Source: http://www.google.com/patents/US6534694?dq=6377161
Timestamp: 2016-05-29 00:10:16
Document Index: 291512543

Matched Legal Cases: ['art 104', 'art 105', 'art 106', 'art 105', 'arts 114', 'art 106', 'art 106']

Patent US6534694 - Elastic structure and a diaper - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsA method of securing an elastic band between two material layers which are at least partially defined by meltable material includes forming perforations in the elastic band, placing the elastic band between two material layers, and bonding the material layers to one another through the perforations by...http://www.google.com/patents/US6534694?utm_source=gb-gplus-sharePatent US6534694 - Elastic structure and a diaperAdvanced Patent SearchPublication numberUS6534694 B2Publication typeGrantApplication numberUS 09/984,506Publication dateMar 18, 2003Filing dateOct 30, 2001Priority dateOct 4, 1989Fee statusLapsedAlso published asUS6340782, US20020156449Publication number09984506, 984506, US 6534694 B2, US 6534694B2, US-B2-6534694, US6534694 B2, US6534694B2InventorsRobert Kling, Berth-Ove WallOriginal AssigneeSca Hygiene Products AktiebolagExport CitationBiBTeX, EndNote, RefManPatent Citations (41), Non-Patent Citations (1), Referenced by (37), Classifications (15), Legal Events (6) External Links: USPTO, USPTO Assignment, EspacenetElastic structure and a diaper
US 6534694 B2Abstract
A method of securing an elastic band between two material layers which are at least partially defined by meltable material includes forming perforations in the elastic band, placing the elastic band between two material layers, and bonding the material layers to one another through the perforations by heat fusion, wherein the perforations in the elastic band are formed at the same time as the material layers are fused together (i.e., the formation of the perforations in the elastic band is directly followed by bonding together, through the perforations, portions of the material layers). An elastic band secured between two material layers for inclusion in articles of one-time use includes the use of material layers that are at least partially defined by meltable material and an elastic band having perforations formed therein. The material layers are positioned on opposite sides of the elastic band and are joined together by heat fusion.
What is claimed is: 1. An elastic structure for use in articles which are intended for one-time use only comprising an elastic band and a material layer positioned on each side of said elastic band, said material layers being at least partially comprised of meltable material, said elastic band having perforations through all of which the material layers are joined together as a result of forming the perforations in the elastic band while stretched directly followed by joining together portions of the material layers located opposite the perforations by heat fusion, the elastic band being movable relative to the material layers.
2. An elastic structure according to claim 1, wherein the elastic band includes at least two regions having different bonding patterns and different elasticity in a direction in which the elastic band acts.
3. An elastic structure according to claim 1, wherein the elastic band includes at least one region of substantially punctiform perforations through which the two material layers are bonded together.
4. An elastic structure according to claim 1, wherein the elastic band includes at least one region with perforations which have a smaller extension in a direction in which the elastic band acts than perpendicularly to said direction and through which the two material layers are bonded together.
5. An elastic structure according to claim 1, wherein the elastic band is comprised of at least one band of elastic foam material having closed cells..
6. An elastic structure according to claim 5, wherein the foam material is a polyester-based polyurethane foam.
7. An elastic structure according to claim 1, wherein the elastic band is comprised of a plurality of separate bands of rubber material.
8. An elastic structure according to claim 1, wherein the elastic band is comprised of a plurality of separate bands of elastic foam material having open cells.
9. An elastic structure according to claim 1, wherein the elastic band is comprised of a plurality of separate bands of elastic foam material having closed cells.
10. An elastic structure according to claim 1, wherein the elastic band is comprised of at least one band of elastic foam material.
11. An elastic structure according to claim 1, wherein said elastic band is comprised of a band of rubber material.
12. A diaper comprising an absorbent pad enclosed between a liquid-permeable casing layer which is intended to face a wearer in use and a liquid-impermeable casing layer which is intended to lie remote from the wearer in use, the diaper having edges that define diaper margins, a front part which is intended to be located forwardly on the wearer in use, a rear part which is intended to be located rearwardly on the wearer in use, and a crotch part which is located between the front part and the rear part and which is intended to be placed between thighs of the wearer in use so that the diaper, when worn, embraces the lower abdomen of the wearer and therewith presents a waist margin around the waist of the wearer and a leg margin around each of the user's thighs, and including at least one elastic band which is secured in a stretched state between two material layers which are at least partially comprised of a meltable material, the at least one elastic band having perforations through all of which the material layers located on opposite sides of the at least one elastic band are bonded to one another as a result of forming the perforations while the elastic band is stretched directly followed by bonding together portions of the material layers located opposite the perforations in the stretched elastic band by heat fusion, the material layers being bonded in a bonding pattern so that the at least one elastic band is held mechanically between the material layers and so that the elastic band is movable relative to the material layers, the at least one elastic band being affixed along at least a part of at least one of the diaper margins, at least one of the material layers being joined to one of the casing layers in at least one of the diaper margins.
13. A diaper according to claim 12, wherein at least one of the material layers comprises one of the casing layers.
16. A diaper according to claim 12, wherein the two material layers comprise a separate casing of meltable material, said separate casing being attached to one of said casing layers.
17. A diaper according to claim 12, wherein the at least one elastic band is attached at least along the waist margin of the rear part of the diaper, the diaper having fastener tabs for securing the diaper, said fastener tabs being affixed to sides of the rear part of the diaper adjacent the waist margin, the at least one elastic band having a pattern of perforations which extend substantially transversely across the at least one elastic band within regions of the waist margin at which the fastener tabs are affixed.
18. A diaper according to claim 12, including an additional elastic band affixed to each leg margin, said additional elastic bands each having at least two regions of different bonding patterns and different degrees of elasticity.
19. A diaper according to claim 18, wherein each of the additional elastic bands has at least three regions of different bonding patterns and different degrees of elasticity, one of said three regions being located in the crotch part of the diaper and having the greatest elasticity.
20. A diaper according to claim 12, including elastic devices which are attached to the diaper by gluing.
21. A diaper according to claim 12, wherein the at least one elastic band is comprised of at least one band of elastic foam material.
22. A diaper according to claim 12, further including elastic devices which are attached to the diaper by welding.
This application is a continuation of application Ser. No. 08/597,377 filed on Feb. 8, 1996, which is a continuation of application Ser. No 08/240,207 filed on May 9, 1994 (now abandoned), which is a continuation of application Ser. No. 07/844,629 filed on Apr. 1, 1992 (now abandoned), which was a national stage filing under 35 U.S.C. �371 of International Application No. PCT/SE90/00631 filed on Oct. 2, 1990, which international application was published by the International Bureau in English on Apr. 18, 1991.
The present invention relates to a method of securing elastic band between two layers of material which are made at least partially of meltable material. The invention also relates to an elastic band secured between two layers of material and intended for use in articles intended for one-time use only, such as disposable diapers, sanitary napkins, surgical dressings, protective clothing or the like, and also to a diaper which includes such an elastic band.
One particular problem in this respect is that of providing elastication edges, for instance elasticated leg, waist and sleeve bands. Normally, elastication in the form of elastic tape, bands or treads is secured along the edges of the article to be elasticated with the aid of melt adhesive. This method has several drawbacks, however. For instance, the glue has an uncontrollable stiffening effect on the elastic devices used, therewith impairing the elasticity of said devices. In the case of disposable diapers, for instance, the elastic devices, or elastication, is normally placed between two casing layers, normally a plastic film and a non-woven fabric layer. The elastic devices are mounted between the casing layers and fastened thereto while in a stretched state, whereafter the elastic devices return to their non-stretched, shorter state and gather together those parts of the casing layers to which the devices are attached. As a result, there is formed, primarily in the plastic film relatively sharp folds which are liable to chafe the skin of the wearer. Gluing of the elastic devices also causes the elasticated edge to become hard and chafing. These known elasticated edges are thus not as comfortable as would be desired.
Another drawback is that the formation of folds in the outer layers, or casing layers, results in the formation of channels between the elastic devices and the wearer's skin. This is particularly disadvantagous when the elastic devices are placed around the leg and waist parts of diapers, since these channels provide routes through which excreted body fluids can escape from the diaper. Neither can the known elastications be considered to satisfy the desire for an attractive, fabric-like appearance, but instead result in a wrinkled and shapeless finished article.
Hitherto, it has not been found possible to provide in a simple and ready fashion elasticated edges which possess varying degrees of elasticity within different parts of the edges, or where certain parts of said edges are completely inelastic, various methods of providing elastication in limited areas, or with varying degrees of pretensioning, in a continuous manufacturing process have been proposed, for instance, in GB 2 113 983, EP 184 072, U.S. Pat. Nos. 4,642,151, 4,425,173, 4,486,192, 4,081,301, 4,711,683 and 4,642,109.
The present invention, however, now provides a simple method of securing an elastic band between two material layers comprised of at least partly meltable material while avoiding the drawbacks experienced with earlier known elastication.
The inventive method is may characterized m that perforations in the form of holes and/or slots are formed in the elastic band, in that the elastic band is placed between the two material layers; and in that material layers opposite said perforations are bonded together by heat fusion through said perforations.
When such an elastic band is fastened onto an article which is intended for one-time use only, there is obtained a soft, non-chafing elastic edge. This is mainly due to the fact that no glue is used to fasten the elastication, but that the elastication is held mechanically between two mutually bonded material layers. Consequently, both the elastication and the material layers will retain their original softness and suppleness. This is also due to the fact that the elastic band can move to a certain extent in relation to the material layers surrounding said band, thereby enabling said layers to pleat or fold independently of one another when the elastic band relaxes. Distinct from the earlier known elastications, which gather the surrounding material layers into sharp, chafing folds, the material layers will form around an inventive elastic band soft, rounded folds which bulge outwardly from the elastication. This is because the material layers are bonded to the elastic band by mutually spaced bonds, those pats of the material layers located between the bonds are not bonded at all.
It should be mentioned that in the present context, the expression elastic band refers to an elongated elastic body whose width has a much-greater extension than the perforations formed therein in accordance with the invention.
A further advantage provided by an inventive elastic band resides in the possibility of achieving varying degrees of stretchability or elasticity within different regions of one and the same elastic band, simply by changing the bonding pattern. This feature is particularly useful in the case of all-in-one type diapers, for instance. Diapers of this kind comprise an absorbent pad which is enclosed between a liquid permeable, inner casing layer and a liquid-impermeable, outer casing layer or backing sheet. The elastication is normally applied along the edges of the absorbent pad, so as to form elasticated waist and leg edges. The diapers also include self-adhesive fastener tabs, which are attached to the corners of the diaper on the backed sheet, i.e. on that part of the diaper which is distal from the wearer in use. The tabs function to hold together the sides of the diaper, so as to obtain a trouser-like configuration around the abdomen of the wearer.
The fastener tabs are secured over the front part of the diaper, i.e. that part of the diaper which faces towards the wearer in use.
When securing the faster tabs, it is desirable that the surface of the diaper material are as smooth as possible. This applies particularly to that part of the front part of the diaper on which the fastener tabs are intended to be secured in use. If this part of the diaper is wrinkled and irregular, the fastener tabs will not grip securely and there is a risk that the diaper will not be held together during use. An advantage is also afforded when the tab rents on the rear part of the diaper have inelastic, smooth regions, since this facilitates securing of the tabs to the diaper during manufacture, and also provides more positive attachment of the fastener tabs. If the tape-fastening areas are elastic and the fastener tabs are secured to the diaper with the elastic devices in a stretched state, there is a serious risk that the tabs will loosen from the diaper when the elastic devices are relaxed from their stretched state and subsequently contract. The present invention, however, enables totally inelastic regions to be readily provided, by selecting an elastic-device bonding pattern such that the elastic devices are broken, down in these regions and loose their elasticity.
It is also possible to adjust the degree of elasticity around the leg openings of the diaper, for instance. The greatest elasticity is preferably found within those regions in which the elasic devices are attached to the crotch region of the diaper, i.e. that part of the diaper which, in use, is intended to lie between the wearer's thighs. On the other hand, there is preferably chosen in those parts of the elastic devices which extend along the front and rear portion of the diaper a bonding pattern which will reduce the elasticity of the elastic devices.
When an inventive elastic band is secured to the surrounding material layers at solely mutually spaced bonding locations, which permits the material layers to fold or pleat freely in relation to the elastic device, there is obtained an airy elastic edge and the soft material folds give a certain padding effect. The risk of the skin becoming irritated is very small, since the folds in the material layers bonded to the elastic band provide a certain ventilating effect, which will keep the skin beneath the elastic band substantially dry during use. The elastic band may also be made from an open-cell foam material, so as to provide air ventilation through the actual band itself, provided that at least one of the surrounding material layers is permeable to air.
FIGS. 10 and 11 illustrate different bonding pattern.
The arrangement of bonding regions in the form of broken lines avoids the occurrence of channels which extend transversely across the full width of the elastic device and through which liquid is able to run when the diaper is worn. Instead, discontinuous folds are formed in the casing 14 around the elastic device 13, these folds preventing the through-passage of liquid but permitting air and water vapour to pass there-through.
As illustrated in FIG. 1, the elastic band 13 with surrounding casing 14 is attached to the liquid-permeable casing layer 1 of the diaper while in a stretched state, for instance with the aid of ultrasonic welding techniques. If the elastic band is manufactured separately, outside the diaper manufacturing line, the actual attachment of the band is effected in the elastic region 16, 18, whereas only a few attachment points are used in the region 17, therewith not to reduce the elasticity of the band and to ensure that no space is formed between the band 13 and the casing layer 1 when the band contracts in this region in the finished product. According to one preferred embodiment, the band 13 will have an incomplete bonding pattern when applied to the casing layer 1, and the bonding pattern is completed by fastening the band to said casing layer. Naturally, the band can also be glued filmy to the casing layer, in which case only a few glue points, or preferably longitudinally extending glue beads will occur in the region 17.
The diaper has an hour-glass configuration and, similar to the diaper of FIG. 1, has a front part 104, a rear part 105, a crotch part 106, and a front and a rear waist edge 107, 108. Diaper fastener tabs 109, 110 are provided on the side edges of the rear part 105, close to the rear waist edge 108. An elastic device 113 is attached along the rear waist edge 108, within a nonwoven fibre casing 114, with a bonding pattern corresponding to the diaper illustrated in FIG. 1. The diaper illustrated in FIG. 2 also includes two further elastic devices 111, 112 of the same kind as the first elastic device, but position in the longitudinal direction of the diaper on either side of the absorbent pad 103. These devices 111, 112 are intended to provide the diaper leg elastication. The devices are enclosed in longitudinally extending folds 116 in the liquid-permeable casing layer 101 of the diaper, as will best be seen from FIG. 3. Similar to the diaper illustrated in FIG. 1, the elastic devices 111, 112 are secured within the folds 116 by ultrasonic welding, wherein the ultrasound perforates the elastic devices 111, 112 in a predetermined pattern and fuses together the surrounding casing parts 114 through the perforations. Each of the elastic devices 111, 112 presents five regions 117-121 having three mutually different bonding patterns and different degress of elasticity. The greatest elasticity is found in the elastic devices 111, 112 within the crotch part 106 of the diaper, where the bonding pattern consists of discrete, punctiform bonds. A bonding pattern in the form of broken, transverse lines has been used within the regions 117, 121 nearest the waist edges 107, 108. As before mentioned, this bonding pattern causes the elastic devices 111, 112 to be practically inelastic within these regions.
The elastic devices 111, 112 are bonded with a pattern of intersecting, broken, oblique lines in those regions 118, 120 located between the inelastic regions 117, 121 at the waist edges 107, 108 of the diaper and the regions 119 in the crotch part 106 thereof. This bonding pattern results in a lower elasticity than the punctiform bonds at the crotch part of the diaper, but in greater elasticity the traverse bonds at the waist edges of the diaper.
FIGS. 4-8 illustrates examples of methods of sewing an inventive elastic device to one edge of a diaper or to some other absorbent product. Corresponding elements in the Figures have been identified with the same reference signs. In all of the embodiments illustrated in FIGS. 4-8, the elastic device consists of an elastic strip of open-cell foamed plastic.
The elastic device 201 illustrated in FIG. 4 is attached in the extension of an absorbent pad 202, which has a liquid-impermeable layer 203 attached to one side thereof, i.e. the outwardly facing side thereof. The liquid-impermeable layer is folded around the edge pat 204 of the absorbent pad, so as to prevent the leakage of fluid past said edge. A liquid-permeable layer 205, for instance a polypropylene nonwoven fabric layer, is attached to the other side, the inwardly facing side, of the absorbent pad 202. The liquid-permeable layer 205 extends beyond the absorbent pad 202 and over the elastic device 201, and is folded back around the free edge 206 of said device and fastened, e.g. with the aid of melt adhesive, to the liquid-impermeable layer 203 on the outer side of the absorbent pad 202. The elastic device 201 is thus enclosed in a fold 207 located externally of the absorbent pad 202 in the liquid-permeable layer 205 and is secured within the fold 207 at discrete bonding locations 208, in accordance with the invention.
FIG. 6 illustrates a further example of a method of securing the elastic device 201 within a fold 207 in the liquid-permeable layer 205. The liquid-permeable layer 205 extends beyond the absorbent pad 202 and is folded around the elastic device 201, without being folded back across the pad 202. The liquid-impermeable layer 203 extends on the outside of the pad 202 up to the free edge 206 of the elastic device. An extremely effective leak-proof construction is achieved in this way.
An inventive elastic device can be secured within a casing in the manner illustrated schematically in FIG. 9. A heat meltable casing material 301, for instance in the form of non-woven fabric or plastic film, extends from a first reel of material, via a guide roller 302. At the same time, a band 303 of elastic material is fed from a second reel while passing between a first pair of rollers 304, is 305, whereafter the casing material 301 is folded around the elastic band 303 by means of a folding plate 306, such that both sides of the band 303 are covered by the casing material 301. The band 303, together with the surrounding casing 301, is then transported over a patterned bonding roller 307. The bonding roller 307 presents raised portions or devices 308 which correspond to the desired bonding pattern of the finished elastic laminate. Bonding is effected with the aid of an ultrasonic horn 309. The ultrasound perforates the elastic band and fuses the casing material together through the perforations thus formed. That is, the perforations are formed in the elastic bond directly followed by bonding together, through the perforations, the portions of the casing located opposite the perforations. The bonding pattern is predetermined and, as before mentioned, is controlled by the raised portions or devices 308 on the bonding roller. The resultant, bonded elastic laminate 310 is then advanced by a second pair of rollers 311 and 312 which are driven at a second speed which is higher than the speed at which the first roller pair 304, 305 is driven. Because the second roller pair 311, 312 is driven at a higher speed than the first roller pair 304, 305, the elastic band 303 will be stretched before it is bonded within the heat-meltable casing 301. The elastic band can be uniformly stretched to pretension the elastic bands.
In order to illustrate how elasticity is affected by the bonding pattern, tests were carried out on two laminate samples having mutually different bonding patterns. The elastic devices used in both samples had a width of 50 mm and a thickness of 2 mm and comprised a band of flexible, polyurethane foam based on polyester. The elastic foam material is retailed by CIRRUS A/S, Denmark, under the designation 2 130 170. The elastic band was enclosed in a non-woven fabric casing or envelope in the manner described with reference to FIG. 9. The band was therewith stretched 70%, meaning that the ratio between the first driving speed and the second driving speed was 1.70. The non-woven fabric casing used comprise heat-bonded polypropylene fibres.
Both samples a) and b) were then subjected to tensile tests on a tensile stress measuring machine sold under the trademark INSTRON 1122, in order to compare their elasticities.
The samples were sketched three times between the O-level determined in the aforesaid manner and a tensile stress of 10 N. The jaws were moved together at a speed of 300 mm/min. and the sample contracting force when relaxing the tension was recorded as a function of contraction in mm. The results obtained with these samples are shown in the diagram in FIG. 12, in which each curve represents an average value of the three stretch tests carried out. The sample a) contracted through 75 mm, whereas the sample b) only contracted through 40 mm. Thus, a bonding pattern in which the bonding locations extend substantially perpendicularly to the direction in which the elastic device acts greatly reduces the elasticity of said device, whereas a punctiform bonding pattern will only slightly influence the elasticity of said device.
Although the inventive elastic device has been described with reference to diapers it will be understood that the device can be used in a number of other applications. For instance, the invention can be applied in the manufacture of surgical dressings, protective clothing, underwear and sportsware.
In FIGS. 1 and 2 of the accompanying drawings, the inventive elastic device has been shown as a single elastic band. It will be understood, however, that the elastic device may consist of two or more separate bands. FIG. 13 shows an embodiment wherein the elastic device consists of two elastic bands 13 a, 13 b. It will also be understood that the elastic foam material used in the exemplifying embodiments may have closed cells or may be replaced with other elastic materials, such as natural rubber, polyurethane rubber or the like. As noted in the examples above, the elastic material can be made of a polyester-based urethane foam.
It is also conceivable to secure an inventive elastic device an the inside of a diaper, supplemented with a corresponding device of the same or a different kind on the outside of the diaper. This additional elastic device will prevent the diaper from ballooning from the wearer's body in use.
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EventsDateCodeEventDescriptionDec 30, 2002ASAssignmentOwner name: SCA HYGIENE PRODUCTS AKTIEBOLAG, SWEDENFree format text: CHANGE OF NAME;ASSIGNOR:MOLNLYCKE AB;REEL/FRAME:013620/0717Effective date: 20010321Aug 27, 2006FPAYFee paymentYear of fee payment: 4Aug 18, 2010FPAYFee paymentYear of fee payment: 8Oct 24, 2014REMIMaintenance fee reminder mailedMar 18, 2015LAPSLapse for failure to pay maintenance feesMay 5, 2015FPExpired due to failure to pay maintenance feeEffective date: 20150318RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services