A METHOD OF MANUFACTURING A FLUID ABSORBING PRODUCT

Abstract: A fluid absorbing product, for instance a sanitary towel, a brief shield, an incontinence shield, a napkin, etc. is manu­ factured from a core (17) of an absorbing material know per se and a carrier material (11) which is extrusion strip coated. A portion of at least one strip (30, 31) of thermoplastics defines the penetration portion (-s) (32, 33, 34, 35, 36) of the product. The placement of the core onto the carrier material preferably is such that thickened plastics layers (37, 38) of the strip/strips extend around narrow side corners and into the fluid absorbing broad side of the product. The invention also provides a new manufacturing method and improved production apparatus.

Description: A FLUID ABSORBING PRODUCT AND A METHOD AND AN APPARATUS FOR MANUFACTURING SUCH PRODUCT. The present invention relates to a fluid absorbing product and a method and a device for manufacturing such product. Known products of said type consist as such of high grade material and material combinations. In the most simple form thereof a fluid absorbing product may be regarded as a piece of equipment that allows inflow of a fluid to an absorbing core via a first side or- portion thereof, but prevents penetration -for the rest. The inflow of a fluid for instance may take place through a layer of so called "fibre cloth" (non-woven) which as such also might possess a certain absorption capacity. A high liquid absorption is obtained by cellulose based fibres (cellulose, cotton, rayon), while synthetic fibres as polypropylene and polyester have a very low absorption capacity. As far as the pliability and handling of the non-woven material are concerned the fibre cloth material does not induce any problems in lines for manufacturing napkins, sanitary napkins, baby napkins, brief shields, sterile dressings, bandage material, etc. The material for instance may be manufactured with a surface 2 weight as low as 10 g/m - and still hav#e an acceptable strength. In addition to the necessary characteristics of allowing passage of fluid to the absorbing core, the fibre cloth material also acts to maintain the core in a proper position. Generally, the core consists of defibrated cellulose (defibrate) and additionally might include inserts of "super absorbing" material. In order to give the fluid absorbing product penetra tlon preventing characteristics - a liquid leakage barrier - in the regions thereof where absorption is not desired, it previously simply has been inserted a loose film of plastics, for instance a polyethylene film, between the core and the carrier material. In certain cases the need for measures against leakage even has been neglected. According to the present invention it has been realized that this is not an acceptable solution to the problem of providing fully acceptable fluid absorbing products by means of a proper manufacturing method and a machinery line that is useful in practice. The object of the present invention, therefore, is to obviate said drawback of' the known technique and offer a more advantageous alternative. The invention provides, in the broadest sense thereof, a product based on a fluid absorbing core having a fluid penetration preventing layer on portion thereof. The product is characterized in that the fluid absorbing core comprises a layer of a fluid absorbing material known per se, for instance a defibrate of cellulose fibres, and in that the penetration preventing layer is formed by at least a portion of at least one strip of a carrier material, for instance a fibre cloth material (non-woven), extrusion strip coated by a thermoplastics material. The strip coated carrier material is coated by using "extrusion coating" thechniques in an extruder having an extrusion orfice cross-wise the machine direction. Thereafter the material is cut length-wise in a suitable manner for providing the desired coverage of the penetration preventing portion of the carrier material. Said at least one strip portion of the carrier material covers preferably at least a portion of a broad side of the core and at least a portion of two narrow sides of the core oriented in the longitudinal direction of the strips. In a preferred embodiment the core with a broad side thereof is placed between two strips/strip portions. According to a further preferred embodiment at least the major portion of a broad side of the core is placed between two strips/strip portions. It is to be preferred that each one of the two strips covers a portion of the broad side of the core and at least a portion of a respective one of the narrow sides of the core. In order to obtain an especially preferable fluid barrier, each strip wit one boarder edge extends a distance into the fluid absorbing side of the core. In the region of said boarder edge the strips/strip portions preferably have thicker plastics layers. This is accomplished by properly cutting in a length-wise direction the carrier material which is coated by strip extrusion coating into an inhomogeneous layer thickness. In order to facilitate the machine handling it is preferred to let the other boarder edge portions overlap and seal them on the side of the core opposite to the fluid absorbing side. In a simple embodiment, said boarder edge portions are sealed by the thermoplastic coating strip. In another embodiment, the boarder edge portions are sealed by a binder, for instance hot melt, which is applied at least along a portion of the boarder edge portions. Preferably, the carrier material is sealed cross-wise the core and the strips for forming products of a desired length. In an advantageous embodiment, the absorbing core is maintained in place against the uncoated areas of the carrier material by being anchored to the pores of the carrier material. The invention also provides a method and a machinery for the manufacture of the product, as more specifically appears from the accompanying claims. Some embodiments of the invention will now be described with reference to the accompanying drawings, where Figure 1 schematically shows a line for the manufacture of fluid absorbing products according to the inven tion, for instance napkins, brief shields, etc., Figure 2 in partial view shows a strip coated carrier material web, Figure 3 shows the web in Figure 2 cut longitudinally and together with an absorbing core, Figure d shows the arrangement in Figure 3 in section, Figure 5 in section shows the core according to Figure 4 with the carrier material applied around the core, and Figures 6 to 9 show variants of the application of strip coated carrier material around absorbing bodies. The reference numeral .10 in Figure 1 indicates a supply. roller of carrier material. Said material consists of strip coated fibre cloth material (non-woven material) which has been extrusion strip coated by thermoplastics, for instance polyethylene, and thereafter cut length-wise into the desired width. The length-wise cutting might for instance be carried out along the broken lines 13 in Figure 2 in an extrusion strip coated, wide material web 14. This gives for instance an addition of thickness of the plastics material in strategically important positions, if the cut material is placed as for instance in Figures 3 to 5. The extrusion coating, namely, inherently implies thickening of the outer edges of the strips. A web 12 of absorbing core material (fluff material), for instance of the defibrated cellulose type, is fed through a chopper 15 to the upper side of the web 11 where the material is spread out as a string 16 of sufficient thickness for the desired absorption capacity. A cross-wise discontinuity for allowing an efficient cross-wise seal is obtained in the web 16 by a rotating multi-orfice suction device 17, in the present case comprising three suction orfices 18, one at each corner-thereof. By giving the suction device a suitable. rotation speed there are obtained individually separated core pieces 19 at the output side thereof. Said pieces 19 are attached by suction to the pores of the carrier material 11 in a suction/pressure station 20. The arrow in Figure 1 represents a pressure function and the box under the web is a suction box. After the station 20, there eventually follows a first binding agent applicator 21, for instance a hot melt applicator, for applying a binding agent for Lhe cross-sealing operation in an end station 22. A first folding bar 23, for folding one 24 (Figure 3) of the side portions of the carrier material protruding from the absorption core 17, is arranged after the suction/ pressure device and applicator 21. If required in certain cases to apply 9 specific binding agent in order-to obtain sealing longitudinally, there is arranged a.further-hot melt applicator 25. Thereafter follows a further folding station 26 for folding inwards and sealing of the other protruding edge portion of the web 27 against the already folded in first portion. Finally, after this sealing, cross-wise se#aling and cutting to finished products 28 is carried out in the end station 22. Figures. 3 to 5 show a first version of an absorbing product, for instance a sanitary towel, brief shield, -etc. In this case the absorbing core 17 is placed such that onebroad side 29 thereof with edge portions extended into the strip coated regions 30, 31 which here broadly coincide with the extension of the edge portions 24, 27. This implies that after the folding of the end portions to the position according to Figure 5, the coated region of the product will cover completely the upper side 32 of the core, the two longitudinal narrow sides 33, 34 and will extend around the corners 35, 36 to positions 37, 38 a distance inwards the fluid penetrating broad side 29 of the absorbing body. This has turned out to be an excellent guarantee against leakage of liquid laterally out from the body, especially as the plastics layer is thicker in the regions 37, 38. If the product for instance is a brief shield, this implies that practically all lateral leakage is prevented independently of displacing forces acting on the shield. In this connection it may be mentioned that the actual brief shield is attached to the brief in a known manner with the upper side 39 of the carrier material against the brief. The longitudinal seal 40 shown in Figure 5 might be a dot-wise or string-wise hot melt seal, alternatively the sealing may be accomplished by directly using the thermoplastics 30, 31. The variants in Figures 6 to 9 show different methods of longitudinally cutting the strip coated carrier material according to the invention and different placements of the absorbing body on the carrier. In the embodiment according to Figures 6 and 7 there is one strip 30 or strip portion merely and the folding of the carrier material is intended to take place along the broken lines 41. The version in Figure 8 discloses an embodiment where the broad side 27 of the absorbing body 17 exposed to fluid penetration is smaller than the distance between the coated strips/strip portions 30, 31. The embodiment according- to Figure 9 resembles the one in Figure 5, but the longitudinal seal 40 is displaced relative the centre line 42 in that the strips/strip por tions have different width. If the carrier material is of the absorbing type the core 17 might advantageously be placed against the "uncoated" side of the carrier material (c.f. Figures 4 and 5).

Claims: CLAIMS 1. A product based on a fluid absorbing core (17) and provided with a fluid penetration preventing layer (30, 31) at a portion thereof, c h a r a c t e r i z e d in that the absorbing core (17} comprises a layer of a fluid absorbing material known per se, for instance a defibrate of cellulose fibres, and in that the penetration preventing layer (30, 31) is formed of at least a portion of a strip of a carrier material (14), for instance a fibre cloth material, extrusion strip coated by a thermoplastics material. 2. A product as in claim 1, c h a r a c t e r i z e d in that said at least one strip portion covers at least partially a broad side of the core (17) and at least partially two narrow sides of the core (Figures 5 to 9) oriented in the longitudinal strip direction. 3, A product as in claim 2, c h a r a c t e r i z e d in that the core (17) with a broad side (29) thereof is placed between two strips/strip portions-(Figures 8, 9). 4. A product as in claim 3, c h a r a c t e r i z e d in that at least the major portion of a broad side of the core is placed between two strips/strip por,t-tions por (Figure 9). 5. A product as in claim 4, c h a r a c t e¯ r i -z e d in that the two strips cover at least a portion of a broad side of the core (17) and each one at least a portion of a respective one of the narrow sides of the core (Figures 8, 9). 6. A product as in claim 5, c h a r a c t e r i z e d in that each strip (30, 31) with one boarder edge (37, 38) thereof extends a distance inwards the fluid absorbing side of the core (Figure 5, 9). 7. A products in claim 6, c h a r a c t e r i z e d in that the carrier material has thicker plastics layers at the region of said boarder edges (37, 38). 8. A product as in claim 7, c h a r a c t e r i z e d in that the other boarder edge portions of the strips overlap and are sealed at the side of the core (17) opposite to the fluid absorbing side (29). 9. A product as in claim 8, c h a r a c t e r i z e d in that said boarder edge portions are sealed by the thermoplastic coating strip (30,31). 10. A product as in claim 8, c h a r a c t e r i z e d in that said boarder edge portions are sealed by a binding agent, for instance hot melt, which has been applied along at least a portion of the boarder edge region. 11. A product as in anyone or any of the preceding claims, c h a r a c t e r i z e d in that the carrier material is sealed cross-wise the core (17) and cross-wise said at least a portion of a strip (30, 31) for forming of a product of a. desired length. 12. A product as in anyone or any of the preceding claims, c h a r a c t e r i z e d in that the core (17) is maintained in position against the uncoated region of the carrier material (11) by being anchored to the pores of the carrier material. 13. A method of manufacturing a product based on a fluid absorbing core and having a fluid penetration preventing layer on a portion thereof according to anyone or any of the claims 1 to 12, c h a r a c t e r i z e d in that a web (14) of a carrier material, for instance a fibre cloth material (non-woven material), extrusion strip coatec by a thermoplastics material is supplied with fluid absorbing material (16) for forming an absorbing core (17) of the product, and that the carrier material is folded around the core (17) such that at least a portion of at least one strip forms said fluid penetration preventing layer. 14. A method as in claim 13, c h a r a c t e r i z e d in that the strip coated carrier material (14) is cut length-wise such that at least one strip portion (30, 31) covers at least a portion of a broad side of the core and covers at least portions of two narrow sides of the core oriented in the longitudinal direction of the strips. 15. A method as in claim 14, c h a r a c t e r i z e d in that the strip coating and the length-wise cutting is accomplished such that a broad side of the core is placeable between two strips/strip portions. t 16. A method as in claim 15, c h a r a c t e r i Z e d in that the dimension relations are selected such that at least the major portion#of a broad side of the core is placeable between two strips. 17. A method as in claim 16, c h a r a c t e r i z e d in that the core is placed such that the two strips/ strip portions cover at least a portion of a broad side of the core and at least a portion of a respective one of the narrow sides of the core. 18. A method as in claim 17, c h a r a c t e r i z e d in that the placement of the core is accomplished such that each strip/strip portion extends; preferably wit} a thickened plastics layer, a distance into the fluid absorbing side of the core. 19. A method as in claim 18, c h a r a c t e r i z e d in that the other boarder edge portions of the strips/strip portions are placed with overlap and sealed against the side of the core opposite to the fluid absorbing side. 20. A method as in claim 19, c h a r a c t e r i z e d in that the sealing is accomplished by the thermoplastics coating. 21. A method as in claim 19, c h a r a c t e r i z e d in that the sealing is accomplished by a binding agent, for instance hot melt, which is applied at least partially along the boarder edge portion. 22. A method as in anyone or any of claims 11 to 20, c h a r a c t e r i z e d in t#at the carrier material is sealed cross-wise the core and cross-wise said at least one portion of a strip for forming of products of a desired lengt. 23. An apparatus for manufacturing products based on a fluid absorbing core and having a fluid penetration preventing layer on a portion thereof, comprising means (10) for supplying a web (11) of a carrier material (12), means (15) for supplying fluid absorbing material (16), for instance a defibrate of a cellulose material, onto said web, and means (23, 26, 22) for folding and sealing the carrier material around the core, c h a r a c t e r i z e d by a suction device (17) periodically operable relative the core material (16) on the carrier material web (11) for removing core material at locations intended as cross sealing positions of the product. 24. An apparatus as in claim 23, c h a r a c t e r i z e d in that the suction device (17) comprises a rotatable device having suction orfices (18, spaced from each other and adjustable rotation speed related to the desired core length. 25. An apparatus as in claim 24, c h a r a c t e r i z e d in that a further suction/pressure device (20) is arranged just downstreams of said suction device (17) and arranged for anchoring desired core material lengths to the carrier material (11).

Inventors: EKSTRAND, STIG, FRANSSON, PER
Applicants: AB AKERLUND & RAUSING
Application year: 1983
Main classification: A61F13
IPC codes: A61F13