation, in particular, on the subsequent longitudinal edge of the crotch section or on the subsequent absorbent body edge, and B as the minimum separation, in particular, in the subsequent side seam area.

The fanning-out degree F. of the second elastification means is advantageously larger in the subsequent back section than in the subsequent belly section.

It may also be advantageous to deactivate the elastic properties of the second elastification means in an overlapping area with the absorbent body. This deactivation may e.g. be realized by a number of separating cuts through the second elastification means in the overlapping area with the absorbent body. Other separating methods are also feasible, e.g. ultrasound welding or laser welding. The elastic properties of the first elastification means may also be deactivated in the overlapping area with the absorbent body.

The extension of the second elastification means and the performance of the second contour cut of the partial webs are advantageously such that the second contour cut is performed along and at a separation (D) from the innermost second elastification means in the longitudinal direction facing the crotch area. This separation (D) is advantageously 2 to 40 mm, in particular 3 to 30 mm, and moreover in particular 4 to 20 mm.

The first and/or second elastification means28,40,42are advantageously fixed to the partial webs under a pretension of 1.5 to 6.0, in particular 2.5 to 5.0. The pretension is thereby defined as the factor of the degree of extension compared to the non-extended/relaxed state of the elastification means.

Thread-shaped or band-shaped elastification means, such as rubber or polyetherpolyurethane or polyesterpolyurethane threads, preferably elastic threads such as LYCRA® or SPANDEX® (elastane) threads, are advantageously used as the first and/or second elastification means. The first and/or second elastification means preferably have a thickness of 300 to 1500 dtex, in particular 500 to 900 dtex, moreover in particular 500 to 600 dtex.

The first and/or second elastification means are advantageously fixed to the partial webs by means of glue. The glue for fixing the first and/or second elastification means may thereby advantageously be applied directly onto the partial webs and/or non-woven cover layers or directly onto the elastification means (thread glue application). The first elastification means are preferably directly provided with glue, in particular by spraying, and the second elastification means are disposed on the glue that has been previously extensively applied to the partial webs and/or non-woven material cover layers.

In accordance with a further preferred embodiment of the inventive method, the second contour cut only includes the partial webs and not the crotch section. For this reason, a discontinuous shape may be formed along the leg openings at the transition area between the crotch section and the belly section or back section.

In accordance with a preferred embodiment of the inventive method, the second contour cut of the partial webs is performed in such a fashion that the curved leg cut-out of the partial web of the subsequent belly section extends in a different shape, in particular a different angle or radius than the curved leg cut-outs of the partial web of the subsequent back section.

In accordance with a preferred embodiment, the second contour cut for forming the substantially curved leg cut-outs is performed in such a fashion that the second contour cut is simultaneously realized both for the partial web of the subsequent belly section and the partial web of the subsequent back section.

In a particularly preferred embodiment, the second contour cut is performed using a cutting roller pair, i.e. a rotational knife with an anvil roller.

In another advantageous fashion, the superposed partial webs are joined to form side seam areas of the incontinence article to be produced and the separating cut is performed in the same method step.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The figures show an incontinence article in the form of pants, which is designated in total by reference numeral2, for receiving solid and liquid body excrements. The incontinence article2is formed from three components which can be largely independently produced, i.e. a front belly section4, a rear back section6, and a crotch section8which is disposed therebetween and comprises an absorbent body7, wherein the crotch section8overlaps a substantial surface portion of the belly section4and also of the back section6, and is permanently connected in the overlapping area during production. As can be gathered fromFIG. 1, this yields an H-shaped basic structure of the incontinence article with a longitudinal direction9. The joined components (FIG. 1) are then also connected to each other at the respective lateral longitudinal edge sections10,12of the belly section4and the back section6during production in order to form the pants shape (schematically shown inFIG. 6), thereby forming side seam areas14on both sides (FIG. 6). In this pants-shaped state of the incontinence article, which is realized by the manufacturer, the belly section4and the back section6continuously extend in the transverse or peripheral hip direction16to the side seam areas14and thereby define a hip opening18, which is closed in the peripheral hip direction, and leg openings19through which the user applies the incontinence article like a pair of pants.

The belly section4can be divided into an area20on the hip side and an area22on the crotch side facing the leg openings. A corresponding subdivision is provided in the back section6, i.e. also into an area24on the hip side and an area26on the crotch side facing the leg openings.

First elastification means28are provided in the area20of the belly section4on the hip side and in the area24of the back section6on the hip side, which may be, in particular, thread-like elastification means, such as LYCRA® (elastane) threads, which are pretensioned and connected to the sheet materials (chassis materials) of the belly section4and the back section6in a so-called stretch-bond method. These first elastification means28extend in the transverse or peripheral hip direction16from one side seam area14to the other.

The section22of the belly section4or26of the back section6on the crotch side facing the leg openings19has an edge contour32or34which extends towards a transverse center axis30of the crotch section8and differs from the transverse or peripheral hip direction16. This edge contour32,34is also curved in the representation ofFIG. 1and therefore suited to delimit the leg openings19. The shape of the area22or26on the crotch side facing the leg openings also realizes a relatively large overlapping area36,38between the crotch section8and the belly section4or back section6, which is essential in view of a tear-resistant connection between the crotch section8and the belly section4or back section6. The larger the overlapping area36,38, the smaller the amount of glue required with respect to the surface, which is advantageous with respect to the rigidity of the chassis materials. The components can be connected, in particular, without having to provide glue on the entire surface.

The respective area22,26of the belly section4or the back section6on the crotch side facing the leg openings19is also elasticised. Second elastification means40and42are provided at that location. The second elastification means40,42extend in each case starting from the side seam areas14towards a longitudinal center axis44of the incontinence article. As is illustrated inFIGS. 1 and 2, the second elastification means40,42fan out towards the longitudinal center axis44. This means that the separation between them increases towards the longitudinal center axis44. This fanning out of the second elastification means40and42can also be quantitatively described in more detail with respect toFIG. 2. The second elastification means42(shown inFIG. 2) of the back section6e.g. have a minimum separation of 3 to 8 mm from each other in the side seam areas14(separation of directly neighboring elastification means) and a maximum separation (separation of directly neighboring elastification means) of 7 to 35 mm on an absorbent body edge46or longitudinal edge48of the crotch section8. The fanning-out degree F. can also be defined with respect toFIG. 2:
F=(A−B)/B*100%

This fanning-out degree may advantageously be between 50 and 900%, in particular between 100 and 700%, and moreover, in particular between 150 and 550%. It is advantageously larger in the back section6than in the belly section4. The values A and B are thereby defined as the separation between the outermost second elastification means40,42in the longitudinal direction9and the innermost second elastification means40,42in the longitudinal direction9, (i.e. not the separation between directly neighboring elastification means), i.e. A as the maximum separation, in particular, on the longitudinal edge48of the crotch section8and B as the minimum separation, in particular, in the side seam area14.

When the fanning-out degree of the second elastification means40,42is selected sufficiently large, the restoring force can thereby be reduced within the area22or26on the crotch side facing the leg openings19in the direction56towards the crotch section8by ensuring that the pretension is not excessively increased due to the larger path of the second elastification means40,42in consequence of the curved extension of the second elastification means40,42facing away from the hip or transverse direction16. A comparison of a region50, which is disposed closer to the side seam area14of the relevant crotch-side area22or26, with a region52, which is disposed closer to the crotch section8, shows that the restoring force that is generated when the region52is extensively stretched (extension in the direction of the elastification means42) is smaller than the restoring force that is produced when the region50is stretched. In consequence of the smaller elastic forces that are exerted by the second elastification means40,42in the illustrated exemplary case, the chassis materials of the belly section4and back section6are advantageously less gathered, such that the number of folds/crimps54is also reduced, starting from the respective side seam area14in the direction56towards the crotch section8. Since the restoring forces that are generated through extensive stretching of the belly section in the area22of the belly section4or area26of the back section6on the crotch side facing the leg openings decrease in the direction of the arrow56, i.e. in general from the side seam area14towards the crotch section8, the wear comfort is considerably improved, since, as was established in accordance with the invention, the use of elastically stretchable materials is particularly problematic especially in these areas, since these materials are particularly strained with respect to tension and extension at these locations in correspondence with the physiology of the body shape of a person. The deliberate inventive reduction of this restoring force, i.e. decreasing restoring force in the direction of arrow56, i.e. in the direction approaching the crotch section8, provides a degree of freedom which could not be achieved before, and solves the above-mentioned problems.

As mentioned above, restoring forces can be determined directly on the chassis of the incontinence article. Towards this end, the relevant area of the belly section4or of the back section6is clamped between two clamping jaws102,104(FIG. 8) of defined identical clamping jaw width (b), and the restoring forces are then determined under defined extension of the areas to be measured of, in particular, 30% or 50% or 80% of the initial length (of the clamping jaw separation in the unclamped state) to simulate the extension exerted during use. The clamping jaws102,104are thereby moved apart from each other. The clamping jaws102,104should fix a maximum amount of, however at least two, neighboring elastification means40,42or28of the area to be measured and should be substantially oriented at right angles with respect to the extension of the elastification means, such that the clamping jaws102,104are extended, i.e. moved apart from each other, substantially in the direction of extension of the elastification means. This is clearly shown inFIGS. 8 and 9.FIG. 8shows, in principle, the arrangement of clamping jaws102,104in order to compare the restoring forces in the area22,26on the crotch side facing the leg openings with the restoring forces in an area20,24on the hip side.FIG. 9shows, in principle, the arrangement of clamping jaws102,104in order to compare the restoring forces in a region closer to the crotch section8with the restoring forces in a region closer to the side seam area14.

In the illustrated preferred embodiment of the incontinence article2, a separation C between the innermost second elastification means40of the belly section4, facing the crotch area, and the corresponding innermost second elastification means42of the back section6, facing the crotch area, is between 250 and 420 mm depending on the size of the incontinence article. The second elastification means40,42substantially extend to the transverse edge58,60, facing the crotch area, of the belly section4and the back section6. The separation between the belly section4and the back section6in the longitudinal direction9is 250-400 mm.

The separation between the innermost second elastification means40,42, facing the crotch area, and the edge contour32,34, defining the leg openings, of the area22,26of the belly section4and the back section6on the crotch side facing the leg openings is preferably 2 to 40 mm, moreover, in particular, preferably 3 to 30 mm, in particular preferably 4 to 15 mm.

The belly section4and the back section6extend in the side seam area14in the longitudinal direction9preferably by between 100 and 220 mm. The maximum extension of the crotch section8in the transverse direction16is advantageously 200 to 350 mm.

The crotch section8comprises a liquid-impermeable backsheet material62, which may be formed, in particular, by a breathable, but liquid-tight foil material, and a topsheet material64that is preferably based on a non-woven material. The absorbent body7is disposed between the backsheet material and the topsheet material (shown inFIGS. 4,5). In the exemplary case, the backsheet material62forms a projection66that extends past the absorbent body7in the transverse direction16. The topsheet64only slightly projects past the absorbent body7in the transverse direction. However, one upright barrier means68is provided on each side of the absorbent body7, which extends in the longitudinal direction9and is typically called an upright cuff element or collar element, and is preferably formed from a hydrophobic, in particular, liquid-impermeable non-woven material, which preferably extends in the transverse direction16to the lateral longitudinal edges48of the crotch section8. The distal ends70of the barrier means68are provided with further elastification means72, which lift the barrier means68against the skin surface of the user during use of the incontinence article, as is schematically shown inFIG. 5. In their respective longitudinal end areas74, the lateral barrier means68are fixed via schematically indicated fixations76,78to the topsheet64or to themselves in a C-shaped folded configuration. It is thereby advantageous and notable that each inner fixation78inFIG. 4fixes the barrier means68onto itself in the transverse direction16within the outer fixation76, which forms a cuff base line80that continuously extends in the longitudinal direction9. However, the inner fixation78is only provided in the longitudinal end areas74of the barrier means68.

It is thereby particularly advantageous for the above-mentioned projection66of the backsheet material62and/or the topsheet material64which extends past the absorbent body7on both sides of the absorbent body, i.e. on the left-hand and right-hand side added together, to be at least 25% with respect to the largest width of the crotch section8. This provides space in the transverse direction16for the arrangement of leg elastification means82that extend along the leg openings19. It has turned out to be advantageous for the leg elastification means82to extend at a given separation from the absorbent body7which comprises a great deal of material and is therefore rather rigid in order not to exert any additional extension or torsional forces onto the absorbent body, which could impair its absorption properties, and also to realize a liquid-tight leg termination which is largely independent of the absorbent body. In the present case, it has turned out to be particularly advantageous for the leg elastification means82to terminate in the longitudinal direction9at a clear distance of, in particular, at least 10 mm, preferably at least 20 mm, upstream of the second elastification means40and42of the belly section4or the back section6. These leg elastification means82preferably terminate in the longitudinal direction9upstream of the belly section4and the back section6. This is advantageous and essential since, in this case, the leg elastification means82do not or hardly influence the stress behavior of the belly section4and the back section6. It was found out that, in view of the inventive aim of improving the wear comfort, in particular, in the areas22and26of the belly section4and back section6on the crotch side facing the leg openings19, it is disadvantageous for the leg elastification means82, which usually have a great pretension and correspondingly large restoring forces, to additionally also extend at that location.

As is illustrated inFIG. 1, the crotch section8projects to a relatively large extent66past the absorbent body7in the transverse direction, in particular, also in areas of the crotch section8, which face the belly section4or the back section6. As mentioned above, this yields a relatively large overlapping area36,38between the crotch section8and the belly section4and the back section6. According to a preferred embodiment variant, the overlapping area36of the crotch section8and belly section4covers at least 12% of the surface of the belly section4, and the overlapping area38of the crotch section8and the back section6covers at least 20% of the surface of the back section6. This is advantageous, since the crotch section8is thereby reliably fixed to the belly section4or the back section6even when the glue is not provided on the full surface. It is thereby also advantageously sufficient to use glue only in sections or in a pattern in order to realize a connection. This advantageously prevents the joined materials from becoming excessively rigid.

Another advantageous detail of the inventive incontinence article is explained with respect toFIG. 7, which corresponds toFIG. 1. The three-component concept for producing the inventive incontinence article produces a transition90between the crotch section8and the belly section4, as well as a transition92between the crotch section8and the back section6, which usually yields a non-continuous shape, i.e. with corners or angles or bends, of the edges of the chassis materials, which define the leg openings19. This is dangerous in that force peaks are formed in the area of the transitions90,92, which could tear the chassis materials, which could, in turn, impair joining of the crotch section8to the belly section4or the back section6. To counteract this, the liquid-impermeable backsheet material62of the crotch section8is provided with a reinforcing coating94,96in the respective transition90and92. It is sufficient to provide this reinforcing coating94,96only in the area indicated by the dashed line ofFIG. 7. In the exemplary, advantageously illustrated case, the reinforcing coating94,96overlaps the belly section4and the back section6in the longitudinal direction9by only approximately 10 to 20 mm, in particular, by approximately 15 mm. The reinforcing coating terminates in the longitudinal direction9in each case upstream of the longitudinal ends98,100of the crotch section, at least 30 mm upstream of the belly-side longitudinal end98and at least 90 mm upstream of the back-side longitudinal end100. This is advantageous in that the reinforcing coating94,96does not thereby unnecessarily reinforce the chassis materials in areas where this is not helpful but rather undesired and disadvantageous. This also saves material costs. However, the possibility to provide the reinforcing coating94,96not only in the transition90or92remains unaffected.

The reinforcing coating94,96advantageously consists of a spunbonded non-woven material of polypropylene having a surface density of 10 to 20 g/m2, in particular 12 to 17 g/m2.

FIGS. 10 through 13show the inventive production method.FIG. 10shows the production of crotch sections8. Towards this end, an endless backsheet material web62and an endless topsheet material web64, and, in succession, the absorbent body7and (only indicated) the leg elastification means82that are associated with the subsequent leg openings, are supplied to a fast running production machine. The absorbent bodies7are disposed at a separation from each other between the topsheet material web64and the backsheet material web62and the composite that is thereby formed is fixed through suitable joining means, in particular glue. The leg elastification means82are also supplied and fixed between the topsheet material web64and the backsheet material web62. This is realized by a first roller pair110and a glue in a fashion that is not illustrated. For completeness, it should be mentioned that the crotch section8additionally comprises lateral upright and preferably elasticised cuffs as side leakage protection. In the present case, these are already provided on the side of the topsheet material web64facing the body but are not shown. They may also be introduced at any point of the production process (FIG. 10) or at a later point.

Continuing in the supply direction, the composite is subjected to a first contour cut112using a cutting roller pair113. During the contour cut112, curved segments114are cut out of the crotch-section8-forming composite of backsheet material web62and topsheet material web64to thereby form leg cut-outs116for the crotch section8. The composite is then supplied to a downstream cutting station118where a separating cut is performed transversely to the supply direction for singling the crotch sections8of the incontinence article to be produced.FIG. 10also indicates a perspective view of the crotch section8with absorbent body7and leg cut-outs116.

After separating the crotch sections8, the crotch sections are turned through 90° during continued supply, and are then further supplied in a direction transverse to the subsequent longitudinal center axis44of the incontinence article2in the machine direction120(FIG. 11). As is also shown inFIG. 11, partial webs122,124on the basis of non-woven material are supplied for producing the subsequent belly section4and back section6of the incontinence article. These partial webs122,124may be formed starting from one single web through separation in the longitudinal direction. The above-mentioned second elastification means40and42are disposed onto these partial webs122,124, and are thereby also supplied in an endless fashion and in the supply direction of the partial webs122,124. For fixing the second elastification means40,42to the partial webs122,124, one non-woven cover layer126,128, which was previously loaded with glue in a glue application station130, is applied such that the second elastification means40,42are laminated between the partial webs122,124and the non-woven cover layers126,128.FIG. 11is a schematic view and therefore does not explicitly show that the second elastification means40,42are supplied at a varying separation from each other, which is realized by an oscillating guiding means (indicated by the double arrow132). The curved fanning-out shape of the second elastification means40,42in the direction towards the crotch section8is thereby formed through corresponding control of the guiding means for each individual elastification means40,42.

The partial webs122,124are then further supplied in the above-mentioned composite and joined with the crotch sections8such that one end of the crotch sections overlaps the partial web122in a longitudinal direction9transversely to the machine direction120and the other end thereof overlaps the other partial web124. The crotch sections8are supplied in such a fashion that, after being joined, they are disposed at a separation from each other in the machine direction. The crotch sections8and the partial webs122,124are fixed to each other in the configuration obtained fromFIG. 11, and are further transported in the machine direction120.

The first elastification means28that extend in the transverse or peripheral hip direction16are then supplied in an endless fashion in the machine direction120and fixed to the partial webs122,124. Non-woven material webs134,136are again supplied. However, the glue is not directly applied onto the non-woven material webs134,136but is disposed onto the first elastification means28. The first elastification means28are then disposed on the partial webs122,124and covered by the non-woven material webs134,136such that they are laminated.

It is also feasible to provide each individual elastification means28,40,42with glue, i.e. to glue each thread. It is also feasible to omit the elastification means28,40,42and the non-woven cover layers126,128,134and/or136irrespective of the way in which the glue is applied. However, the non-woven cover layers are advantageous in that they simultaneously form a soft inner side of the incontinence article.

Subsequent thereto,FIG. 11shows a further cutting roller pair140, i.e. a rotating knife with an anvil roller, between which the previously formed composite is guided through in the machine direction120with the described orientation. A second contour cut142is thereby performed, in the course of which one respective curved segment144is advantageously separated from each partial web122,124, i.e. from the mutually facing transverse edges or edge sections58and60of the partial webs122,124, to also form leg cut-outs146for the partial webs122,124. Since the second contour cut142does not include the crotch section8but only the partial webs122,124the second contour cut142extends substantially along the machine direction120in any case at a small angle transversely thereto. In this fashion, the cut can be optimally configured like the first contour cut112during production of the crotch section8. On the whole, the subsequent leg openings19of the incontinence article2can be formed with high precision in accordance with the optimum requirements. The second contour cut142may thereby advantageously have a different shape on the partial web122than on the partial web124. The shape of the leg cut-outs146and the subsequent leg openings19of the incontinence article2may thereby have different configurations in the belly section4and in the back section6.

The composite formed in this fashion is further transported and folded onto itself in a folding station148(only indicated inFIG. 12) about a folding line150that extends in the machine direction120, such that one partial web124comes to rest on top of the other partial web122. Subsequent thereto, a respective side seam area14is formed between the partial webs122,124in a joining station152, i.e. the actual pant shape is formed. Subsequent to this method step, a separating cut is performed transversely to the machine direction120in a separating station154, which singles the finished incontinence articles2. It is also feasible to design the joining station152at the same time as a separating station, e.g. in the form of a separating welding means, such that the side seam areas14are formed and the incontinence articles2are singled at the same time.

FIG. 13finally schematically shows the procedure, wherein sections of the backsheet material web62are provided with a reinforcing coating94described in connection withFIG. 7, i.e. during supply of the backsheet material web62for producing the crotch sections, which was already explained in connection withFIG. 10. In contrast toFIG. 8, the reinforcing coating94, which may, in particular, be a non-woven material section, extends substantially over a major part of the crotch section8. The backsheet material web62at the longitudinal ends of the crotch section8to be formed remains uncoated.