Abstract:
A hygiene article has a fluid permeable protective layer, a rear, fluid impermeable layer and an absorbing body arranged between the layers. The article has a first longitudinal direction and a second transverse direction. Fastening elements are provided for removably fastening the hygiene article when worn by a user. The fastening elements include a clip which cooperates with an application zone of the hygiene article. Each fastening element has a first zone, by means of which the fastening element can be attached to the hygiene article, and a second zone, arranged at a distance from the first zone in the transverse direction and in which the clip is provided. Each fastening element is folded in a zigzag manner along folding lines extending in the longitudinal direction. The second zone provided with the clip is arranged outside of the zigzag folded configuration in the transverse direction.

Description:
BACKGROUND 
   The invention relates to a hygiene article, also particularly a diaper for incontinence, having a fluid-pervious top sheet, a fluid-impervious back sheet and an absorbent core disposed therebetween, and having fastening elements for releasably closing the hygiene article when applied to the user. 
   Hygiene articles with fastening elements folded over on themselves prior to use are known, for example, from EP 0 669 121 A1 or WO 95/16425. Fastening elements folded over on themselves in a Z-shape for disposable hygiene articles are also known from U.S. Pat. No. 4,237,890 
   SUMMARY 
   Based on this prior art, the object of the present invention is to improve a hygiene article of this type with respect to ease of attachment of the fastening elements during manufacture of the hygiene article, but also to simplify the handling of the hygiene article after the fastening elements are attached in a high-speed production machine and during a subsequent packaging process. A further object of the present invention is to improve the manageability of the hygiene article during unfolding, positioning and closing of the fastening elements when the hygiene article is attached to a user. 
   This object is achieved by a hygiene article of the type described in accordance with the invention by placing the second zone having the securing means outside the folded, Z-shaped configuration in the transverse direction. 
   The present invention accordingly proposes to fold the fastening element in the longitudinal direction in such a way that the result is a Z-shaped configuration, of which one part, or section, of the fastening element which has the second zone with the securing means projects transversely, is thus located outside the folded, Z-shaped configuration. In this way it is possible to affix, i.e. to attach, the particular fastening element with its first zone on a surface of the hygiene article. The part or section of the fastening element projecting at the side, in the transverse direction from the folded Z-shaped configuration, can now be grasped easily under the invention. Since the gummy or otherwise adhesively configured securing means is furnished there, advantages also accrue with respect to manufacture; the securing means is prevented from interfering in a distracting fashion with the folded, Z-shaped configuration. 
   In a further aspect of the invention, the particular fastening element with a zone lying outside the folded, Z-shaped configuration forms a releasable retentive connection with the top side of the hygiene article by providing adhesive or retaining means. For example, the second section of the fastening element could have spots of glue at any location which adhere to the top side of the hygiene article in an easily releasable manner and thus retain the fastening element in the intended assembled position. It would also be conceivable that the second zone, which has the active securing means, is overlaid with a detachable covering which in turn has an adhesive coating to releasably retain the section to the top side of the hygiene article. 
   However, in a further aspect of the invention it is proposed that the releasable retentive connection is formed by the securing means in the second zone of the fastening element itself. 
   It also proves to be advantageous if the particular securing means is formed by mechanically acting closures. To create a releasable retentive connection, the closures can coact with a textile-like top side of the hygiene article, for example, in the manner of a hook-and-loop material. 
   With respect to the attachment of the fastening elements to the hygiene article, an arrangement on the inner user facing side, that is, on the side of the fluid-pervious top sheet, could be considered, or an attachment by means of fork-shaped or Y-shaped retaining tabs, which clasp the combined top sheet and back sheet of the hygiene article from both sides and are attached there. However, in embodying the present invention, it proves to be particularly advantageous if the fastening elements are attached to a side of the hygiene article facing away from the body. 
   The side facing away from the body can advantageously have a textile-like surface. This textile-like surface advantageously comprises the fluid-impervious back sheet and can be made from a nonwoven-plastic film laminate. In this embodiment it is possible to implement the releasable retentive connection through mechanically acting closures which are located outside the folded, Z-shaped configuration and coact directly with the textile-like surface in an adherent manner. 
   In accordance with a further aspect of the invention, the folded, Z-shaped fastening elements are spaced apart in the transverse direction from a longitudinal edge of the hygiene article in such a way that the second zone with the securing means is located at least almost entirely inside the longitudinal edge. This is intended to convey that the second zone with the securing means should protrude as little as possible, preferably not at all, beyond the longitudinal edge of the hygiene article. This is to prevent the protruding area of the securing means from catching on the top sheet when the hygiene article is folded onto the body facing top sheet and damaging said top sheet when it is detached. The second zone should not protrude outwardly more than 5 mm, preferably less than 3 mm, most specifically less than 2 mm in the transverse direction beyond the longitudinal edge. The side sections of the rear area of the hygiene article, often described as “ears” and carrying the fastening elements, are folded in on the body facing top sheet as part of the folding of the hygiene article during manufacture. This prevents the particular securing means from becoming entangled with the surface of the normally fleecy top sheet and damaging said top sheet. Furthermore, fleecy material could become stuck on the securing means and negatively affect the closing ability of the mechanically acting closures. 
   In a further aspect of the invention it is proposed to configure the fastening elements in such a way that a pull tab is furnished for the user to take hold of with a finger. The pull tab is furnished in the transverse direction outside the second zone of the particular fastening element and on the side of the second zone facing away from the folded, Z-shaped configuration. 
   In yet another aspect of this inventive concept, the fastening element is positioned on the surface of the hygiene article facing away from the body and attached there in such a way that its pull tab protrudes beyond a longitudinal edge of the hygiene article in the transverse direction. This proves to be advantageous insofar as with the hygiene article spread out and unfolded, the particular fastening element with its pull tab projects in the transverse direction beyond the longitudinal edges of the hygiene article on both sides and are thus visible. The tabs can then be easily grasped by a user&#39;s fingers, who takes hold of the pull tab with one hand, and with the other hand, perhaps with thumb and forefinger, takes holds of a longitudinal edge area of the hygiene article and then exerts a pulling motion. The releasable retentive connection between the fastening element and the surface of the diaper is thereby broken and the folded, Z-shaped configuration is unfolded, so that the fastening element can be moved in a direction encircling the hips towards the contact zone provided in the front area of the hygiene article, to be secured there to close the hygiene article when applied to a user. 
   The particular fastening element can have a first section of a first supporting layer and a second section of a second supporting layer which is disposed in the transverse direction next to the first section and is connected thereto. The first section has the first zone and the second section has the second zone. 
   It proves to be advantageous if a fold line of the fastening element running in the longitudinal direction runs at least in sections along a material transition between the first and second section of the fastening element. The ability of the fastening element to be folded is thereby improved, and the thickness of the folded, Z-shaped configuration is kept as small as possible. 
   Preferably the fold line runs immediately along a longitudinal edge of the second section of the fastening element. 
   The first and the second section of the particular fastening element can be joined in any way whatsoever, i.e., they could butt against each other and be overlaid by a third, specifically strip-shaped, fastening element which joins the two sections non-detachably. It is also conceivable and advantageous for the first and the second section of the fastening element to be overlapped in the transverse direction and be joined in the overlap area. In this case, it proves advantageous if a fold line of the fastening element running in the longitudinal direction runs immediately along a longitudinal edge of the first zone. 
   In a further aspect of the invention, it proves advantageous if a further fold line of the folded, Z-shaped configuration runs immediately along a longitudinal edge of an adhesive coating in the first zone. The adhesive coating of the first zone can be of any extent, where to achieve very good securing of the folded, Z-shaped configuration on the top side of the hygiene article, as extensive an application of adhesive as possible, specifically delineated as a rectangle in plan view, is recommended. 
   It furthermore proves advantageous if the second supporting layer of the fastening element comprises an essentially inelastic material and is essentially not extensible in the transverse direction. In contrast, it is proposed that the first supporting layer of the fastening element comprises a material essentially extensible at least in the transverse direction and is configured elastically extensible in this transverse direction. 
   As used herein, elastically extensible refers to a material which can be stretched by at least 1.2 times its original dimension when tension is applied and, when tension is removed, contracts again at least far enough to nullify at least half of the stretched length. Of course, materials are known and preferred for use as the first supporting layer which demonstrate much more pronounced retraction characteristics. 
   To achieve these elastically extensible properties for the first supporting layer, elastic nonwovens or so-called “stretchbond” laminates with one or more nonwoven and/or plastic film layers can be employed. 
   In a further aspect of the inventive concept, it is proposed to secure the folded, Z-shaped configuration of the fastening element releasably to itself. This can be achieved, for example, by securing the folded, Z-shaped configuration with a plurality of 1 to 10, preferably 3 to 5 discrete attachment points, such as weld spots, with a cross-sectional area of less than 1 mm 2 , so that the folded, Z-shaped configuration is prevented from unfolding during the manufacturing or packaging process or before the hygiene article is unfolded as intended when it is applied. 
   It was ascertained in a further development of this inventive concept that the folded, Z-shaped configuration can also be secured to itself when longitudinal sections forming a particular fastening element are severed from a continuous web in the transverse direction; fibers from the layers folded over on each other in a Z-shape are worked or pulled into the layer disposed thereunder at the cut edge thus created. So when these longitudinal sections are severed, a type of needling effect in fibrous nonwovens can be achieved, which is sufficient to hold the folded, Z-shaped configuration to itself When the longitudinal sections are severed, particularly if a “crush cut” is made, fibers from one layer are pulled into the layer disposed thereunder in the direction of the cut. This “crush cut” is preferably performed by a compliant knife, specifically a knife under pre-tension, or at least mounted to yield a small amount. This knife is preferably disposed on a rotating cylinder and when performing the cut, can be positioned under suitable pressure against a counter cylinder over which the web is guided and which forms an anvil for the knife. 
   In accordance with a further inventive concept of intrinsically independent significance, a recess in the material is provided in a longitudinal end zone of the rear part on both sides in the transverse outboard direction, such that the extension of the rear part in the longitudinal direction at the particular longitudinal side edge of the diaper is less than in the area between the recesses and such that the closures and their mating elements are so disposed respective to the rear part and the front part that when the diaper is applied, the back part extends farther upward than the front part, so the rear part reaches up higher than the front part. Expressed differently, this means that the securing means in the back part and the contact zone in the front part of the diaper are at different distances from the corresponding longitudinal end of the diaper in the back part or front part, respectively: the securing means are farther in the longitudinal direction from the longitudinal end of the rear part of the diaper than the contact zone is from the longitudinal end of the front part. 
   This creates the impression of a slim product which is configured narrow and long. In fact, a greater longitudinal extension of the diaper can be achieved thereby, for example, if the extension of the back part in the longitudinal direction is advantageously greater than the extension of the front part. 
   The aforementioned recesses are preferably formed by forming blanks in the diaper or as cut-outs from a laminate comprising the top sheet and the back sheet. 
   In a further aspect of the inventive concept, an edge of the back part bounding the particular recesses is located at the same height as a transverse edge bounding the front part, as said first edge transitions to a longitudinal side edge of the diaper. 
   Observing this aspect of the diaper when applied to the user, the transition of the edge bounding the recess to the longitudinal side edge of the diaper, meaning the corner or transition point of the diaper side area (frequently described as the ear), is essentially at the same height as the corresponding corner or transition point of the front part. 
   In a further aspect of the inventive concept, it is proposed to provide the zone for the fastening elements containing the securing means and the corresponding contact zone with an essentially identical longitudinal extent, so that the user is thereby forced to position the fastening means correctly on the contact zone. A correct fit and correct application of the diaper to the user is thereby achieved. 
   It furthermore proves to be visually attractive and, with respect to achieving an optimal fit, advantageous when the diaper is applied, if the edge of the back part bounding the particular recess terminates in the transverse direction so that it always merges into the transverse edge bounding the front part or terminates therein. While a section or recess running diagonally to the longitudinal and transverse direction would be conceivable to achieve the effect in accordance with the invention, the preceding embodiment proves advantageous, since a smooth merging of the edge bounding the particular recess and the transverse edge bounding the front part is achieved thereby. 
   In a further aspect of the invention, a second material recess can be furnished in the front part in a longitudinal end zone on both sides in the transverse direction outboard such that the extension of the front part in the longitudinal direction at the specific longitudinal side edge is less than in the area between the recesses. The corresponding difference in the extension will preferably be much less than in the back part. 
   Furthermore, it proves to be especially advantageous if fastening elements are used in the back part which have adequate extension in the longitudinal direction of 4 to 10 cm, so that the tension arising when the diaper is closed is introduced uniformly into the back part of the diaper, which has a relatively large longitudinal extension. 

   
     BRIEF DESCRIPTION OF THE DRAWING 
     Additional details and benefits of the invention can be found in the appended claims and the illustrative drawings and the subsequent description of a preferred embodiment of the invention. In the drawings: 
       FIG. 1  shows a sectional view of a fastening element for a hygiene article in accordance with the invention; 
       FIG. 2  shows a plan view of the fastening element from  FIG. 1 ; 
       FIG. 3  shows a sectional view of the fastening element from  FIGS. 1 and 2  in the folded, Z-shaped configuration; 
       FIG. 4  shows a plan view of a hygiene article in accordance with the invention with fastening elements folded over on one side and unfolded on the other side; 
       FIG. 5  shows a photographic rendering of the cut edge of the folded, Z-shaped fastening element observed in an epimicroscope; 
       FIG. 6  is a schematic representation of a cutting device for severing individual folded, Z-shaped fastening elements and 
       FIG. 7  shows a side view of the diaper in accordance with the invention when worn. 
   

   DETAILED DESCRIPTION 
     FIGS. 1 and 2  show a fastening element in accordance with the invention, identified overall as  2 . The fastening element  2  comprises a first section  4  of a first supporting layer  6  and a second section  8  of a second supporting layer  10 . 
   The fastening element  2  has been severed as a longitudinal section from a continuous web, where the continuous web extends in a first longitudinal direction. The second section  8  is located in a transverse direction  14  next to the first section  4 , where in the instance shown, the first section  4  and the second section  8  overlap one another so that an overlap area  16  is formed to which the two sections  4 ,  8  are bonded non-detachably by means of a glue  18 , by weld spots or in some other fashion. 
   A first zone  22  which carries an adhesive coating  24  with which the fastening element can be joined to a hygiene article is furnished on a first top side  20  of the first section  4 . 
   Securing means  27  in the form of mechanically acting closures  28 , preferably in the form of a hook component of a hook-and-loop material, are furnished in a second zone  26  of the second section  8 , specifically adhered by means of a glue  30 . The second zone  26  is preferably furnished on the same top side  20  of the fastening element  2  as the first zone  22 . 
   Furthermore, first and second fold lines  32 ,  34  are indicated in  FIG. 2  and can be seen in  FIG. 3  around which the fastening element  2  is folded in a Z-shape in longitudinal direction  12  so that the configuration  35  shown in  FIG. 3  is created. Advantageously, the first fold line  32  runs immediately along a longitudinal edge  36  of the adhesive coating  24  in the first zone  22 . The second fold line  34  advantageously runs immediately along the material transition between first and second section  4  or  8 , along an edge  38  of the overlap area  16 . 
   As can be seen from  FIG. 3 , the second zone  26  of the second section  8  is spaced apart far enough from the overlap area  16  or from any other material transition area between first section  4  and second section  8  that it is located in the transverse direction  14  outside the folded, Z-shaped configuration  35  of the fastening element  2 , which proves advantageous in several respects. In the instance shown, a longitudinal edge  40  of the second zone  26  facing the first section  4 , and thus the mechanically acting fasteners  28 , extends in the transverse direction almost to the first fold line  36  in the folded, Z-shaped configuration  25 . It would also be conceivable that the second zone  26  is positioned with respect to the second section  8  in such a way that the mechanically acting closures  28 , or their longitudinal edge  40 , are at a distance of a few millimeters from the folded, Z-shaped configuration  35  of the fastening element. 
   It should be mentioned that the first section  4  is configured elastically extensible in the transverse direction  14  and that the second section  8  is configured essentially not elastically extensible in the transverse direction  14 . 
   It is contemplated that the extension of the fastening element  2  can measure 2 to 10 cm in the longitudinal direction in specific embodiments. If desired or required, the extension of the first section  4  of the fastening element  2  in an elastically configured area between the longitudinal edge  36  of the first zone and the material transition to the second section can measure between about 0.5 to 4.5 cm in the transverse direction, with certain embodiments having a value between about 2 and 3 cm in the transverse direction. Where desired or required, the extension of the second zone of the hygiene article can measure about 0.5 to 2.1 cm in the transverse direction. Where desired or required, it is contemplated that the extension of the pull tab of the fastening element can measure from 0.5 to 2.0 cm in the transverse direction; with the measurement being from 0.7 to 1.2 cm in some embodiments. 
   An adhesive coating in the first zone  24  and the securing means  27  in the second zone  26  can be applied uninterruptedly and continuously in the longitudinal direction  12  onto a correspondingly continuous web of the first supporting layer  6  and of the second layer  8 . In corresponding fashion, the first and second supporting layer  6 ,  8  are bonded to each other without interruption by a continuous strip of glue  18  or in some other way in the longitudinal direction  12 . Simultaneous production of two symmetrically, but offset in the longitudinal direction by π/2, as known from EP 0 669 121 A1 for example, is also conceivable and advantageous. 
   When the fastening element with its adhesive application  24  in the first zone  22  is applied to a hygiene article, the second zone  26  with its mechanically acting closures  28  is, as already mentioned, located outside the folded, Z-shaped configuration and can thus serve to affix the fastening element, or the second section  8 , to a textile surface of a hygiene article. This is explained in what follows, making reference to  FIG. 4 . 
   The affixing of the second section  8  to the hygiene article is intended to serve only to secure the fastening element during manufacture and packaging until the hygiene article is applied to a user, at which time at the latest this connection is broken. A user reaches with his fingers between the top side of the hygiene article and a free end zone  42  of the second section  8 , which then acts as a pull tab  44 . 
     FIG. 4  shows a plan view of a diaper  50  in accordance with the invention with fastening elements  2  disposed on both sides in a back part of the diaper  50 , as described in conjunction with  FIGS. 1 to 3 . On the left side in  FIG. 4 , the fastening element  2  is shown unfolded and on the right side it is shown folded in a Z-shape. The particular fastening element  2  is affixed non-detachably with its first zone  22  and the rectangular adhesive coating  24  to an outside of a diaper, that is to a top side  54  of a fluid-impervious back sheet  56  of the diaper when used as intended. The top side  54  is formed of a textile-like nonwoven covering of a fluid-impervious film. The back sheet  56  is consequently formed of a nonwoven/plastic film laminate. 
   The fastening element  2  is located in the transverse direction  14  at such distance from a longitudinal edge  58  of the diaper  50  in the side flap or ear area of the diaper  50  that only its pull tab projects beyond the longitudinal edge  50  in the transverse direction  14 . Care is taken in particular that the second area  26  in which the mechanically acting closures  28  are provided (in the Z-shaped fold of the fastening element) does not project, or projects very little, 5 mm at the most, beyond the longitudinal edge  58  in the transverse direction  14 . This prevents the closures  28  from becoming caught when the side flap or ear areas are folded onto the body facing top sheet layer and related damage from occurring. 
   As can be seen from  FIG. 4  in conjunction with  FIG. 3 , the second zone  26  with the closures  28  is located outside the folded, Z-shaped configuration  35  and thus lies against the top side  54  of the back sheet  56  of the diaper  50 . The mechanically acting closures  28  form a releasably adhering connection to the textile-like top side  54  and keep the fastening element  2  in its folded, Z-shaped configuration  35 . In particular, this prevents the second section  8  with the zone  26  from becoming detached from the top side  54 . In this way manageability of the hygiene article is improved after the fastening elements  2  are attached and they remain in their installed position. The diaper  50  can be handled in the production machinery, in particular folded, stacked and taken for packaging. 
   The unfolded state of the fastening elements  2  is shown on the left in  FIG. 4 . To obtain this, a user grasps the pull tab and with the other hand he holds a longitudinal edge area  52  of the diaper  50  and pulls the two components apart. The releasably adhering connection of the closures  28  to the textile-like top surface  54  is broken, and the fastening elements  2  assume the shape shown on the left in  FIG. 4  as the folded, Z-shaped configuration  35  unfolds. To apply the diaper  50  to a user, the fastening elements can now be brought to a contact zone  55  in the form of a loop material in the front part of the diaper  50  and attached thereto. 
   To further secure the fastening elements  2  in a folded, Z-shaped configuration  35 , it is conceivable to provide discrete attaching points, such as weld spots  51 , which releasably join together the layers of the fastening element  2  folded in a Z-shape over on each other. However, it has been shown that the folded, Z-shaped configuration  35  can be secured in a way which satisfies requirements when the longitudinal sections forming the specific fastening elements are severed from a continuous web; fibers are pulled from the layers disposed above one another in the Z-shape into the layer lying thereunder, so that a form of needling effect is achieved which secures the Z-shaped configuration  35  releasably to itself. 
     FIG. 5  shows a schematic outline for a cutting device for severing longitudinal sections  90  from a continuous web  92  which already has the folded, Z-shaped configuration for creating the fastening elements. The cutting device comprises an anvil cylinder  94  across which the continuous web  92  is passed and a knife cylinder  96  having a knife  98  which is under pre-tension and mounted in a floating manner or is intrinsically compliant, with a cutting edge  100 . To perform the cut, the knife cylinder  96  is positioned opposite the anvil cylinder  94  in such a manner that the cutting edge  100  of the knife  98  touches the surface of the anvil cylinder  94  and can retract very slightly. The continuous web  92  is thus contacted over a relatively short circumferential area by the cutting edge  100  of the knife  98 . In contrast to merely shearing, when a “crush cut” is performed, fibers of the layers overlaid on each other are hereby deflected out of one layer and pulled, crushed or worked into the layer thereunder, so that in the severed longitudinal section  90  the layers folded over on each other in a Z-shape are at least slightly connected to each other and unintentional unfolding is thereby prevented. 
   A division into a front part  60  and a back part  62  with a crotch area  64  between them can further be seen from  FIG. 4 . The crotch area  64  is intended as that area which comprises leg cut-outs  66  to form leg openings when the diaper is applied. In diapers in which no leg cut-outs are provided and whose width or extension in the transverse direction  14  does not change or changes only slightly, the crotch area is defined as that area over whose longitudinal extension the longitudinal edge sections bounding the leg openings run. Front part  60  and back part  62  then adjoin the crotch area  64  in the longitudinal direction  62 , the crotch area being symmetrical with respect to a transverse center line  68 . 
   As shown in  FIG. 4 , a recess in the material  72 ,  74  is furnished in a longitudinal end zone  70  of the back part  62  outwardly on both sides in the transverse direction  14 . The material recess  72 ,  74  is bounded by an arcuate edge  76  or  78 , which first runs diagonally from the longitudinal edge  58  and then inward in essentially a transverse direction  14  and is finally turned in the longitudinal direction  12  and then, essentially in the longitudinal direction, meets essentially perpendicularly a first transverse edge  80  which bounds the back part  62 . Because of the recesses  72 ,  74 , the extension L a  in the area of the longitudinal side edge  50  is less than the longitudinal extension L i  in the area between the recesses  72 ,  74 . This creates the impression of a slim diaper. 
   It proves advantageous that the extension of the fastening elements  2  in the longitudinal direction  12  is about 50% of the longitudinal extension of the entire back part  62 , so that the tension generated when the diaper is closed is transferred in a highly uniform manner into the material forming the outside of the diaper. 
     FIG. 4  further shows that the longitudinal extension of the contact zone  55  (indicated by arrow  82 ) essentially matches the longitudinal extension of the closures  28  of the fastening element  2  (indicated by arrow  84 ). This obliges the fastening elements  2  in the contact zone  55  to be correctly positioned and thus the diaper to be correctly seated. The fit shown in  FIG. 7  from the side then results. It can be seen that the edge  76  bounding the recesses  72 ,  74  in the transition to the longitudinal side edge  50  of the back part  62  is located at the same height as a second transverse edge  86 , which bounds a longitudinal end of the front part  60  of the diaper. Optimal fit of the diaper is thereby achieved. In the instance shown in  FIGS. 4 and 7 , a less pronounced recess  88  corresponding to recesses  72 ,  74  is furnished in the front area  60 . 
   However, this is not absolutely necessary.