Refastenable pant with hook on insert and method of producing refastenable pant

Abstract

Methods for manufacturing an absorbent pant with a perforation line across a waistband to enable opening and closing of the pant in use, and corresponding pants. The methods include positioning hook material on an absorbent core insert or onto a nonwoven material forming a front waistband, wherein the hook material can be used to selectively open or close the product.

Description

International Patent Application JOARef. 1000.331_PCT Attorney Docket No. 510169.00079REFASTENABLE PANT WITH HOOK ON INSERT AND METHOD OF PRODUCING REFASTENABLE PANTCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 687,500 filed on August 27, 2024, which application is incorporated herein by reference in its entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH Not applicable.BACKGROUND

[0002] The present disclosure relates to wearable absorbent products such as disposable pants and diapers that include a waist panel that is removably attached to an absorbent insert, and which includes a weakened region that is easy to tear open to remove and reposition the disposable pants. More specifically, the present disclosure is addressed to wearable absorbent products that can be re-sealed with a hook and / or a hook and loop connection, and to methods for producing these products.

[0003] Wearable absorbent products including, for example, adult incontinence products, incontinence pants, training pants and other pant-style diapers often incorporate a hook and loop fastening mechanism that allows for easy and adjustable fastening for multiple uses throughout a day. Typically, wearable absorbent products of this type have a single unitary hook secured to a waistband of the product. Applying the hook to the waistband, however, results in a rigid and stiff waistband, and a hook that is prone to detach, resulting in opening of the product in use. Therefore, there is a need for a wearable absorbent product with a hook and loop closing that provides a stronger hook and loop attachment and a more flexible waistband. The disclosure addresses these and other issues.SUMMARY

[0004] The disclosed process can include various process stages, including forming an absorbent core, insertion of a backsheet and leg elastic, insertion of a topsheet and cuff, front and rear waistband formation, and final assembly, which takes input from core formation, backsheet1QB\91770933.1International Patent Application JOARef. 1000.331_PCT Attorney Docket No. 510169.00079 and leg elastic insertion, topsheet and cuff insertion, and front and rear waistband formation, and forms a disposable pant product.

[0005] In particular, the hook material can, in some cases, be applied with a slip cut unit or a multi-knife slip cut unit with transfer dauber and cammed infeed of hook material, by way of example. A loop section may be added to the front waistband panel using a multi-piece hook that is applied on an absorbent core insert of the front waistband panel. The hook is applied to the absorbent core insert that is then glued or secured to the front waistband panel between the perforated cuts using an adhesive.

[0006] In some embodiments, the hooks are then applied to a landing zone where the loop section may further be applied. The elastic strands on the front waistband panel can be deactivated.

[0007] The absorbent core body contains an acquisition distribution layer (ADL) that is provided between the top and bottom sheets. The rear panel waistband can be folded over end of core top edges of the front and rear waistbands are aligned. A side seam bonder then ultrasonically joins front and back waistbands and forms side seams of product. A cutting unit or knife then can sever the continuous stream into discrete products along defined.

[0008] In one aspect, the current disclosure is addressed to a method of producing a disposable pant product which includes a front waistband, a rear waistband, and an absorbent core insert disposed between the front waistband and the rear waistband. The front and rear waistbands are bonded together at first and second side edges to form a waist opening. The method comprises the steps of forming an absorbent core; adhering at least one segment of hook material to a backsheet web material; inserting the absorbent core between a topsheet web material and the backsheet web material including the at least one segment of hook material to form an absorbent core insert; coupling elastic strands between at least one outer nonwoven web and at least one inner nonwoven web to form a waistband assembly comprising a front waistband and a rear waistband; deactivating the elastic strands at first and second predetermined positions across the front and rear waistbands to form front and rear deactivation sections in the front and rear waistbands, respectively; forming first and second perforation lines extending from a top to a bottom edge across the front waistband; adhering first and second opposing ends of the absorbent core insert to the deactivation sections, wherein the at least one segment of hook material is positioned adjacent at least one of the first2QB\91770933.1International Patent Application JOARef. 1000.331_PCT Attorney Docket No. 510169.00079 and second perforation lines; folding the front and rear waistbands together; and bonding a side seam joining the opposing ends of the front and rear waistbands.

[0009] The step of coupling the elastic strands can comprise applying ultrasonic bonding, and / or can comprises using an adhesive.

[0010] The method can also include applying at least one segment of loop material to the outer nonwoven web forming the front waistband in a position selected to enable the at least one segment of hook material to be coupled to the at least one segment of loop material to re-close the pant product when the pant product is torn along the perforation lines. The method can also comprise the step of laminating the nonwoven backsheet web to a liquid impermeable web. An ADL layer can also be positioned between the topsheet web and the absorbent core.

[0011] The step of forming a core can comprise fiberizing pulp and applying the pulp to a forming drum. The step of forming a core can also include debulking and embossing the pulp received from the forming drum.

[0012] In another aspect of the disclosure, a method of producing a disposable pant product which includes a front waistband, a rear waistband, and an absorbent core insert disposed between the front waistband and the rear waistband, wherein the front and rear waistbands are bonded together at first and second side edges to form a waist opening, is disclosed. The method comprises the steps of forming an absorbent core; inserting the absorbent core between a topsheet web and a backsheet web; adhering a segment of hook material to a nonwoven continuous web material and cutting the nonwoven continuous web material to form a hook assembly section comprising the segment of hook material; coupling elastic strands between at least one outer nonwoven sheet and at least one inner nonwoven web to form a waistband assembly, comprising a front waistband and a rear waistband; adhering the hook assembly section to a portion of the inner nonwoven web comprising; deactivating the elastic strands at first and second predetermined positions across the front and rear waistbands to form front and rear deactivation sections in the front and rear waistbands, respectively; forming at least one perforation line extending from a top edge to a bottom edge across the front waistband, wherein the tab section is positioned adjacent the at least one perforation line; adhering first and second opposing ends of the absorbent core insert to the deactivation sections; folding the front and rear waistbands together; and bonding a side seam joining the opposing ends of the front and rear waistbands.3QB\91770933.1International Patent Application JOARef. 1000.331_PCT Attorney Docket No. 510169.00079

[0013] The step of adhering a segment of hook material to a nonwoven continuous web material and cutting the nonwoven continuous web material to form a tab section can comprise adhering a plurality of segments of hook material in a spaced relationship along a length of nonwoven substrate material and cutting the nonwoven substrate material into first and second lanes such that the first lane includes odd-numbered segments of the plurality of segments of hook material and the second lane includes even-numbered segments of the plurality of segments of hook material. The first and second lanes of tabs can be cut into a plurality of hook assembly sections, with respective hook assembly sections from the first and second lanes of tabs being adhered on opposing sides of the front waistband adjacent to and on opposing sides of the absorbent core insert. The hook assembly sections, further, can each comprise a plurality of hook segments. The step of cutting the first and second lanes of tabs can form individual tabs in the first and second lanes of tabs, and wherein each of the tabs is individually moveable relative to the other of the individual tabs. The method can also include the step of folding the hook assembly section prior to the step of adhering the hook assembly section to an inner nonwoven web. The method can also include the step of adhering hook material to the backsheet of the absorbent core insert, wherein the hook material stiffens the absorbent core insert.

[0014] The method can also include the step of adhering the nonwoven substrate to a tape material. The tape material can be split into first and second lanes, and the nonwoven substrate can be adhered between the first and second lanes of tape material.

[0015] The method can also comprise the step of adhering a segment of loop material to the inner nonwoven material of the front waistband. The segment of loop material can be positioned adjacent the perforation line.

[0016] The method can further include the step of forming a second perforating line, wherein the perforation line and the second perforation line are positioned adjacent and on opposing sides of the absorbent core insert.

[0017] The system may be better understood with reference to the following drawings and the description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles disclosed. Moreover, in the figures, like-referenced numerals designate corresponding parts throughout the different views.4QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 shows a schematic view of a system for manufacturing disposable pant products or diapers in accordance with the disclosure;

[0019] FIG. 2 is a schematic view of absorbent inserts during the steps of manufacture with the system of FIG. 1 in accordance with an embodiment of the invention;

[0020] FIG. 3 is a schematic view of disposable pant products during the steps of manufacture with the system of FIG. 1 prior to the leg die cutting step;

[0021] FIG. 4 is a schematic view of disposable pant products during the steps of manufacture with the system of FIG. 1 during and after the leg die cutting step;

[0022] FIG. 5A is a plan view of a representative pant product manufactured with the system of FIG. 1 according to the process of FIGS. 2-4;

[0023] FIG 5B is a perspective view of the pant product of FIG. 5 A;

[0024] FIG. 6 is a plan view of the representative pant product of FIG. 5A shown in an open position;

[0025] FIG. 7 is a schematic view of a system for manufacturing disposable pant products or diapers in accordance with another aspect of the disclosure;

[0026] FIG. 8 is a schematic view of an offline system for manufacturing hook assemblies that may be provided to the system of FIG. 7;

[0027] FIG. 9 is a simplified top view of a web of hook assemblies produced by the system of FIG. 8;

[0028] FIG. 10 is a schematic view of absorbent inserts during the steps of manufacture with the system of FIG. 8 in accordance with an embodiment of the invention;

[0029] FIG. 11 is a schematic view of disposable pant products during the steps of manufacture with the system of FIG. 8 prior to the leg die cutting step;

[0030] FIG. 12 is a schematic view of disposable pant products during the steps of manufacture with the system of FIG. 8 during and after the leg die cutting step;

[0031] FIG. 13 A is a plan view of a representative pant product manufactured with the systems of FIGS. 7 and 8 according to the process of FIGS. 10-12;

[0032] FIG 13B is a perspective view of the pant product of FIG. 13A;QB\91770933.1International Patent Application JOARef. 1000.331_PCT Attorney Docket No. 510169.00079

[0033] FIG. 14 shows a cross-sectional view of the pant product of FIG. 13 A taken along lineA - A;

[0034] FIG. 15 shows a cross-sectional view of the pant product of FIG. 13 A taken along lineB - B;

[0035] FIG. 16 is a schematic view of the pant product of FIG. 13A with the perforations tom for use, and the product in the open position;

[0036] FIG. 17 shows a cross-sectional view of the pant product of FIG. 13A taken along lineA - A, in the re-fastened or closed position;

[0037] FIG. 18 shows a cross-sectional view of the pant product of FIG. 13A taken along lineB - B, in the re-fastened or closed position.

[0038] The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals.DETAILED DESCRIPTION

[0039] As described above, the present disclosure relates to a refastenable pant with an absorbent core insert, and to methods for manufacturing a refastenable pant with an absorbent core insert.

[0040] Referring first to FIG. 1, a block diagram of one a system for constructing disposable pants or diapers in accordance with the disclosure is shown. The system includes subsystems for forming an absorbent core insert 100, forming the backsheet and elastic leg portions of the absorbent insert 200, forming the topsheet and cuff portions of the absorbent insert 300, forming the front and rear waistbands 400, and final assembly 500, which takes input from core formation subsystem 100, absorbent insert backsheet and leg elastic portion formation subsystem 200, absorbent insert topsheet and cuff formation subsystem 300, and front and rear waistband formation subsystem 400, and forms a disposable pant product. In the disposable pant product, the core is enclosed within the topsheet and backsheet, and is adhered between the front and rear waistband. Each of these subsystems is discussed more fully below.

[0041] Referring still to FIG. 1 and also to FIG. 2, to form an absorbent insert (subsystem 100), pulp 101, which is typically a cellulose material, can be fed to a mill / fiberizer 102 that breaks pulp sheet into fibers. An optional feed unit 104 can be used to feed Superabsorbent into the stream of6QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079 fiber 105 exiting the mill / fiberizer 102. Alternatively, feed unit 104 is provided and mill / fiberizer 102 is omitted. The absorbent stream exiting mill / fiberizer 102 and / or feed unit 104 can be fed onto a horizontal screen (not shown) or a forming drum 106 including a permeable (e.g., a screen or perforated) forming surface 110, which can include one or more depressions that define a shape of the absorbent core to be formed. The depression(s) can be shaped to create a continuous core or multiple, discrete cores, in which case the forming drum surface can include multiple shaped pockets that define the 2D or 3D shape of the discrete cores. A continuous “form-on” web material 108, such as nonwoven or tissue web material, can be fed onto the forming surface of the drum, and the core can be formed on the web material 108. Specifically, pulp / SAP feed can be deposited onto form-on web 108 and sucked against the forming surface via application of a vacuum. If the form-on web material 108 is omitted, the fiberized pulp / SAP can be fed directly against the forming surface 110. An optional cover continuous web 112 (nonwoven or tissue) can be fed onto the pulp / SAP layer as it exits forming drum 106, resulting in a core construction with the pulp / SAP core positioned between facing web layers 108 and 112. Cover web 112 can be omitted, for example, if the core is formed entirely unwrapped or if the form-on web 108 is provided with wider width, which can then be folded around core as it exits the drum 110. In this case, a folding unit (not shown) can be provided downstream of the forming drum 110. Additional optional process steps can include use of a debulk unit 114, for compressing and reducing the thickness of the core by, for example, using mating rollers for compression. An optional emboss unit 116 can be used to produce a raised or embossed pattern on the core. The emboss unit can be provided, for example, in the form of mating rollers impact the core. In some applications, a core knife 118 can be used to cut the output of continuous absorbent core inserts into discrete insert sections. The core knife 118 can be provided as a separate unit, or may be integrated in downstream components, such as a cut / turn / place unit, described below.

[0042] Referring still to FIGS. 1 and 2, the subsystem for forming the backsheet and leg elastic portion of the absorbent insert 200 can include cutting hook material 202 into sections and adhesively joining the hook material sections to laminated continuous backsheet material 206, which can be, for example, a nonwoven web (or alternatively a woven material, film, foam, and / or a composite or laminate of any of these material types) coupled to a liquid impermeable (e g., poly film) web with an adhesive unit 204. The hook material 202 can be cut and applied with a slip cut7QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079 unit or a multi-knife slip cut unit with transfer dauber and cammed infeed of hook material 202, a die with a pair of transfer daubers, or a slip cut unit with transfer dauber, by way of examples. The hook material 202 may be cut into a length suitable to provide a closure for the entire pant product, or into a plurality of shorter lengths which can be spaced along a closure, as described below. Optionally, leg elastic 210 can be laminated to backsheet 206, using, for example, an adhesive applicator 212.

[0043] Referring still to FIGS. 1 and 2, and now to subsystem 300, the unit for forming the topsheet and cuff elastic section of an absorbent insert is shown. Here a cuff web 302, which can be a nonwoven sheet, can be fed to slitter 304 which slits the cuff web into 2 portions or “lanes” for use in forming right and left cuffs. Optionally, cuff elastic 306 can be coupled to cuff nonwoven web using, for example, adhesive. The cuff is then folded using a cuff folding unit 308, such as, for example a plow folder, and is joined to an infeed of topsheet web 310 using a bonding unit 311, for example, a heat and / or pressure unit that forms mechanical attachments, tack downs, or an adhesive bonding unit. The topsheet can be a nonwoven material, by way of example, or woven materials, films, foams, and / or composites or laminates of any of these material types. Optionally, an acquisition-distribution layer (ADL) 312 can be cut and transferred onto the topsheet assembly via a slip cut unit 316, and an adhesive applicator 314 used to adhere the ADL 312 to the topsheet assembly.

[0044] Referring still to FIG. 1 and newly to FIG. 3, in subsystem 400 a front and rear waistband can be formed from an infeed 403 supplying inner nonwoven web 402, an infeed 407 supplying outer nonwoven web 404, and an infeed 405 supplying elastic strands 406. In alternative embodiments infeeds 403, 407 may supply woven materials, films, foams, and / or composites or laminates of any of these material types. A back tag infeed 409 and optional loop application section 410 corresponding to the hook applied above can also optionally be added to the waistband. An adhesive applicator 414 applies adhesive to an infeed 409 of back tag 408, which is fed to a slip cut unit 412 that transfers discrete back tag segments onto the inner nonwoven material 402. An optional adhesive applicator 414 can also be provided to apply adhesive to a loop material 415, which may be applied via a slip cut unit 416 onto the assembly of the inner nonwoven material 402 and the back tag 408. Alternatively, a multi -knife slip cut unit with transfer dauber and cammed infeed can cut the loop material. The outer nonwoven material 404 can be slit by slitter8QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079418 into front and rear waistbands 452, 454 (FIG. 3). The inner nonwoven material 402, or an assembly including the inner nonwoven material 402, back tag 408, and loop 410, can also be slit into front and rear waistband lanes with slitter unit 422. Elastic strands 406 are fed under tension between the inner and outer nonwoven materials 402 and 404 and attached thereto via one or more adhesive applicators 420, 424. Although adhesive applicators are described here, a mechanical bonding unit such as a pressure, thermal, or ultrasonic bonding unit, may be used instead to form spaced welds to couple the tensioned elastic strands 406 in position between the inner and outer nonwoven materials 402, 404. In another alternative, elastic strands 406 can be coupled between full width inner nonwoven web 402 and outer nonwoven web 404 via adhesive or mechanical bonds, and then split into front and rear waistband lanes via single downstream slitter (not shown).

[0045] Referring still to FIGS. 1 and 3, the elastic strands 406 can then be deactivated via an optional masticating unit 426, which cuts through web material 402 and 404, and severs the elastic 406, or alternatively, using a crush cut unit that severs the elastic 406 via pinching action without cutting through web material 402, 404. One example of a crush cut unit is described more fully in US 9,539,735, which is incorporated herein by reference for its description of this device. A perforation unit 428 operates against a common anvil 430 with the deactivation roll 426 and creates a perforation line in the front waist band. The front waist band 452 (FIG. 3) can be perforated along a line 466 from a top edge to a bottom edge of the waistband 452 (FIG. 3) to enable tearing and opening of the front waistband, and the elastic strands 406 can be deactivated with offset blades on a common anvil with slight spacing between blades.

[0046] Following the front waistband perforation, in the final combining subsystem 500, a continuous absorbent core insert web 502 is formed by combining output from the subsystem 300 (topsheet and cuff), subsystem 200 (backsheet and leg elastic), and subsystem 100 (core) via at least one adhesive applicator 503. The resultant core insert web 502 comprises the core insert from subsystem 100 encased between the topsheet 310 and backsheet 206. As described above, hook material is adhered to the backsheet 206.

[0047] Referring still to FIGS. 1 and 3, an adhesive can be applied via applicator 504 to the web assembly 502, which can then be provided to a Cut / Turn / Place unit 506, which cuts the absorbent core insert web 502 into discrete absorbent core inserts 450 (FIG. 2), including a core body 470 with an acquisition distribution layer 472 (ADL). The discrete absorbent core inserts 4509QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079 are then rotated, and repitched to match product pitch, and applied between incoming front and rear waistband webs from subsystem 400. One example of a cut / tum / place unit is disclosed in US10391660, which is incorporated herein by reference for its description of these devices.

[0048] One or more optional adhesive applicators 507 can then apply adhesive to one or both of the front and rear waistbands 452, 454, and subsequently, the edge(s) of one of the nonwoven sheets of either or both waistbands can be folded over the opposing sheet with a folding unit 510, to form a folded waist edge (as shown in FIG. 3 relative to the rear waistband 454). A leg die 512 can then cut a leg opening profde 512A from the received web as shown in FIGS. 1 and 4. The leg opening profde 512A can, for example, be cut into a portion of front and / or rear waistbands. The stream of web material can then enter a folding unit 514 that folds the continuous stream in half along a line extending in the machine direction (MD) so that the top edges of the front and rear waistbands 452 and 454 are aligned. A side seam bonder 516, such as, for example, a thermal, pressure, or ultrasonic bonding unit or an adhesive applicator, then joins front and rear waistbands 452 and 454 and forms side seams 460 of the product. A cutting unit or knife 518 then severs the continuous stream into discrete products 600 (FIGS. 5 and 6) along defined cut lines 519 that are aligned between side seams 460 of adjacent products. The discrete products 600 (FIGS. 5 and 6) are then moved to a turner 520, which rotates and folds the discrete products before they are transferred to a packaging system 521.

[0049] Referring now to FIG. 5A, a pant product 600 constructed in accordance with the system and process described above is illustrated after the front waistband panel 452 and rear waistband panel 454 are folded and coupled together through the side seam bond 460, and then cut.

[0050] Still referring to FIG. 5A, the pant product 600 comprises an absorbent insert 450 extending between and coupled to the front waistband panel 452 and the rear waistband panel 454. The front and rear waistbands 452 and 454 each include elastic strands 406 which are enclosed between inner and outer nonwoven webs of material 402 and 404. The elastic strands 406 are cut or otherwise deactivated or deadened (e.g., by heat and / or pressure) along two spaced deactivation lines 453 extending between a top and a bottom edge of each of the front and rear waistbands 452 and 454. The deactivation cuts form flat deactivation areas 455, where the elastic strands 406 are not tensioned, and within which the waistbands 452 and 454 are therefore relatively flat. The insert10QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079450 can be adhered, or otherwise connected to the front and rear waistbands 452 and 454 in the deactivation area 455, and lay substantially flat. First and second perforation lines 466A and 466B extend from the top edge to the bottom edge of the front waistband 452 to enable the waistband to be opened in use, and subsequently re-closed, as described below.

[0051] Referring still to FIG. 5A and also to FIG. 6, the absorbent insert 450 includes a core body 470 enclosed between topsheet 310 and backsheet 206. The insert 450 can include an ADL 472 which, in use, receives liquid from the topsheet 310 and laterally distributes the liquid before entering the core body 470, accelerating the diffusion and penetration of liquids by assisting the movement of liquid away from the user’s skin and into the core body 470. The topsheet 310 of the absorbent core insert 450 is adhered to the front waistband 452 with an adhesive 462 and to the rear waistband 454 with an adhesive 464.

[0052] Referring still to FIGS. 5 A and 6, first and second sections of hook material 202, hooks 456A and 456B, are adhered to the backsheet 206 of the absorbent core insert 450 in the deactivation area of the front waistband 452, on opposing sides of the adhesive patch 462. The width of the adhesive patch 462 can be narrower than the width of the adhesive patch 464 to accommodate the hooks 456 and 457. The hooks 456A and 456B can comprise a single elongate section of hook material 202, or can, as illustrated, comprise a plurality of aligned sections of hook material 202. First and second mating loops 410A and 410B can optionally be adhered to the inner nonwoven sheet 402 of the front waistband 452 adjacent the hooks 456A and 456B, respectively. Alternatively, the hook material 202 and inner nonwoven sheet material 402 can be selected to enable the hooks 456A and 456B to connect directly to the inner nonwoven sheet 402.

[0053] The pant product 600 is illustrated in FIG. 5A after the front and rear waistbands 452 and 454 are folded together, a side seam bond 519 is formed between the front and rear waistbands 452 and 454, and pant product 600 is cut from the stream of continuous products along the cut line 519.

[0054] Referring now to FIG. 5B, in use, the front waistband 452 can be tom along the perforated lines 466A and 466B located on opposing sides of the deactivation area to create three separate front waistband regions 452A, 452B, and 452C. Front waistband regions 452A and 452B can now be used to open the pant product, while region 452C remains connected to the absorbent core 450 Subsequently, to re-close the pant product 600. To re-close the product 600, the open11QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079 ends of the front waistband regions 452A and 452B can be connected to the absorbent core 450 either through direct connection to the hooks 456A and / or 456B, or by an interconnection between loops 410A, 410B and hook 456A, 456B.

[0055] Referring now to FIG. 7, an alternate system for producing a pant product is shown. Here, the subsystems 100 (absorbent core insert forming), 200 (backsheet and leg elastic), 300 (insert topsheet and cuff), and 500 (final assembly) are as described above with reference to FIG. 1, and are numbered here in accordance with the description of FIG. 1. The waistband formation subsystem 401 is similar to subsystem 400 described above, and like components are identified with like numbers. Subsystem 401, however, includes a cut, turn, and place unit 618 that cuts, rotates and transfers discrete hook assembly segments 768 (FIG. 9) onto the front waistband 652 (FIG. 11), as described in detail below nonwoven nonwoven.

[0056] Referring now to FIG. 8, a schematic diagram for a system 700 for producing a hook assembly 768 including hook material 701 attached to tabs 705 A-D (FIG. 9) manufactured from a continuous web nonwovenmaterial 702 (e.g., nonwoven or any of the other material types referenced herein) that is fed into subsystem 401 is shown. As illustrated here, similar to the subsystem described with reference to FIG. 1, an applicator 705 applies adhesive to an infeed of hook material 701, and the adhesive-coated hook material 701 is then provided to a taper unit 707 including a cutting unit 707a, such as a reciprocating blade or a single or multi-up knife roll, that acts against a full hard or multi -up anvil 707b to cut the hook material 701 into sections. A rotary dauber 707c presses a nonwoven web 702 toward the anvil 707b and into contact with the adhesive-coated individual hooks to form a hook / nonwoven tab web assembly 703. Taper unit 707 may be replaced with other known cutting and re-pitching units in alternative embodiments. An infeed 699 of a frontal tape 704 (e.g., nonwoven or any of the other material types referenced herein) is simultaneously fed to a slitter 706 which slits the frontal tape 704 into two sections 704A and 704B along a cut line aligned in the machine direction (MD). The two sections of the tape infeed 704A and 704B are then spread apart in the cross-machine direction (CD) by a spreader 708. Referring now also to FIG. 9, an applicator 709 applies adhesive to each of the spread tape sections 704A and 704B, and the hook / nonwoven tab web assembly 703 is adhered between the spread tape sections 704A and 704B to produce a tab assembly 720. A stepped or wavy die 710 cuts the assembly 720 into two separate structures 720A and 720B, wherein every other hook12QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079 extends from an opposing side, such that odd numbered hooks 705A, 705C extend from structure 720A and even numbered hooks 705B, 705D extend from structure 720B. A folding unit 714 folds the tabs of each lane 720A and 720B over the continuous portion of the tab assembly, providing a hook assembly outfeed 716 comprising the two lanes 720A and 720B. Referring again to FIG. 7, adhesive is applied via applicator 715 to the resultant hook assembly outfeed 716, which is then provided to a cut, turn, and place unit 618 or other transfer device that cuts the hook assembly outfeed 716 into hook assembly sections 768A and 768B (FIG. 9) and reorients those sections prior to transferring these sections to opposing side edges of the inner nonwoven web 402 forming the front waistband 452.

[0057] Referring still to FIG. 7 and also to the process shown in FIG. 11, in addition to the components included in waistband formation subsystem 400, described above, the waistband formation subsystem 401 includes an optional hook application subsystem 618 with an applicator 614 that applies adhesive to an infeed of loop material 610, a slip cut unit 616 that forms discrete sections of the loop material 610 and transfers those sections to outer nonwoven web 404 of the front waistband 652.

[0058] Still referring to FIG. 11, hook assemblies 768A, 768B are applied to the inner nonwoven 702 of the front waistband 652 after which the elastic threads 406 in the front and rear waistbands 652, 654 are deactivated at deactivation lines 453. Thereafter, perforation lines 666A, 666B are formed in the front waistband 652 adjacent and inboard of hook assemblies 768A, 768B. The absorbent core inserts 650 are then applied to span the distance between the front and rear waistbands 652, 654. Leg die cuts 658 are then formed in the front and / or rear waistbands 652, 654 as shown in FIG 12. The continuous stream of products is folded about a line extending in the machine direction (MD) and side seam bonds 660 are formed.

[0059] Referring now to FIG. 13A, a schematic illustrating pant product 604 as constructed by the process of FIGS. 10-12 is shown. The product 604 includes front and rear waistbands 652 and 654 which are generally constructed as described above with reference to FIGS. 11 and 12, specifically with elastic threads 406 extending between inner and outer nonwoven sheets 402 and 404. An absorbent core insert 650 extends between the front and rear waistbands 652 and 654, and is coupled to the front and rear waistbands on adhesive patches 662 and 664, respectively. The absorbent core insert 650 includes an absorbent core 670, which may include an optional ADL13QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079 layer 672. Leg die cuts 658 may be provided in the rear waistband 654, as shown, and / or in the front waistband 652 (not shown). The elastic strands 406 in each of the front and rear waistbands may be cut in the area 455 where the insert 650 overlaps the front and rear waistbands 652 and 654 to deactivate the elasticity in these areas, thereby allowing the absorbent core section 650 to lay substantially flat when adhered to the front and rear waistbands 652 and 654.

[0060] Referring still to FIG. 13 A, as described in the process steps above with reference to FIGS. 11 and 12, the product 604 includes one or more hook assembly sections 768A and 768B with folded tabs 705 A - D that include hook material 701 on a nonwoven substrate 702 adhered to the inner nonwovenweb sheet 402. The tab or tabs 705A - D can be substantially square, as shown here, rectangular, or any shape that can be easily gripped by a user of the pant product 604. Here, four tabs 705A - D are shown for a given product 604, however more or less tabs can be included in alternative embodiments. As assembled, hook assembly section 768A comprising tabs 705A and C is positioned proximate perforation line 666A, and hook assembly section 768B comprising tabs 705B and 705D is positioned proximate perforation line 666B. Referring again to FIG. 10, an optional loop connector patch 610 can be adhered extending substantially between the perforation lines 666A and 666B. As illustrated here, the loop connector patch 610 is substantially elongate in shape and extends from a first point adjacent the top edge of the front waistband 652 to a second point adjacent the bottom edge of the front waistband 652. Hook material 202 forming one or more optional hooks 612A and 612B can also be adhered to the backsheet 206 of the absorbent core insert 650.

[0061] Referring now to FIG. 12, the process continues with the cutting of a leg opening profile 658 in the rear waistband 654 (and optionally also in the front waistband 652 (not shown). Thereafter the rear waistband 654 is folded onto the front waistband 652 (or vice versa), such that the top edges of the front and rear waistbands 652 and 654 align. A side seam bonds 660 are formed between adjacent pant products 604, sealing the front and rear waistbands 652 and 654 together for each pant product 604. A final cut is made between the seam bonds 660 to create discrete pant products 604.

[0062] Referring now to FIG. 14, a cross-sectional view of the pant product 604 is shown as taken along the line A - A of FIG. 13 A. As illustrated here, in the folded position, at least a portion of the front waistband 652 and the rear waistband 654 are layered over one another. The hook14QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079 assembly 658A includes a tab 705A with a segment of hook material 701 that is adhered to tape 704. The hook material 701 and tape 704 forming the individual tabs 705 A - D are adhered to a first portion of the tab nonwoven material 702, while another portion is folded over the hook material 701. Hooks 612A and 612B formed on the backsheet 206 of the absorbent core insert 650 are aligned with the folded nonwoven material 702 forming the tab 705 A. A loop 610 is optionally formed on the outer nonwoven sheet 404 forming the front waistband 652. As illustrated here, the loop 610 extends substantially between the perforation lines 666A and 666B. Referring now also to FIG. 15, a cross-sectional view taken along line B - B of FIG. 13 A is shown. As illustrated here, absorbent core 670 is provided between topsheet 310 and backsheet 206 forming the absorbent core insert 650. Here, the cross-sectional view illustrates tabs 705C and 705D of hook assemblies 658A and 658B, respectively, which have the same construction as that described above with reference to tab 705 A.

[0063] Referring now to FIG. 16, and also to FIG. 13B, the pant product 604 is shown in an “open” position. To put the pant product 604 into the open position, the front waistband 652 is tom along perforation lines 666A and 666B, dividing the front waistband 652 into left and right segments 652A and 652B. A third central segment of the front waistband 652C, which can include the loop 610, remains adhered to the core insert 650. The tab nonwoven material 702 can be folded out, such that tabs 705A and 705C extend from segment 658A, and tabs 703B and 703D extend from segment 658B.

[0064] Referring now to FIGS. 16 and 17, cross-sectional views of the pant product 604 are shown in the re-closed position. To re-close the pant product 604, the front waistband segments 652A and 652B are folded toward the core insert 650, and onto the segment 652C of the front waistband, and the hook material 701 on the tabs 705A - D is folded onto the segment 652C of nonwoven material forming the waistband, which can be made of a nonwoven material that is suitable for interconnection with the hook material 701, or which may include a loop 610. The loop material can be provided as a single strip extending across the front waistband section 652C, or may be segments of loop material (not shown) provided on opposing sides of the waistband section 652C. Hook material 612A, 612B provided on the backsheet 206 of the absorbent core insert 650 can stiffen the insert 650 to more easily enable tearing along the perforation lines 666A15QB\91770933.1International Patent Application JOARef. 1000.331_PCT Attorney Docket No. 510169.00079 and 666B and to maintain stability of the absorbent insert 650 when re-closing the pant product 604.

[0065] Within this specification, embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. For example, it will be appreciated that the features described herein are applicable to all aspects of the embodiments described herein. Further, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the description or illustrated in the drawings. The present disclosure is capable of other configurations and of being practiced or of being carried out in various ways. For example, although a specific ordered series of steps is described above, the order of these steps can be varied. For example, in some applications providing components to a skew correction station can be performed at alternate stages of the process.

[0066] Thus, it will be appreciated by those skilled in the art that, while the disclosure has been described above in connection with particular non-limiting examples and examples, the disclosure is not necessarily so limited, and numerous other non-embodiments, examples, uses, modifications and departures from the non-limiting examples, examples and uses are intended to be encompassed by the claims attached hereto. The figures, similarly, depict selected configurations and are not intended to limit the scope of the present disclosure. The present disclosure is to be accorded the widest scope consistent with the principles and features disclosed herein.

[0067] Various features and advantages of the invention are set forth in the following claims.16QB\91770933.1

Claims

International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.00079CLAIMS1. A method of producing a disposable pant product which includes a front waistband, a rear waistband, and an absorbent core insert disposed between the front waistband and the rear waistband, wherein the front and rear waistbands are bonded together at first and second side edges to form a waist opening, the method comprising the steps of forming an absorbent core; adhering at least one segment of hook material to a backsheet web material; inserting the absorbent core between a topsheet web material and the backsheet web material including the at least one segment of hook material to form an absorbent core insert; coupling elastic strands between at least one outer nonwoven web and at least one inner nonwoven web to form a waistband assembly comprising a front waistband and a rear waistband; deactivating the elastic strands at first and second predetermined positions across the front and rear waistbands to form front and rear deactivation sections in the front and rear waistbands, respectively; forming first and second perforation lines extending from a top to a bottom edge across the front waistband; adhering first and second opposing ends of the absorbent core insert to the deactivation sections, wherein the at least one segment of hook material is positioned adjacent at least one of the first and second perforation lines; folding the front and rear waistbands together; and bonding a side seam joining the opposing ends of the front and rear waistbands.

2. The method of claim 1, wherein the step of coupling the elastic strands comprises ultrasonic bonding.

3. The method of claim 1, wherein the step of coupling the elastic strands comprises using an adhesive.17QB\91770933.1International Patent Application JOARef. 1000.331_PCT Attorney Docket No. 510169.000794. The method of claim 1, further comprising the step of applying at least one segment of loop material to the outer nonwoven web forming the front waistband in a position selected to enable the at least one segment of hook material to be coupled to the at least one segment of loop material to re-close the pant product when the pant product is tom along the perforation lines.

6. The method of claim 1, further comprising the step of laminating the backsheet web to a liquid impermeable web.

7. The method of claim 1, further comprising the step of positioning an ADL layer between the topsheet web and the absorbent core.

8. The method of claim 1, wherein the step of forming a core comprises fiberizing pulp and applying the pulp to a forming drum.

9. The method of claim 8, wherein the step of forming a core further comprises the steps of debulking and embossing the pulp received from the forming drum.

10. A method of producing a disposable pant product which includes a front waistband, a rear waistband, and an absorbent core insert disposed between the front waistband and the rear waistband, wherein the front and rear waistbands are bonded together at first and second side edges to form a waist opening, the method comprising the steps of: forming an absorbent core; inserting the absorbent core between a topsheet web and a backsheet web; adhering a segment of hook material to a nonwoven continuous web material and cutting the nonwoven continuous web material to form a hook assembly section comprising the segment of hook material; coupling elastic strands between at least one outer nonwoven sheet and at least one inner nonwoven web to form a waistband assembly comprising a front waistband and a rear waistband; adhering the hook assembly section to a portion of the inner nonwoven web comprising the front waistband;18QB\91770933.1International Patent Application JOARef. 1000.331_PCT Attorney Docket No. 510169.00079 deactivating the elastic strands at first and second predetermined positions across the front and rear waistbands to form front and rear deactivation sections in the front and rear waistbands, respectively; forming at least one perforation line extending from a top edge to a bottom edge across the front waistband, wherein the tab section is positioned adjacent the at least one perforation line; adhering first and second opposing ends of the absorbent core insert to the deactivation sections; folding the front and rear waistbands together; and bonding a side seam joining the opposing ends of the front and rear waistbands.

11. The method of claim 10, wherein the step of adhering a segment of hook material to a nonwoven continuous web material and cutting the nonwoven continuous web material to form a hook assembly section comprises adhering a plurality of segments of hook material in a spaced relationship along a length of nonwoven substrate material and cutting the nonwoven substrate into first and second lanes such that the first lane includes odd-numbered segments of the plurality of segments of hook material and the second lane includes even-numbered segments of the plurality of segments of hook material.

12. The method of claim 11, further comprising the steps of cutting the first and second lanes of tabs into a plurality of hook assembly sections and adhering respective hook assembly sections from the first and second lanes of tabs on opposing sides of the front waistband adjacent to and on opposing sides of the absorbent core insert.

13. The method of claim 12, wherein the hook assembly sections each comprise a plurality of hook segments.

14. The method of claim 11, wherein the step of cutting the first and second lanes of tabs forms individual tabs in the first and second lanes of tabs, and wherein each of the tabs is individually moveable relative to the other of the individual tabs.19QB\91770933.1International Patent Application JOARef. 1000.331 PCT Attorney Docket No. 510169.0007914. The method of claim 10, further comprising the step of adhering hook material to the backsheet of the absorbent core insert, wherein the hook material stiffens the absorbent core insert.

15. The method of claim 10, further comprising the step of folding the hook assembly section prior to the step of adhering the hook assembly section to an inner nonwoven web.

16. The method of claim 10, further comprising the step of adhering the nonwoven substrate to a tape material.

17. The method of claim 16, further comprising the step of splitting the tape material into first and second lanes, and adhering the nonwoven substrate between the first and second lanes of tape material.

18. The method of claim 10, further comprising the step of adhering a segment of loop material to the inner nonwoven material of the front waistband.

19. The method of claim 18, further comprising the step of positioning the segment of loop material adjacent the perforation line.

20. The method of claim 10, further comprising the step of forming a second perforating line, wherein the perforation line and the second perforation line are positioned adjacent and on opposing sides of the absorbent core insert.20QB\91770933.1

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