Method for forming and folding absorbent sanitary articles
Patent Information
- Application Number
- JP2022202954
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2021-12-23
- Filing Date
- 2022-12-20
- Publication Date
- 2025-10-17
AI Technical Summary
Existing methods for forming and folding refastenable diapers, such as those described in US8556790B2, are mechanically complex and require heavy cutting devices, making them cumbersome and inefficient.
A method involving a continuous multilayer web with absorbent pads, closure elements, and lines of weakness allows for folding and separation of diapers without sharp cutting devices, using folding wheels that are lighter and less complex.
The method simplifies the folding process by pre-cutting and tearing, resulting in lighter and more compact folding equipment, enhancing efficiency and reducing mechanical complexity.
Smart Images
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Abstract
Description
Technical Field
[0001] The present invention relates to a method for forming and folding absorbent hygiene articles. More specifically, the present invention relates to a method for separating and folding individual diapers of the type known as "refastenable" or "T-shaped" diapers from a continuous web.
Background Art
[0002] The most common prior art diapers for children and adults are essentially of two types: refastenable diapers and "pant-type diapers".
[0003] Refastenable diapers are basically in the shape of an H, where the legs of the H are the parts of the diaper that wrap around the wearer's waist, and the connecting part of the H is the crotch with an absorbent pad. Generally speaking, at the ends of the legs of the H, these diapers have tabs, which are used to fix the diaper around the wearer's waist when the diaper is being worn.
[0004] On the other hand, pant-type diapers look and are worn like pants and have an elastic waistband, which is welded or joined by a permanent connection.
[0005] Recently, another type of diaper, also known as a "refastenable diaper", has become more common. This type of diaper is basically in the shape of a T when opened. In this type of diaper, the elastic waistband is the horizontal part of the T, and the crotch containing the absorbent pad corresponds to the leg part of the T. The crotch part is folded towards the waistband both during use and during manufacture, and the end of the waist is folded towards the center line and fixed to the folded crotch part.
[0006] A special feature of this type of diaper is that it can be worn like pants by inserting the legs into the corresponding openings, but it can also be adjusted at the waist like a conventional diaper if needed.
[0007] In fact, the ends of the waistband are secured to the outside of the crotch area by a releaseable fastening mechanism.
[0008] During manufacturing, diapers that can be fastened repeatedly are cut from a continuous web and folded. Essentially, absorbent pads are attached at regular intervals to a continuous elastic band, which is then cut after the pads have been folded onto it.
[0009] An example of a system and method for folding such diapers is described in reference US8556790B2, in which individual diapers are separated from each other by a cutting step performed on a folding wheel.
[0010] In practice, the folding wheel also comprises multiple anvils and a cutting device that must be synchronized with the wheel to cut the continuous web before the diaper is folded, in addition to the moving parts necessary to fold the product.
[0011] Folding wheels are mechanically very complex and heavy. [Overview of the project]
[0012] Therefore, in this field, there is a need for a simpler, more reusable method of forming and folding diapers than those known in the prior art.
[0013] More specifically, the present invention aims to provide a method for forming and folding diapers that can be repeatedly fastened, which makes it easy and effective to cut a continuous web into individual products and fold each individual product.
[0014] This objective is achieved by a method for forming and folding an absorbent sanitary article, comprising the technical features described in one or more of the claims of the appended patent claims. The dependent claims correspond to various possible embodiments of the present invention.
[0015] According to a first aspect, the present invention relates to a method for forming and folding absorbent sanitary articles.
[0016] The absorbent sanitary article comprises a waistband and an absorbent pad extending from the middle portion of the waistband and separating the first flap and the second flap of the waistband. The absorbent sanitary article comprises a first closing element at one end of the first flap and a second closing element at one end of the second flap.
[0017] The absorbent pad is folded toward the waistband to define the crotch of the absorbent sanitary article, at least during use or manufacture of the absorbent sanitary article, and the first and second flaps are folded onto the folded absorbent pad and secured to the absorbent pad by the first and second closing elements, respectively, to define the pant-like article.
[0018] The forming and folding method is: The steps include preparing a continuous multilayer web and supplying it in the supply direction, The steps include applying a series of spaced-apart absorbent pads onto a continuous multilayer web, preferably such that the series of absorbent pads protrude outward from there, The steps include folding a series of absorbent pads onto a continuous multilayer web, The steps include temporarily securing a series of folded absorbent pads to a continuous multilayer web, The steps of applying a series of first closing elements to a continuous multilayer web, The method includes the step of applying a series of second closure elements to a continuous multilayer web.
[0019] Each absorbent pad is positioned between one of a series of first closing elements and one of a series of second closing elements.
[0020] The forming and folding method comprises a step of forming a series of weakened lines in a continuous multi-layer web between each second closure element and a first closure element following the second closure element in the supply direction of the continuous multi-layer web, each weakened line being disposed between absorbent articles that are continuous in the supply direction of the continuous multi-layer web.
[0021] The method further comprises a step of folding the first flap of each absorbent article towards the corresponding absorbent pad, and a step of folding the second flap of each absorbent article towards the corresponding absorbent pad.
[0022] The step of folding the first flap of each absorbent article towards the corresponding absorbent pad or the step of folding the second flap of each absorbent article towards the corresponding absorbent pad includes tearing the continuous multi-layer web along the weakened lines, thereby separating the absorbent articles.
[0023] By separating the individual absorbent articles by pre-cutting and tearing, it is possible to separate them without using a sharp cutting device. When the folding and separation of the absorbent articles are preferably performed on a folding wheel, the folding wheel need not comprise a web cutting device and is thus lighter, less complex and more compact than prior art solutions.
[0024] According to one aspect, the step of folding the first flap of each absorbent article towards the corresponding absorbent pad is performed before the step of folding the second flap of each absorbent article towards the corresponding absorbent pad.
[0025] According to one aspect, the step of folding the first flap of each absorbent article towards the corresponding absorbent pad is performed after the step of folding the second flap of each absorbent article towards the corresponding absorbent pad.
[0026] According to one aspect, the step of folding the first flap of each absorbent article toward the corresponding absorbent pad is carried out simultaneously with the step of folding the second flap of each absorbent article toward the corresponding absorbent pad.
[0027] According to one aspect, the step of folding the first flap of each absorbent article toward the corresponding absorbent pad includes the step of attaching the first flap to the corresponding absorbent pad using a first closure element.
[0028] According to one aspect, the step of folding the second flap of each absorbent article toward the corresponding absorbent pad includes the step of attaching the second flap to the corresponding absorbent pad using a second closure element.
[0029] According to one aspect, the step of temporarily fixing a series of folded absorbent pads to a continuous multi-layer web includes the step of plastically deforming at least a portion of each folded absorbent pad and at least a portion of the continuous multi-layer web at that portion of the folded absorbent pad to create a mechanical interference between the series of absorbent pads and the continuous multi-layer web.
[0030] According to one aspect, at least the following steps, namely, the step of folding the first flap of each absorbent article toward the corresponding absorbent pad, and the step of folding the second flap of each absorbent article toward the corresponding absorbent pad are performed using a folding wheel.
[0031] According to one aspect, the method includes at least the step of holding the continuous multi-layer web on the folding wheel.
[0032] Further features and advantages of the present invention will become more apparent in the following exemplary, and thus non-limiting, description of a preferred but non-exclusive embodiment of a method for forming and folding absorbent hygiene articles.
Brief Description of the Drawings
[0033] The description is provided below with reference to the accompanying drawings, which are provided for illustrative purposes only and without limiting the scope of the present invention. [Figure 1-8] A series of steps of the forming and folding method according to this disclosure are schematically shown. [Figure 9] A very schematic diagram of a folding wheel for carrying out the forming and folding method described herein is shown. [Modes for carrying out the invention]
[0034] Referring to Figure 8, the number 1 represents a wearable absorbent sanitary item known as a “reusable” type, which will also be referred to simply as a “diaper” below.
[0035] Diaper 1 basically comprises an elastic waistband or strip 2 and an absorbent pad 3 attached to the waistband 2.
[0036] The waistband 2 is, for example, a piece of a multilayer web containing first and second webs of nonwoven fabric joined together. The elasticity of the waistband 2 is typically provided by elastic bodies placed between the webs of the nonwoven fabric.
[0037] The absorbent pad 3 is attached to the middle portion 2a of the elastic waistband 2 and protrudes from there when the diaper 1 is open, forming a T-shaped structure.
[0038] The elastic waistband 2 is the horizontal portion of T, and the absorbent pads 3 are the legs of T.
[0039] In the elastic waistband 2, the absorbent pad 3 separates the two parts, or wings, or side flaps 2b, 2c.
[0040] Article 1 includes a first closing element 4 attached to one end of the flap 2b, which faces the wearer (not shown) when in use.
[0041] Article 1 includes a second closing element 5 attached to one end of the flap 2c, which faces the wearer (not shown) when in use.
[0042] Closure elements 4 and 5 are substantially of known type and, in the illustrated example, extend along the corresponding edges of the respective flaps.
[0043] When article 1 is in use or during its manufacture, the absorbent pad 3 is folded toward the waistband 2 to define the crotch 6 of article 1.
[0044] In these cases at least, the flaps 2b and 2c are folded onto the folded absorbent pad 3 and secured to the absorbent pad 3 by the first closure element 4 and the second closure element 5, respectively.
[0045] In embodiments not shown, article 1 may include a closure element attached to the absorbent pad 3 on the side opposite to the wearer, so that the closure elements 4, 5 of the elastic waistband 2 engage with the closure elements on the absorbent pad 3.
[0046] As schematically shown in Figure 8, the closed diaper 1 is essentially like a pair of pants.
[0047] The forming and folding method includes the steps of preparing a continuous multilayer web W intended to form a plurality of waistbands 2 and supplying it along a supply path in the supply direction V.
[0048] The web W includes, for example, first and second webs of nonwoven fabric joined together, and a plurality of elastic bodies 7 positioned between them. At least some of these elastic bodies are shown and labeled in the accompanying drawings. These elastic bodies 7 are preferably spread across the entire width of the web W.
[0049] The first and second webs may be bonded and / or welded to each other, for example, by substantially known methods, such as ultrasound.
[0050] Referring to Figure 2, the forming and folding method includes the step of applying a series of absorbent pads 3, spaced apart by an interval that is at least a function of the size of the absorbent article 1, to a continuous multilayer web W, preferably using an adhesive, such that the series of absorbent pads 3 protrude outward (i.e., in a relief).
[0051] Preferably, the method includes the step of folding the edge W1 of the web W (the upper edge as shown in the drawing) onto the absorbent pad 3.
[0052] Next, the absorbent pad 3 is folded onto the web W around a fold line L parallel to the web W and the supply direction of the web W, as shown in the illustrated example.
[0053] This method includes the steps of folding an absorbent pad 3 onto a continuous multilayer web W, and temporarily fixing the folded absorbent pad 3 to the continuous multilayer web W.
[0054] The absorbent pad 3 is temporarily secured to the web W to retain its folded configuration as shown in Figure 3 until the remaining steps of the method are performed on the absorbent pad 3.
[0055] Preferably, the step of temporarily fixing the folded absorbent pad 3 to the continuous multilayer web W includes the step of plastically deforming a portion P3 of the folded absorbent pad 3 and a portion PW of the continuous multilayer web W substantially located over the portion P3, thereby causing mechanical interference between the absorbent pad 3 and the continuous multilayer web W.
[0056] Preferably, the step of plastic deformation is carried out by cold blanking and / or thermomechanical blanking.
[0057] This method includes the step of applying a series of first closure elements 4 and a series of second closure elements 5 on a continuous multilayer web W.
[0058] As shown in Figure 4 as an example, each absorbent pad 3 is positioned between the first closing element 4 and the second closing element 5.
[0059] If the web W is formed from a first web bonded to a second web, and an elastic body 7 is positioned between them, the method may include the step of cutting or blocking the elastic body 7 in the zone to which the closing elements 4, 5 are applied.
[0060] For example, the attached drawing shows zone Z of closing elements 4 and 5, where the elastic body 7 is cut or removed.
[0061] If the web W is formed from a first web bonded to a second web, and an elastic body 7 is positioned between them, the method may include the step of cutting or blocking the elastic body 7 in the zone to which the absorbent pad 3 is applied.
[0062] If the web W is formed from a first web welded to a second web, and an elastic body 7 is placed between them, the method may include the step of welding the first web to the second web, except for the zones to which the closing elements 4, 5 are applied.
[0063] If the web W is formed from a first web welded to a second web, and an elastic body 7 is placed between them, the method may include the step of welding the first web to the second web, except for the zone to which the absorbent pad 3 is applied.
[0064] In the embodiment shown as an example, the method includes the step of contouring the web W between the absorbent pads 3.
[0065] Referring to Figure 5, for example, note that web W includes contours 8 from which parts of web W have been removed.
[0066] The method includes the step of forming a series of vulnerable lines WL in a continuous multilayer web between each closure element 5 and a closure element 4 that follows that closure element in the supply direction V, wherein each vulnerable line WL includes, for example, a series of notches that perforate the web W.
[0067] In practice, each weak line WL defines the end of the flap 2c of the first absorbent article 1a and the end of the flap 2b of the second absorbent article 1b that follows the first absorbent article 1a in the supply direction V.
[0068] Each weak line WL separates absorbent article 1 from what follows it along the web W.
[0069] The forming and folding method includes the steps of folding a first flap 2b of each absorbent article 1 toward the corresponding absorbent pad 3, and folding a second flap 2c of each absorbent article 1 toward the corresponding absorbent pad 3.
[0070] Folding the first flap 2b of each absorbent article 1 toward the corresponding absorbent pad 3, or folding the second flap 2c of each absorbent article 1 toward the corresponding absorbent pad 3, includes tearing the continuous multilayer web W at the fragile line WL, thereby separating the absorbent articles 1 from each other.
[0071] In the illustrated example, particularly referring to Figure 7, the absorbent web W is torn at the fragile line WL by folding the second flap 2c.
[0072] In the embodiment of the present method schematically shown in the attached drawings, the step of folding the first flap 2b of the absorbent article 1 toward the corresponding absorbent pad 3 is performed before the step of folding the second flap 2c of the absorbent article 1 toward the corresponding absorbent pad 3.
[0073] In embodiments of the present method not shown, the step of folding the first flap 2b of the absorbent article 1 toward the corresponding absorbent pad 3 is performed after the step of folding the second flap 2c of the absorbent article 1 toward the corresponding absorbent pad 3.
[0074] In embodiments of the present method not shown, the step of folding the first flap 2b of the absorbent article 1 toward the corresponding absorbent pad 3 is performed simultaneously with the step of folding the second flap 2c of the absorbent article 1 toward the corresponding absorbent pad 3.
[0075] According to this method, the step of folding the first flap 2b of the absorbent article 1 toward the corresponding absorbent pad 3 includes the step of attaching the first flap 2b to the corresponding absorbent pad 3 using the first closing element 4.
[0076] According to this method, the step of folding the second flap 2c of the absorbent article 1 toward the corresponding absorbent pad 3 includes the step of attaching the second flap 2c to the corresponding absorbent pad 3 using the second closing element 5.
[0077] Referring to the schematic diagram in Figure 9, the steps of folding the first flap 2b of each absorbent article 1 toward the corresponding absorbent pad 3 and folding the second flap 2c of each absorbent article 1 toward the corresponding absorbent pad 3 are performed on the folding wheel 100.
[0078] The folding wheel 100 is of the type shown in reference US8556790, for example, except for the anvil 31 and the cutting device 30.
[0079] The method includes, at least when it is performed on a folding wheel 100, the step of holding at least a continuous multilayer web W on the folding wheel 100 via, for example, a suction system or a belt system (an example of which is labeled 110).
[0080] The solutions described herein offer significant advantages. In particular, by separating individual absorbent articles by pre-cutting and tearing, separation becomes possible without the use of sharp cutting devices. If the folding and separation of the absorbent articles is preferably performed on a folding wheel, the folding wheel does not require a web cutting device, and is therefore lighter, less complex, and more compact than conventional solutions. [Prior art documents] [Patent Documents]
[0081] [Patent Document 1] US8556790B2
Claims
1. A method for forming and folding an absorbent hygienic article (1), comprising: The absorbent sanitary article (1) comprises a waistband (2) and an absorbent pad (3) extending from a middle portion (2a) of the waistband (2), The absorbent pad (3) separates the first and second flaps (2b, 2c) of the waistband (2); The absorbent sanitary article (1) comprises a first closure element (4) at one end of the first flap (2b) and a second closure element (5) at one end of the second flap (2c), the absorbent pad (3) is, at least in use, folded towards the waistband (2) to define a crotch (6) of the absorbent article (1), and the first and second flaps (2b, 2c) are folded over the folded absorbent pad (3) and secured to the absorbent pad (3) by the first and second closure elements (4) and (5), respectively, to define pants; The forming and folding method comprises: providing a continuous multi-layer web (W) and feeding it in a feed direction (V); applying a series of spaced apart absorbent pads (3) onto said continuous multi-layer web (W); folding said series of absorbent pads (3) onto said continuous multi-layer web (W); temporarily fixing the series of folded absorbent pads (3) to the continuous multi-layer web (W); applying a series of first closure elements (4) onto said continuous multi-layer web (W); applying a series of second closure elements (5) onto the continuous multi-layer web (W), wherein each absorbent pad (3) is inserted between one of the series of first closure elements (4) and one of the series of second closure elements (5); The forming and folding method comprises: forming a series of lines of weakness (WL) in the continuous multi-layer web (W) between each second closure element (5) and a first closure element (4) following said second closure element (5) in said feed direction (V), each line of weakness (WL) being formed and positioned between successive absorbent articles in said feed direction (V), said forming and folding method comprising: Folding the first flap (2b) of each absorbent article (1) towards the corresponding absorbent pad (3); and folding the second flap (2c) of each absorbent article (1) towards the corresponding absorbent pad (3), The forming and folding method, wherein the step of folding the first flap (2b) of each absorbent article (1) toward the corresponding absorbent pad (3) or the step of folding the second flap (2c) of each absorbent article (1) toward the corresponding absorbent pad (3) includes a step of tearing the continuous multi-layer web (W) at the line of weakness (WL), thereby separating the absorbent articles (1) from each other.
2. 2. The forming and folding method of claim 1, wherein the step of folding the first flap (2b) of the absorbent article (1) towards the corresponding absorbent pad (3) is performed before the step of folding the second flap (2c) of the absorbent article (1) towards the corresponding absorbent pad (3).
3. 2. The forming and folding method of claim 1, wherein the step of folding the first flap (2b) of the absorbent article (1) towards the corresponding absorbent pad (3) is performed after the step of folding the second flap (2c) of the absorbent article (1) towards the corresponding absorbent pad (3).
4. 2. The forming and folding method of claim 1, wherein the step of folding the first flap (2b) of the absorbent article (1) towards the corresponding absorbent pad (3) is performed simultaneously with the step of folding the second flap (2c) of the absorbent article (1) towards the corresponding absorbent pad (3).
5. 5. The forming and folding method according to any one of claims 1 to 4, wherein the step of folding the first flap (2b) of the absorbent article (1) towards the corresponding absorbent pad (3) comprises the step of attaching the first flap (2b) to the corresponding absorbent pad (3) using the first closure element (4).
6. 5. The forming and folding method according to any one of claims 1 to 4, wherein the step of folding the second flap (2c) of the absorbent article (1) towards the corresponding absorbent pad (3) comprises the step of attaching the second flap (2c) to the corresponding absorbent pad (3) using the second closure element (5).
7. 5. A forming and folding method according to any one of claims 1 to 4, wherein the step of temporarily fixing the folded absorbent pads (3) to the continuous multi-layer web (W) includes a step of plastically deforming at least a portion (P3) of each folded absorbent pad (3) and at least a portion (PW) of the continuous multi-layer web in that portion (P3) of each folded absorbent pad (3) to create mechanical interference between the absorbent pads (3) and the continuous multi-layer web (W).
8. 8. The forming and folding method of claim 7, wherein said step of plastically deforming is performed by cold blanking and / or thermomechanical blanking.
9. At least the next steps, i.e. Folding the first flap (2b) of each absorbent article (1) towards the corresponding absorbent pad (3); and The step of folding the second flap (2c) of each absorbent article (1) towards the corresponding absorbent pad (3) comprises: The forming and folding method according to any one of claims 1 to 4, carried out on a folding wheel (100).
10. 10. The forming and folding method of claim 9, further comprising the step of retaining at least said continuous multi-layer web (W) on said folding wheel (100).