Methods and apparatuses for making elastomeric laminates with elastic strands provided with a spin finish

The present disclosure relates to methods for making elastomeric laminates that may be used as components of absorbent articles. The methods and apparatuses may be configured with a plurality of elastic strands wound onto a beam, wherein one or more elastic strands comprises a spin finish. During assembly of an elastomeric laminate, the beam is rotated to unwind the elastic strands from the beam. A portion of the spin finish may be removed from the advancing elastic strand with a spin finish removal apparatus. The spin finish removal apparatus may be configured to apply detergent to an advancing elastic strand and may also wipe and/or dry the advancing elastic strand. The treated stretched elastic strand may then be connected between a first substrate and a second substrate. In some configurations, adhesive may be applied to the treated the elastic strand, the first substrate, and/or the second substrate.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbent articles, and more particularly, to apparatuses and methods for making elastomeric laminates that may be used as components of absorbent articles.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example, diapers and other absorbent articles, may be assembled by adding components to and/or otherwise modifying an advancing, continuous web of material. For example, in some processes, advancing webs of material are combined with other advancing webs of material. In other examples, individual components created from advancing webs of material are combined with advancing webs of material, which in turn, are then combined with other advancing webs of material. In some cases, individual components created from an advancing web or webs are combined with other individual components created from other advancing webs. Webs of material and component parts used to manufacture diapers may include: backsheets, topsheets, leg cuffs, waist bands, absorbent core components, front and/or back ears, fastening components, and various types of elastic webs and components such as leg elastics, barrier leg cuff elastics, stretch side panels, and waist elastics. Once the desired component parts are assembled, the advancing web(s) and component parts are subjected to a final knife cut to separate the web(s) into discrete diapers or other absorbent articles.

Some absorbent articles have components that include elastomeric laminates. Such elastomeric laminates may include an elastic material bonded to one or more nonwovens. The elastic material may include an elastic film and/or elastic strands. In some laminates, a plurality of elastic strands are joined to a nonwoven while the plurality of strands are in a stretched condition so that when the elastic strands relax, the nonwoven gathers between the locations where the nonwoven is bonded to the elastic strands, and in turn, forms corrugations. The resulting elastomeric laminate is stretchable to the extent that the corrugations allow the elastic strands to elongate.

In some assembly processes, stretched elastic strands may be advanced in a machine direction and may be adhered between two advancing substrates, wherein the stretched elastic strands are spaced apart from each other in a cross direction. Some assembly processes are also configured with several elastic strands that are very closely spaced apart from each other in the cross direction. In some configurations, close cross directional spacing between elastic strands can be achieved by drawing elastic strands from windings that have been stacked in the cross direction on a beam. For example, various textile manufacturers may utilize beam elastics and associated handling equipment, such as available from Karl Mayer Corporation. However, problems can be encountered in manufacturing processes when drawing elastic strands stacked on a beam.

For example, relatively low decitex elastic strands supplied on a beam may include a coating, sometimes referred to a yarn finish or spin finish, to help prevent the elastics strands from adhering to themselves, each other, and/or downstream handling equipment. When constructing absorbent articles, hot melt adhesives are sometimes used to adhere stretched elastic stands to advancing substrates to create elastic laminates. However, hot melt adhesives used to adhere stretched elastic strands to substrates when constructing absorbent articles may not adhere well to strands having a spin finish. As such, increased amounts of adhesive may be required to adequately adhere the stretched elastic strands to the substrates than would otherwise be required for elastic stands without a spin finish. In turn, relatively larger amounts of adhesives required to bond the elastic strands to the substrates may have a negative impact on aspects of the resulting product, such as with respect to costs, functionality, and aesthetics.

Consequently, it would be beneficial to provide methods and apparatuses for producing elastomeric laminates by removing or substantially removing the spin finish from elastic strands unwound from beams before adhering the elastic strands to advancing substrates.

SUMMARY OF THE INVENTION

In one form, a method for making an elastomeric laminate comprises the steps of: providing an elastic strand wound onto a beam, wherein the elastic strand comprises a spin finish; rotating the beam to unwind the elastic strand from the beam; advancing the elastic strand from the rotating beam; removing a portion of the spin finish from the advancing elastic strand; stretching the elastic strand; and connecting the stretched elastic strand between a first substrate and a second substrate.

In another form, a method for making an elastomeric laminate comprises the steps of: providing a plurality of elastic strands wound onto a beam, wherein each elastic strand comprises a spin finish; rotating a first roller about a first axis of rotation extending in a cross direction, the first roller comprising an outer circumferential surface comprising a surface speed S1; providing a first substrate comprising a first surface and an opposing second surface; advancing the first surface of the first substrate onto the outer circumferential surface of the first roller; rotating the beam to unwind the plurality of elastic strands from the beam in a machine direction at a speed S2, wherein the plurality of elastic strands are separated from each other in the cross direction, and wherein S2 is less than S1; advancing the plurality of elastic strands from the beam in the machine direction; removing a portion of the spin finish from each of the advancing elastic strands; stretching the plurality of elastic strands in the machine direction by connecting the plurality of elastic strands with the second surface of the first substrate; and advancing the combined first substrate and the plurality of elastic strands from the first roller.

In yet another form, an apparatus for assembling an elastomeric laminate comprises: a means for advancing a first substrate; a beam comprising a plurality of elastic strands wound onto the beam, wherein each elastic strand comprises a spin finish; a means for applying detergent to remove a portion of the spin finish from each of the plurality of elastic strands; a means for stretching the plurality of elastic strands; and a means for connecting the stretched elastic strands with the first substrate.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding the present disclosure:

“Absorbent article” is used herein to refer to consumer products whose primary function is to absorb and retain soils and wastes. “Diaper” is used herein to refer to an absorbent article generally worn by infants and incontinent persons about the lower torso. The term “disposable” is used herein to describe absorbent articles which generally are not intended to be laundered or otherwise restored or reused as an absorbent article (e.g., they are intended to be discarded after a single use and may also be configured to be recycled, composted or otherwise disposed of in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materials exhibiting elastic properties, which include any material that upon application of a force to its relaxed, initial length can stretch or elongate to an elongated length more than 10% greater than its initial length and will substantially recover back to about its initial length upon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby an element is directly secured to another element by affixing the element directly to the other element, and configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicular from a waist edge to a longitudinally opposing waist edge of an absorbent article when the article is in a flat out, uncontracted state, or from a waist edge to the bottom of the crotch, i.e. the fold line, in a bi-folded article. Directions within 45 degrees of the longitudinal direction are considered to be “longitudinal.” “Lateral” refers to a direction running from a longitudinally extending side edge to a laterally opposing longitudinally extending side edge of an article and generally at a right angle to the longitudinal direction. Directions within 45 degrees of the lateral direction are considered to be “lateral.”

The term “substrate” is used herein to describe a material which is primarily two-dimensional (i.e. in an XY plane) and whose thickness (in a Z direction) is relatively small (i.e. 1/10 or less) in comparison to its length (in an X direction) and width (in a Y direction). Non-limiting examples of substrates include a web, layer or layers or fibrous materials, nonwovens, films and foils such as polymeric films or metallic foils. These materials may be used alone or may comprise two or more layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to the direction of material flow through a process. In addition, relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.

The term “cross direction” (CD) is used herein to refer to a direction that is generally perpendicular to the machine direction.

The term “taped diaper” (also referred to as “open diaper”) refers to disposable absorbent articles having an initial front waist region and an initial back waist region that are not fastened, pre-fastened, or connected to each other as packaged, prior to being applied to the wearer. A taped diaper may be folded about the lateral centerline with the interior of one waist region in surface to surface contact with the interior of the opposing waist region without fastening or joining the waist regions together. Example taped diapers are disclosed in various suitable configurations in U.S. Pat. Nos. 5,167,897, 5,360,420, 5,599,335, 5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537, 6,118,041, 6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787, 6,617,016, 6,825,393, and 6,861,571; and U.S. Patent Publication Nos. 2013/0072887 A1; 2013/0211356 A1; and 2013/0306226 A1, all of which are incorporated by reference herein.

The term “pant” (also referred to as “training pant”, “pre-closed diaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refers herein to disposable absorbent articles having a continuous perimeter waist opening and continuous perimeter leg openings designed for infant or adult wearers. A pant can be configured with a continuous or closed waist opening and at least one continuous, closed, leg opening prior to the article being applied to the wearer. A pant can be preformed or pre-fastened by various techniques including, but not limited to, joining together portions of the article using any refastenable and/or permanent closure member (e.g., seams, heat bonds, pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can be preformed anywhere along the circumference of the article in the waist region (e.g., side fastened or seamed, front waist fastened or seamed, rear waist fastened or seamed). Example diaper pants in various configurations are disclosed in U.S. Pat. Nos. 4,940,464; 5,092,861; 5,246,433; 5,569,234; 5,897,545; 5,957,908; 6,120,487; 6,120,489; 7,569,039 and U.S. Patent Publication Nos. 2003/0233082 A1; 2005/0107764 A1, 2012/0061016 A1, 2012/0061015 A1; 2013/0255861 A1; 2013/0255862 A1; 2013/0255863 A1; 2013/0255864 A1; and 2013/0255865 A1, all of which are incorporated by reference herein.

The present disclosure relates to methods for manufacturing absorbent articles, and in particular, to methods for making elastomeric laminates that may be used as components of absorbent articles. The elastomeric laminates may include a first substrate, a second substrate, and an elastic material located between the first substrate and second substrate. During the process of making the elastomeric laminate, the elastic material may be advanced and stretched in a machine direction and may be joined with either or both the first and second substrates advancing in the machine direction. The methods and apparatuses according to the present disclosure may be configured with a plurality of elastic strands wound onto a beam, wherein one or more elastic strands comprises a spin finish. During assembly of an elastomeric laminate, the beam is rotated to unwind the elastic strands from the beam. The elastic strands may be stretched while advancing in a machine direction. A portion of the spin finish may be removed from the advancing elastic strand with a spin finish removal apparatus. As discussed below, the spin finish removal apparatus may treat the advancing elastic strand to remove some or all the spin finish from the elastic strand. The spin finish removal apparatus may be configured to apply detergent to an advancing elastic strand and may also wipe and/or dry the advancing elastic strand. The treated stretched elastic strand may then be connected between a first substrate and a second substrate. In some configurations, adhesive may be applied to the treated the elastic strand, the first substrate, and/or the second substrate. As such, the methods and apparatuses are adapted to utilize elastic strands having a spin finish that are unwound from beams to produce elastomeric laminates. By removing the spin finish from the elastics strands, relatively less adhesive may be utilized to adhere the strands between the substrates.

As previously mentioned, the elastomeric laminates made according to the processes and apparatuses discussed herein may be used to construct various types of components used in the manufacture of different types of absorbent articles, such as diaper pants and taped diapers. To help provide additional context to the subsequent discussion of the process embodiments, the following provides a general description of absorbent articles in the form of diapers that include components including the elastomeric laminates that may be produced with the methods and apparatuses disclosed herein.

FIGS.1A,1B, and2show an example of a diaper pant100that may include components constructed from elastomeric laminates assembled in accordance with the apparatuses and methods disclosed herein. In particular,FIGS.1A and1Bshow perspective views of a diaper pant100in a pre-fastened configuration, andFIG.2shows a plan view of the diaper pant100with the portion of the diaper that faces away from a wearer oriented toward the viewer. The diaper pant100includes a chassis102and a ring-like elastic belt104. As discussed below in more detail, a first elastic belt106and a second elastic belt108are bonded together to form the ring-like elastic belt104.

With continued reference toFIG.2, the diaper pant100and the chassis102each include a first waist region116, a second waist region118, and a crotch region119disposed intermediate the first and second waist regions. The first waist region116may be configured as a front waist region, and the second waist region118may be configured as back waist region. The diaper100may also include a laterally extending front waist edge121in the front waist region116and a longitudinally opposing and laterally extending back waist edge122in the back waist region118. To provide a frame of reference for the present discussion, the diaper100and chassis102ofFIG.2are shown with a longitudinal axis124and a lateral axis126. In some embodiments, the longitudinal axis124may extend through the front waist edge121and through the back waist edge122. And the lateral axis126may extend through a first longitudinal or right side edge128and through a midpoint of a second longitudinal or left side edge130of the chassis102.

As shown inFIGS.1A,1B, and2, the diaper pant100may include an inner, body facing surface132, and an outer, garment facing surface134. The chassis102may include a backsheet136and a topsheet138. The chassis102may also include an absorbent assembly140, including an absorbent core142, disposed between a portion of the topsheet138and the backsheet136. As discussed in more detail below, the diaper100may also include other features, such as leg elastics and/or leg cuffs to enhance the fit around the legs of the wearer.

As shown inFIG.2, the periphery of the chassis102may be defined by the first longitudinal side edge128, a second longitudinal side edge130, a first laterally extending end edge144disposed in the first waist region116, and a second laterally extending end edge146disposed in the second waist region118. Both side edges128and130extend longitudinally between the first end edge144and the second end edge146. As shown inFIG.2, the laterally extending end edges144and146are located longitudinally inward from the laterally extending front waist edge121in the front waist region116and the laterally extending back waist edge122in the back waist region118. When the diaper pant100is worn on the lower torso of a wearer, the front waist edge121and the back waist edge122may encircle a portion of the waist of the wearer. At the same time, the side edges128and130may encircle at least a portion of the legs of the wearer. And the crotch region119may be generally positioned between the legs of the wearer with the absorbent core142extending from the front waist region116through the crotch region119to the back waist region118.

As previously mentioned, the diaper pant100may include a backsheet136. The backsheet136may also define the outer surface134of the chassis102. The backsheet136may also comprise a woven or nonwoven material, polymeric films such as thermoplastic films of polyethylene or polypropylene, and/or a multi-layer or composite materials comprising a film and a nonwoven material. The backsheet may also comprise an elastomeric film. An example backsheet136may be a polyethylene film having a thickness of from about 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Further, the backsheet136may permit vapors to escape from the absorbent core (i.e., the backsheet is breathable) while still preventing exudates from passing through the backsheet136.

Also described above, the diaper pant100may include a topsheet138. The topsheet138may also define all or part of the inner surface132of the chassis102. The topsheet138may be liquid pervious, permitting liquids (e.g., menses, urine, and/or runny feces) to penetrate through its thickness. A topsheet138may be manufactured from a wide range of materials such as woven and nonwoven materials; apertured or hydroformed thermoplastic films; apertured nonwovens, porous foams; reticulated foams; reticulated thermoplastic films; and thermoplastic scrims. Woven and nonwoven materials may comprise natural fibers such as wood or cotton fibers; synthetic fibers such as polyester, polypropylene, or polyethylene fibers; or combinations thereof. If the topsheet138includes fibers, the fibers may be spunbond, carded, wet-laid, meltblown, hydroentangled, or otherwise processed as is known in the art. Topsheets138may be selected from high loft nonwoven topsheets, apertured film topsheets and apertured nonwoven topsheets. Exemplary apertured films may include those described in U.S. Pat. Nos. 5,628,097; 5,916,661; 6,545,197; and 6,107,539.

As mentioned above, the diaper pant100may also include an absorbent assembly140that is joined to the chassis102. As shown inFIG.2, the absorbent assembly140may have a laterally extending front edge148in the front waist region116and may have a longitudinally opposing and laterally extending back edge150in the back waist region118. The absorbent assembly may have a longitudinally extending right side edge152and may have a laterally opposing and longitudinally extending left side edge154, both absorbent assembly side edges152and154may extend longitudinally between the front edge148and the back edge150. The absorbent assembly140may additionally include one or more absorbent cores142or absorbent core layers. The absorbent core142may be at least partially disposed between the topsheet138and the backsheet136and may be formed in various sizes and shapes that are compatible with the diaper. Exemplary absorbent structures for use as the absorbent core of the present disclosure are described in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores that contain reduced amounts of cellulosic airfelt material. For instance, such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even 1% of cellulosic airfelt material. Such a core may comprise primarily absorbent gelling material in amounts of at least about 60%, 70%, 80%, 85%, 90%, 95%, or even about 100%, where the remainder of the core comprises a microfiber glue (if applicable). Such cores, microfiber glues, and absorbent gelling materials are described in U.S. Pat. Nos. 5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. Patent Publication Nos. 2004/0158212 A1 and 2004/0097895 A1.

As previously mentioned, the diaper100may also include elasticized leg cuffs156. It is to be appreciated that the leg cuffs156can be and are sometimes also referred to as leg bands, side flaps, barrier cuffs, elastic cuffs or gasketing cuffs. The elasticized leg cuffs156may be configured in various ways to help reduce the leakage of body exudates in the leg regions. Example leg cuffs156may include those described in U.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115; 4,909,803; and U.S. Patent Publication No. 2009/0312730 A1.

As mentioned above, diaper pants may be manufactured with a ring-like elastic belt104and provided to consumers in a configuration wherein the front waist region116and the back waist region118are connected to each other as packaged, prior to being applied to the wearer. As such, diaper pants may have a continuous perimeter waist opening110and continuous perimeter leg openings112such as shown inFIGS.1A and1B. The ring-like elastic belt may be formed by joining a first elastic belt to a second elastic belt with a permanent side seam or with an openable and reclosable fastening system disposed at or adjacent the laterally opposing sides of the belts.

As previously mentioned, the ring-like elastic belt104may be defined by a first elastic belt106connected with a second elastic belt108. As shown inFIG.2, the first elastic belt106extends between a first longitudinal side edge111aand a second longitudinal side edge111band defines first and second opposing end regions106a,106band a central region106c. And the second elastic108belt extends between a first longitudinal side edge113aand a second longitudinal side edge113band defines first and second opposing end regions108a,108band a central region108c. The distance between the first longitudinal side edge111aand the second longitudinal side edge111bdefines the pitch length, PL, of the first elastic belt106, and the distance between the first longitudinal side edge113aand the second longitudinal side edge113bdefines the pitch length, PL, of the second elastic belt108. The central region106cof the first elastic belt is connected with the first waist region116of the chassis102, and the central region108cof the second elastic belt108is connected with the second waist region118of the chassis102. As shown inFIGS.1A and1B, the first end region106aof the first elastic belt106is connected with the first end region108aof the second elastic belt108at first side seam178, and the second end region106bof the first elastic belt106is connected with the second end region108bof the second elastic belt108at second side seam180to define the ring-like elastic belt104as well as the waist opening110and leg openings112.

As shown inFIGS.2,3A, and3B, the first elastic belt106also defines an outer laterally extending edge107aand an inner laterally extending edge107b, and the second elastic belt108defines an outer laterally extending edge109aand an inner laterally extending edge109b. As such, a perimeter edge112aof one leg opening may be defined by portions of the inner laterally extending edge107bof the first elastic belt106, the inner laterally extending edge109bof the second elastic belt108, and the first longitudinal or right side edge128of the chassis102. And a perimeter edge112bof the other leg opening may be defined by portions of the inner laterally extending edge107b, the inner laterally extending edge109b, and the second longitudinal or left side edge130of the chassis102. The outer laterally extending edges107a,109amay also define the front waist edge121and the laterally extending back waist edge122of the diaper pant100. The first elastic belt and the second elastic belt may also each include an outer, garment facing layer162and an inner, wearer facing layer164. It is to be appreciated that the first elastic belt106and the second elastic belt108may comprise the same materials and/or may have the same structure. In some embodiments, the first elastic belt106and the second elastic belt may comprise different materials and/or may have different structures. It should also be appreciated that the first elastic belt106and the second elastic belt108may be constructed from various materials. For example, the first and second belts may be manufactured from materials such as plastic films; apertured plastic films; woven or nonwoven webs of natural materials (e.g., wood or cotton fibers), synthetic fibers (e.g., polyolefins, polyamides, polyester, polyethylene, or polypropylene fibers) or a combination of natural and/or synthetic fibers; or coated woven or nonwoven webs. In some embodiments, the first and second elastic belts include a nonwoven web of synthetic fibers, and may include a stretchable nonwoven. In other embodiments, the first and second elastic belts include an inner hydrophobic, non-stretchable nonwoven material and an outer hydrophobic, non-stretchable nonwoven material.

The first and second elastic belts106,108may also each include belt elastic material interposed between the outer substrate layer162and the inner substrate layer164. The belt elastic material may include one or more elastic elements such as strands, ribbons, films, or panels extending along the lengths of the elastic belts. As shown inFIGS.2,3A, and3B, the belt elastic material may include a plurality of elastic strands168which may be referred to herein as outer, waist elastics170and inner, waist elastics172. Elastic strands168, such as the outer waist elastics170, may continuously extend laterally between the first and second opposing end regions106a,106bof the first elastic belt106and between the first and second opposing end regions108a,108bof the second elastic belt108. In some embodiments, some elastic strands168, such as the inner waist elastics172, may be configured with discontinuities in areas, such as for example, where the first and second elastic belts106,108overlap the absorbent assembly140. In some embodiments, the elastic strands168may be disposed at a constant interval in the longitudinal direction. In other embodiments, the elastic strands168may be disposed at different intervals in the longitudinal direction. The belt elastic material in a stretched condition may be interposed and joined between the uncontracted outer layer and the uncontracted inner layer. When the belt elastic material is relaxed, the belt elastic material returns to an unstretched condition and contracts the outer layer and the inner layer. The belt elastic material may provide a desired variation of contraction force in the area of the ring-like elastic belt. It is to be appreciated that the chassis102and elastic belts106,108may be configured in different ways other than as depicted inFIG.2. The belt elastic material may be joined to the outer and/or inner layers continuously or intermittently along the interface between the belt elastic material and the inner and/or outer belt layers.

In some configurations, the first elastic belt106and/or second elastic belt108may define curved contours. For example, the inner lateral edges107b,109bof the first and/or second elastic belts106,108may include non-linear or curved portions in the first and second opposing end regions. Such curved contours may help define desired shapes to leg opening112, such as for example, relatively rounded leg openings. In addition to having curved contours, the elastic belts106,108may include elastic strands168,172that extend along non-linear or curved paths that may correspond with the curved contours of the inner lateral edges107b,109b.

As previously mentioned, apparatuses and methods according to the present disclosure may be utilized to produce elastomeric laminates that may be used to construct various components of diapers, such as elastic belts, leg cuffs, and the like. For example,FIGS.4-11show schematic views of converting apparatuses300adapted to manufacture elastomeric laminates302. As described in more detail below, the converting apparatuses300shown inFIGS.4-11operate to advance a continuous length of elastic material304, a continuous length of a first substrate306, and a continuous length of a second substrate308along a machine direction MD. It is also to be appreciated that in some configurations, the first substrate and second substrate306,308herein may be defined by two discrete substrates or may be defined by folded portions of a single substrate. The apparatus300stretches the elastic material304and joins the stretched elastic material304with the first and second substrates306,308to produce an elastomeric laminate302. Although the elastic material304is illustrated and referred to herein as strands, it is to be appreciated that elastic material304may include one or more continuous lengths of elastic strands, ribbons, and/or films.

The elastomeric laminates302can be used to construct various types of diaper components. For example, the elastomeric laminates302may be used as a continuous length of elastomeric belt material that may be converted into the first and second elastic belts106,108discussed above with reference toFIGS.1-3B. As such, the elastic material304may correspond with the belt elastic material168interposed between the outer layer162and the inner layer164, which in turn, may correspond with either the first and/or second substrates306,308. In other examples, the elastomeric laminates may be used to construct waistbands and/or side panels in taped diaper configurations. In yet other examples, the elastomeric laminates may be used to construct various types of leg cuff and/or topsheet configurations.

As discussed in more detail below, the converting apparatuses300may include metering devices arranged along a process machine direction MD, wherein the metering devices may be configured to stretch the advancing elastic material and/or join stretch elastic material with one or more advancing substrates. In some configurations, a metering device may comprise a beam of elastic strands wound thereon. During operation, elastic material may advance in a machine direction from a rotating beam to a downstream metering device to be joined with one or more advancing substrates. The elastic material advancing from the rotating beam may include a spin finish, and as such, the apparatuses herein may be configured to remove some or all the spin finish before joining the elastic material with the substrates. It is to be appreciated that the apparatuses and methods of assembly of elastomeric laminates and absorbent articles described herein and illustrated in the accompanying drawings are non-limiting example configurations. The features illustrated or described in connection with one non-limiting configuration may be combined with the features of other non-limiting configurations. Such modifications and variations are intended to be included within the scope of the present disclosure.

As shown inFIGS.4-6, a converting apparatus300for producing an elastomeric laminate302may include a first metering device310and a second metering device312. The first metering device may be configured as a beam314with a plurality of elastic strands316wound thereon.FIG.4shows an example of an empty beam314that includes two side plates317a,317bthat may be connected with opposing end portions of a mandrel core318, wherein elastic strands may be wound onto the mandrel core318. It is to be appreciated that beams of various sizes and technical specifications may be utilized in accordance with the methods and apparatuses herein, such as for example, beams that are available from ALUCOLOR Textilmaschinen, GmbH. During operation, the plurality of elastic strands316advance in the machine direction MD from the beam314to the second metering device312. In addition, the plurality of elastic strands316may be stretched along the machine direction MD between the beam314and the second metering device312. The stretched elastic strands316are also joined with a first substrate306and a second substrate308at the second metering device312to produce an elastomeric laminate302. As discussed in more detail below, one or more of the elastic strands316aadvancing from the beam314may include a spin finish320located on outer surfaces of the elastics strands. In turn, all or some of the spin finish320may be removed from the advancing elastic strands316awith a spin finish removal apparatus322. In turn, treated stretched elastic strands316bmay then be connected between the first substrate306and the second substrate308.

It is to be appreciated the elastic strands316may include various types of spin finish320, also referred herein as yarn finish, configured as coating on the elastic strands316that may be intended to help prevent the elastics strands from adhering to themselves, each other, and/or downstream handling equipment. In some configurations, a spin finish may include various types of oils and other components, such as disclosed for example in U.S. Pat. Nos. 8,377,554; 8,093,161; and 6,821,301. In some configurations, a spin finish may include various types of silicone oils, such as for example, polydimethylsiloxane. In some configurations, a spin finish may include various types of mineral oils.

As shown inFIGS.5and6, the second metering device312may include: a first roller324having an outer circumferential surface326and that rotates about a first axis of rotation328, and a second roller330having an outer circumferential surface332and that rotates about a second axis of rotation334. The first roller324and the second roller330rotate in opposite directions, and the first roller324is adjacent the second roller330to define a nip336between the first roller324and the second roller330. The first roller324rotates such that the outer circumferential surface326has a surface speed S1, and the second roller330may rotate such that the outer circumferential surface332has the same, or substantially the same, surface speed S1.

With continued reference toFIGS.5and6, the first substrate306includes a first surface338and an opposing second surface340, and the first substrate306advances to the first roller324. In particular, the first substrate306advances at speed S1 to the first roller324where the first substrate306partially wraps around the outer circumferential surface326of the first roller324and advances through the nip336. As such, the first surface338of the first substrate306travels in the same direction as and in contact with the outer circumferential surface326of the first roller324. In addition, the second substrate308includes a first surface342and an opposing second surface344, and the second substrate308advances to the second roller330. In particular, the second substrate308advances at speed S1 to the second roller330where the second substrate308partially wraps around the outer circumferential surface332of the second roller330and advances through the nip336. As such, the second surface344of the second substrate308travels in the same direction as and in contact with the outer circumferential surface332of the second roller330.

Still referring toFIGS.5and6, the beam314includes elastic strands316wound thereon, and the beam314is rotatable about a beam rotation axis346. In some configurations, the beam rotation axis346may extend in the cross direction CD. As the beam314rotates, the elastic strands316advance from the beam314at a speed S2 with the elastic strands316being spaced apart from each other in the cross direction CD. From the beam314, the elastic strands316advance in the machine direction MD to the nip336. In some configurations, the speed S2 is less than the speed S1, and as such, the elastic strands316are stretched in the machine direction MD. In turn, the stretched elastic strands316advance through the nip336between the first and second substrates306,308such that the elastic strands316are joined with the second surface340of the first substrate306and the first surface342of the second substrate308to produce a continuous length of elastomeric laminate302.

As discussed above, one or more of the elastic strands316aadvancing from the beam314may include a spin finish320. In turn, the advancing elastic strands316amay be treated with the spin finish removal apparatus322that may remove some or all the spin finish320. As such, the treated elastic strands316bhaving some or all the spin finish320removed may advance from the spin finish removal apparatus322to be joined with the first substrate306and the second substrate308to form the elastomeric laminate302. As shown inFIG.5, the first substrate306may advance past an adhesive applicator device348that applies adhesive350to the second surface340of the first substrate306before advancing to the nip336. It is to be appreciated that the adhesive350may be applied to the first substrate306upstream of the first roller324and/or while the first substrate306is partially wrapped around the outer circumferential surface326of the first roller324. It is to be appreciated that adhesive may be applied to the treated elastic strands316bbefore and/or while being joined with first substrate306and second substrate308. In addition, it is to be appreciated that adhesive may be applied to the first surface342of the second substrate308before or while being joined with the treated elastic strands316band the first substrate306.

As shown inFIGS.5and6, the spin finish removal apparatus322may be configured to include a bath352containing a detergent354. As such the elastic strands316ahaving a spin finish320advance from the beam314to the bath352, wherein the elastic strands316aadvance through the detergent354adapted to remove some or all the spin finish320from the elastic strands316. As shown inFIGS.5and6, the spin finish removal apparatus322may also be configured to include a drying apparatus356to remove the detergent354from the elastic strands316. It is to be appreciated that the drying apparatus356may be configured in various ways, such as a fan, a blower, a heater, and/or combinations thereof. In some configurations, the drying apparatus356may move air or some other gas358relative to the elastic strands316to evaporate the detergent from the elastic strands316. As such, the treated elastic strands316bmay advance from the bath352to the drying apparatus356to remove some or all the detergent from the treated elastic strands316b. In turn, the treated elastic strands316bmay advance from the drying apparatus356to be combined with the first substrate306and the second substrate308.

It is to be appreciated that various configurations of detergent354may be used to remove spin finish320from the elastic strands316. For example, in some configurations, a detergent may include various different ingredients, such as those included for example in TISSOCYL RC available from Zschimmer & Schwarz GmbH.

It is to be appreciated that different components may be used to construct the elastomeric laminates302in accordance with the methods and apparatuses herein. For example, the first and/or second substrates306,308may include nonwovens and/or films. In addition, the elastic strands316may be configured in various ways and having various decitex values. In some configurations, the elastic strands316may be configured with decitex values ranging from about 10 decitex to about 500 decitex, specifically reciting all 1 decitex increments within the above-recited range and all ranges formed therein or thereby. It is also to be appreciated the beam314may be configured in various ways and with various quantities of elastic strands. Example beams, also referred to as warp beams, that may be used with the apparatus and methods herein are disclosed in U.S. Pat. Nos. 4,525,905; 5,060,881; and 5,775,380; and U.S. Patent Publication No. 2004/0219854 A1. AlthoughFIG.6shows nine elastic strands316advancing from the beam314, it is to be appreciated that the apparatuses herein may be configured such that more or less than nine elastic strands316advance from the beam314. In some configurations, the elastic strands316advancing from the beam314may include from about 100 to about 2000 strands, specifically reciting all 1 strand increments within the above-recited range and all ranges formed therein or thereby. In some configurations, the elastic strands316may be separated from each other by about 0.5 mm to about 4 mm in the cross direction, specifically reciting all 0.1 mm increments within the above-recited range and all ranges formed therein or thereby. As discussed herein, the elastics in the plurality of elastic strands may be pre-strained prior to joining the elastic strand to the first or second substrate layers306,308. In some configurations, the elastic may be pre-strained from about 75% to about 300%, specifically reciting all 1% increments within the above-recited range and all ranges formed therein or thereby. It is also to be appreciated that one or more beams of elastics may be arranged along the cross direction CD of a converting process and/or arranged along a machine direction MD in various different portions of a converting process. It is also to be appreciated that the beam314can be connected with one or more motors, such as servo motors, to drive and control the rotation of the beam314.

It is to be appreciated that the apparatuses300herein may be configured in various ways with various features described herein to assemble elastomeric laminates302having various stretch characteristics. For example, the apparatus300may be configured to assemble elastomeric laminates302with elastic strands316unwound from more than one beam and/or in combination with elastic stands supplied from an overend unwinder. The elastic strands may be joined with the first and second substrates306,308such that the elastomeric laminate302may have different stretch characteristics in different regions along the cross direction CD. For example, when the elastomeric laminate302is elongated, some elastic strands may exert contraction forces in the machine direction MD that are different from contraction forces exerted by other elastic strands. Such differential stretch characteristics can be achieved by stretching some elastic strands more or less than other elastic strands before joining the elastic strands with the first and second substrates306,308. It is also to be appreciated that the elastic strands may have various different material constructions and/or decitex values to create elastomeric laminates302having different stretch characteristics in different regions. In some configurations, the elastomeric laminate may have regions where the elastic strands are spaced relatively close to one another in the cross direction CD and other regions where the elastic strands are spaced relatively farther apart from each other in the cross direction CD to create different stretch characteristics in different regions. In some configurations, the elastic strands may be supplied on the beam in a stretched state, and as such, may not require additional stretching (or may require relatively less additional stretching) before being combined with the first substrate306and/or the second substrate308.

It is to be appreciated that the spin finish removal apparatus322may be configured in various ways. For example as shown inFIG.7, the spin finish removal apparatus322may include one or more detergent applicator devices360, such as a nozzle, that sprays detergent354onto the spin finish320of advancing elastic strands316a. With continued reference toFIG.7, the spin finish removal apparatus322may also include a wiper362downstream of the detergent applicator device360that is configured to wipe detergent354and/or spin finish320from the elastic strands316. The elastic strands316may then advance from the wiper362to the drying apparatus356such as described above. It is to be appreciated that the wiper362may be in direct contact with the elastic strands and may be configured as a static device or may be configured to move relative to the elastic strands316. For example, the wiper362may be configured with an outer surface in contact with the elastic strands316that rotates in a direction opposite of the machine direction MD of the advancing elastic strands316. In some configurations, the wiper362may be configured with an outer surface in contact with the elastic strands316that rotates in a same direction as the machine direction MD of the advancing elastic strands316wherein the outer surface may move faster or slower than the speed of the elastic strands316.

In some configurations, the first and/or second substrates306,308may be used in conjunction with a wiper362to remove detergent354and/or spin finish320from the elastic strands316. For example,FIG.8shows a configuration wherein the advancement path of second substrate308is configured such that the second substrate308contacts the elastic strands316to remove detergent354and/or spin finish320. As shown inFIG.8, the spin finish removal apparatus322may include one or more rotating drums364arranged such that before the second substrate308is combined with the elastic strands316and the first substrate306, the second substrate308contacts the elastic strands316. For example, the second substrate308may advance onto a first drum364awherein the second substrate308advances at a first speed S1. The first drum364arotates and brings first surface342of the second substrate308into contact with the elastic strands316advancing at a second speed S2, wherein S1 is not equal S2. As such, the second substrate308and the elastic strands316move relative to each other when in contact. In turn, the relative movement between the second substrate308and the elastic strands316may wipe detergent354and/or spin finish320from the elastic strands316. From the first drum364a, the second substrate308may advance to a second drum364bbefore being combined with the elastic strands316and the first substrate306to form the elastomeric laminate302.

It is to be appreciated that the advancement path of either or both the first substrate306and the second substrate308may be configured such that either or both the first substrate306and the second substrate308may advance and contact to the elastic strands316to wipe detergent354and/or spin finish320from the elastic strands316. It is also to be appreciated that that the first surface338and/or the second surface340of the first substrate306and/or the first surface342and/or the second surface344of the second substrate308may be used to contact the elastic strands316and wipe detergent354and/or spin finish320from the elastic strands316. In some configurations, the advancement path of the assembled elastic laminate302may be configured such that the either or both the first substrate306and the second substrate308of the elastic laminate302may contact the elastic strands316and wipe detergent354and/or spin finish320from the elastic strands316before the elastic strands316are joined with the first substrate306and the second substrate308. In some configurations, the spin finish320and/or detergent354may be wiped onto one surface of either or both the first and second substrates306,308and wherein the elastic strands316are bonded to the opposing surface of either or both the first and second substrates306,308to help improve adhesion of the elastic strands316to the first substrate306and/or the second substrate308.

It is to be appreciated that the apparatuses300herein may be configured in various ways with various features of the spin finish removal apparatuses322described herein to assemble elastomeric laminates302. For example, in a second configuration of the apparatus300shown inFIG.9, the second roller330may be positioned downstream from the first roller324. As such, the first roller324may be configured as the second metering device312and the second roller330may be configured as a third metering device366. As shown inFIG.9, the first substrate306advances at speed S1 to the first roller324where the first substrate306partially wraps around the outer circumferential surface326of the first roller324and advances from the first roller to the second roller330to be combined with second substrate308. As the beam314rotates, the elastic strands316advance from the beam314at a speed S2 with the elastic strands316being spaced apart from each other in the cross direction CD. From the beam314, elastic strands316ahaving a spin finish320advance to a spin finish removal apparatus322generically illustrated by a dashed-line rectangle. It is to be appreciated that the spin finish removal apparatus322may be configured with various combinations of features of the spin finish removal apparatus322described herein. In turn, all or some of the spin finish320may be removed from the advancing elastic strands316awith the spin finish removal apparatus322. As such, the treated elastic strands316bhaving some or all the spin finish320removed may advance from the spin finish removal apparatus322to the first roller324and are positioned on the second surface340of the first substrate306. In some configurations, the speed S2 is less than the speed S1, and as such, the elastic strands316are stretched in the machine direction MD.

With continued reference toFIG.9, the first substrate306and the elastic strands316advance from the outer circumferential surface326of the first roller324to the second roller330. In addition, the second substrate308advances at speed S1 to the second roller330where the second substrate308partially wraps around the outer circumferential surface332of the second roller330. In turn, the combined first substrate306and the stretched elastic strands316,316badvance from first roller324to the second roller330and are combined with the second substrate308such that the elastic strands316,316bare joined with the second surface340of the first substrate306and the first surface342of the second substrate308to produce a continuous length of elastomeric laminate302. As discussed above, the first substrate306may advance past an adhesive applicator device348that applies adhesive350to the second surface340of the first substrate306while advancing to the first roller324. It is to be appreciated that the adhesive350may be applied to the first substrate306while the first substrate306is partially wrapped around the outer circumferential surface326of the first roller324. It is to be appreciated that adhesive may also be applied to the elastic strands316,316bbefore and/or while being joined with first substrate306and second substrate308. In addition, it is to be appreciated that adhesive may be applied to the first surface342of the second substrate308before or while being joined with the elastic strands316and first substrate306.

In another configuration shown inFIG.10, the apparatus300may be configured with only the first roller324and without a second roller330. As such, the first roller324may be configured as the second metering device312. As shown inFIG.10, the first substrate306advances at speed S1 to the first roller324where the first substrate306partially wraps around the outer circumferential surface326of the first roller324. While partially wrapped around the outer circumferential surface326of the first roller324, the first substrate306is combined with the elastic strands316,316band the second substrate308. As the beam314rotates, the elastic strands316advance from the beam314at a speed S2 with the elastic strands316being spaced apart from each other in the cross direction CD. From the beam314, elastic strands316ahaving a spin finish320advance to a spin finish removal apparatus322generically illustrated by a dashed-line rectangle. As discussed above, it is to be appreciated that the spin finish removal apparatus322may be configured with various combinations of features of the spin finish removal apparatus322described herein. In turn, all or some of the spin finish320may be removed from the advancing elastic strands316awith the spin finish removal apparatus322. As such, the treated elastic strands316bhaving some or all the spin finish320removed may advance from the spin finish removal apparatus322to the first roller324and are positioned on the second surface340of the first substrate306. In some configurations, the speed S2 is less than the speed S1, and as such, the elastic strands316are stretched in the machine direction MD.

With continued reference toFIG.10, the second substrate308advances at speed S1 to the first roller324and partially wraps around the outer circumferential surface326of the first roller324. In turn, the second substrate308is combined with the first substrate306and the stretched elastic strands316while on the first roller324such that the elastic strands316are joined with the second surface340of the first substrate306and the first surface342of the second substrate308to produce a continuous length of elastomeric laminate302. As discussed above, the first substrate306may advance past an adhesive applicator device348that applies adhesive350to the second surface340of the first substrate306while advancing to the first roller324. It is to be appreciated that the adhesive350may be applied to the first substrate306while the first substrate306is partially wrapped around the outer circumferential surface326of the first roller324. It is to be appreciated that adhesive may also be applied to the elastic strands316before and/or while being joined with first substrate306and second substrate308. In addition, it is to be appreciated that adhesive may be applied to the first surface342of the second substrate308before or while being joined with the elastic strands316and first substrate306.

As illustrated herein, the apparatuses and processes may be configured such that elastic strands may be advanced from the beams and directly to the assembly process without having to touch additional machine components, such as for example, guide rollers. It is also to be appreciated that in some configurations, elastic strands may be advanced from beams and may be redirected and/or otherwise touched by and/or redirected before advancing to the assembly process. For example,FIG.11shows a configuration where the beam rotation axis346may extend in a first cross direction CD1. As the beam314rotates, the elastic strands316advance from the beam314in a first machine direction MD1with the elastic strands316being spaced apart from each other in the first cross direction CD1. The elastic strands316may then be redirected by rollers321from the first machine direction MD1to a second machine direction MD2, wherein the elastic strands316may remain separated from each other in a second cross direction CD2. From the rollers321, the elastic strands316may advance in the second machine direction MD2to be combined with the first and second substrates306,308to form the elastomeric laminate302. Thus, it is to be appreciated that the beam314may be arranged and/or oriented such that the beam rotation axis346may be parallel, perpendicular, or otherwise angularly offset with respect to the machine direction advancement of the elastomeric laminate302and/or the substrates306,308.

The apparatus shown inFIG.11also includes a spin finish removal apparatus322generically illustrated by a dashed-line rectangle, which may be configured with various combinations of features of the spin finish removal apparatus322described herein. As discussed above, the spin finish removal apparatus322is configured to remove all or some of the spin finish320from the advancing elastic strands316a. And in turn, the treated elastic strands316bhaving some or all the spin finish320removed may advance downstream to be joined with the first substrate306and the second substrate308. It is to be appreciated that the spin finish removal apparatus322may be positioned in various locations along the advancement path of the elastic strands316. For example, the spin finish removal apparatus322may be positioned upstream or downstream of the rollers321shown inFIG.11.

This application claims the benefit of U.S. Provisional Application No. 62/436,589, filed on Dec. 20, 2016; 62/483,965, filed on Apr. 11, 2017; 62/553,538, filed on Sep. 1, 2017; 62/553,149, filed on Sep. 1, 2017; 62/553,171, filed on Sep. 1, 2017; and 62/581,278, filed on Nov. 3, 2017, the entireties of which are all incorporated by reference herein.