Abstract:
Continuous edge folds of a top sheet in disposable products prepare the top sheet for placement/attachment of discrete side panels to the folded-over portion of top-sheets oriented so that the side panels lay on top of the top-sheet without any further folding steps required. Later, a back sheet can be added and back sheet edges then folded over to cover edges of top-sheet/side panel sandwich.

Description:
RELATED APPLICATION 
       [0001]    This application claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 61/600,877, filed 20 Feb. 2012. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    In prior art methods, side panels are bonded to top sheets, and then the side panels are folded over for further processing, such as folding and packaging. In other methods, side panels are attached like fastening tape to top-sheets, then folded over for further processing. 
         [0003]    Traditional methods may result in skewed side panel placement, wrinkled side panels, and skewed side panel folding. 
       SUMMARY OF THE INVENTION 
       [0004]    A continuous edge fold of a top sheet prepares the top sheet for placement/attachment of discrete side panels to the folded-over portions of the top-sheet. The folded over portions are oriented so side panels can be applied and lay on top of top-sheet without any further folding steps required. Later, a back-sheet is added and back-sheet edges then can be folded over to cover edges of top-sheet/side panel sandwich. 
         [0005]    By applying the cut panel to the pre-folded edge of the continuous top sheet web, it is easier to better control the squareness of the panel to the top sheet. This ultimately improves the quality and appearance of the ear fold in the finished product. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1A  is a cross sectional view of side panels bonded to a top sheet; 
           [0007]      FIG. 1B  is a cross sectional view of side panels bonded to a top sheet as in  FIG. 1A , with the side panels folded over top sheet, with the side panels tack bonded (also known as fugitively bonded) to one another; 
           [0008]      FIG. 1C  is a cross sectional view of an alternative bonding pattern of the prior art, with a long portion of panel applied to a web and a short side folded over. This method was common for us and also had skewing issues. 
           [0009]      FIG. 2A  is a side view of a top sheet; 
           [0010]      FIG. 2B  is the top sheet of  FIG. 2A , with continuous edges fold created along side edges of the top sheet, with adhesive applied to top regions of the continuous edge folds; 
           [0011]      FIG. 2C  is a side view of the top sheet of  FIG. 2B , with side panels deposited atop the top sheet, and bonded to the top regions of the continuous edge folds, and the side panels tack bonded to one another; 
           [0012]      FIG. 3  is an alternative embodiment of the product shown in  FIG. 2C , with the side panels provided with a pre-fold at the center-lying regions, which allows for longer length side panels; 
           [0013]      FIG. 4  is a side view of two side panels overlying a top sheet (preferably non-woven); 
           [0014]      FIG. 5  is a side view of two side panels overlying a top sheet (preferably non-woven) with continuous edge folds created along side edges of the top sheet; 
           [0015]      FIG. 6  is a side view of side panels which have been gathered, or pre-folded, for larger sized side panels, and coupled with continuous edge folds created along side edges of the top sheet, and a back sheet wrapped over the top sheet and side panels; 
           [0016]      FIG. 7  is a finished product showing side panels which have been gathered, or pre-folded, for larger sized side panels, and coupled with continuous edge folds created along side edges of the top sheet, and a back sheet wrapped over the top sheet and side panels; 
           [0017]      FIG. 8  is a side view of a top sheet overlain by side panels extending past edges of a top sheet; 
           [0018]      FIG. 9  is a side view of a top sheet overlain by side panels extending past edges of a top sheet, with continuous edge folds created along side edges of the top sheet; 
           [0019]      FIG. 10  is a side view of a top sheet overlain by side panels extending past edges of a top sheet, with continuous edge folds created along side edges of the top sheet, and a back sheet wrapped over the top sheet and side panels; 
           [0020]      FIG. 11  is a side view of finished product showing a top sheet overlain by side panels extending past edges of a top sheet, with continuous edge folds created along side edges of the top sheet, and a back sheet wrapped over the top sheet and side panels. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0021]    Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 
         [0022]    Referring now to  FIG. 1A , a cross sectional view of side panels  20  bonded at bond sites B to a top sheet  30  is shown as constructed by prior art methods. As shown in  FIG. 1B , side panels  20  are bonded to top sheet  30 , and side panels  20  are folded over top sheet  30 , with the side panels tack bonded (also known as fugitively bonded) to one another at bond site B′. 
         [0023]    Referring now to  FIG. 1C  a cross sectional view of an alternative bonding pattern of the prior art is shown, with a long portion of panel  20  is applied to a web  30  and a short side of the panel  20  (where the adhesive is shown) is then folded over (not shown, but similar in result to  FIG. 1B ). 
         [0024]    These methods of the prior art presented skewing issues. Namely the side panels panels  20  could run somewhat off of parallel with the track of edges of top sheet  30 . 
         [0025]    Referring now to  FIGS. 2A-2C , a first embodiment of the present invention is shown. Top sheet  30  is folded over at its edges to create continuous edge folds  32 , and adhesive  34  is applied to top regions of the continuous edge folds  32  (and elsewhere in the drawings, where shown). Side panels  20  are deposited atop the top sheet  30 , and bonded to the top regions of the continuous edge folds  32 , and the side panels tack bonded to one another at bond site B′. 
         [0026]    A method of forming bonds between discrete components of disposable articles is disclosed in  FIGS. 2A-2C , the method comprising providing a top sheet layer  30  in a machine direction (the direction of view of the cross-sectional views of  FIGS. 2A-2C ), the top sheet layer having a first and a second cross-machine direction edge, generally at the left and the right of the views of  FIGS. 2A-2C . Next a portion of the top sheet layer  30  is folded over at the two cross-machine direction edges (the left and the right edges layer  30  of  FIGS. 2A-2C ). 
         [0027]    Adhesive  34  couples the side panels  20  to the top sheet  30 . Preferably, the first and second side panels  20  overlap, and are bonded together with a fugitive, or temporary, or weak bond. 
         [0028]    Referring now to  FIG. 3 , an alternative embodiment of the product shown in  FIG. 2C  is shown, with the side panels  20  provided with pre-folds  22  at the center-lying regions of the side panels  20 . This allows for longer length side panels. 
         [0029]    Referring now to  FIGS. 4-7 , a second embodiment of the present invention is shown.  FIG. 4  is a side view of two side panels  20  overlying a top sheet  30  (preferably non-woven), and as shown in  FIG. 5  continuous edge folds  32  are created along side edges of the top sheet  30 . As shown in  FIG. 6 , side panels  20  can be gathered, or pre-folded, for larger sized side panels  20 , and coupled with continuous edge folds  32  created along side edges of the top sheet  30 , and a back sheet  40  is wrapped over the top sheet  30  and side panels  20  as shown, to create a finished product as in  FIG. 7 , shown having laid back what previously were the top regions of the continuous edge folds  32 , and having re-extended the previously pre-folded, for larger sized side panels  20 . 
         [0030]    Referring now to  FIGS. 8-11 , a third embodiment of the present invention is shown. In this embodiment, top sheet  30  is overlain by side panels  20  extending past edges of top sheet  30 , and continuous edge folds  32  are created along side edges of the top sheet  30  as shown in  FIG. 9 . A back sheet  40  is wrapped over the top sheet  30  and side panels  20  to create a finished product as shown in  FIG. 11 . 
         [0031]    Steps of the method can comprise A1: Continuous top-sheet  30  is provided; A2. Fold edges of top-sheet  30  (folded portion to the top) to create folds  32 ; and A3. Intermittent adhesive is added to top of folded-over portion  32  of top-sheet  30 . Alternatively, this adhesive could be applied to side panel  20  edges instead (which would then be step B1.5). 
         [0032]    Next, step B1 can comprise Continuous side-panel  20  web provided (left and right, possible interfolded ends); and B2. Side panel  20  web cut to discrete parts (left and right, possible interfolded ends); and B3. Discrete side panel pieces  20  placed onto adhesive patches located on top-sheet folded edges  32 . 
         [0033]    Alternatively, step C1 can comprise a Back-sheet continuous web  40 , and this can be added to any of the embodiments described above. A fugitive (or temporary) adhesive can be applied to keep side panel  20  ends temporarily attached to each other or to top-sheet  30  to control loose ends through downstream processing. 
         [0034]    Still alternatively, top sheet  30  and an attached ear or side panel  20  can be composed as shown in  FIGS. 2A-2C , and then unfolded prior to combining with back sheet  40 . 
         [0035]    The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.