Closing element, method and machine for producing absorbent sanitary articles and related absorbent sanitary article

Abstract

To provide a closing element for producing reclosable absorbent sanitary articles.SOLUTION: A closing element for producing reclosable absorbent sanitary articles comprises a non-woven web folded according to a general omega-shaped configuration, and includes: a base (14); two intermediate flaps (18) connected to respective ends of the base (14) by respective first folds (20); and two distal flaps (24) connected to respective ends of the respective intermediate flaps (18) by respective second folds (26), where the closing element (10) includes surface fastening elements (30) arranged on respective surfaces of the distal flaps (24) facing respective intermediate flaps (18).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] [Description] The present invention relates to a closure element intended to be used for producing absorbent sanitary articles.

[0002] The present invention has been developed in particular for producing reclosable absorbent hygienic articles such as diapers, diaper pants, absorbent articles for incontinent adults and the like.

[0003] The invention can be used in particular in the so-called "Cross Direction" production process.

[0004] The invention also relates to absorbent sanitary articles produced with such closure elements.

[0005] According to another aspect, the present invention relates to a machine for producing absorbent sanitary articles.

[0006] [Prior art] Established techniques for producing reclosable absorbent hygienic articles involve forming a continuous composite web comprising at least one continuous waistband parallel to the machine direction and a plurality of absorbent cores extending transversely to the machine direction attached to the continuous waistband. In certain cases, two continuous waistbands parallel to the machine direction are used, with an absorbent core attached between them. In some cases, the production process involves the use of a single continuous waistband parallel to the machine direction and with ends of an absorbent core extending transversely to the machine direction attached.

[0007] This production technique, called cross-direction, differs from that called machine direction, which involves producing absorbent sanitary articles while proceeding along a longitudinal axis parallel to the machine direction.

[0008] Examples of methods for producing absorbent sanitary articles according to the cross-direction method are described in the documents EP 1013251, IT 1379452, IT 1410464 and IT 1410465 by the same applicant.

[0009] To produce a reclosable absorbent sanitary article, a refastenable closure element is applied to one of the longitudinally spaced continuous waistbands.

[0010] EP 1523968-A by the same applicant describes a closure element for producing absorbent sanitary articles that can be worn in the form of panties, comprising a base comprising a nonwoven web folded according to a general omega-shaped configuration and divided into two sections located on either side of a central plane; two intermediate flaps located on either side of the central plane, connected to the respective outer edges of the base section and permanently secured to the base; and two distal flaps located on either side of the central plane, connected to the respective inner edges of the respective intermediate flaps by respective folds and secured in a separable manner to the respective intermediate flaps. The base of the closure element is secured to the waistband of the sanitary article. Respective surface fasteners are secured to the surface of each distal flap facing the base.

[0011] One of the problems with this solution is that the surface fastening elements (eg, Velcro® type micro hook elements) are exposed on one surface of the waistband during the manufacturing process.

[0012] This solution is suitable when the absorbent sanitary article is a panty-like closed type before packaging. In this case, during the production process, the absorbent sanitary article is folded so that the surface fastening elements of the closure elements come into contact with corresponding closure elements for closing the absorbent sanitary article in the manner of panties.

[0013] However, when absorbent sanitary articles are intended to be packaged in an open configuration and to be closed when the article is worn, the exposed surface fasteners on the waistband tend to stick to any fabric or similar surface both during the manufacturing and packaging process and when the article is worn.

[0014] US2003078558A1 describes an absorbent hygienic article having a rear waistband with two closure elements, each comprising a nonwoven substrate with a distal portion provided with a microhook fastener and a proximal portion permanently attached to the outer surface of the rear waistband. Each closure element may be folded over itself, with the folds held in place by adhesive, heat, or ultrasonic welding. To avoid contact between the microhook material and the wearer's clothing, the microhook fastening portion may be folded inward, so that the microhook surface adheres to the surface of the nonwoven substrate.

[0015] The main drawback of the solution according to US2003078558A1 is that during the production process, two separate closure elements have to be applied to each absorbent sanitary article, which complicates the equipment and the production process. Summary of the Invention

[0016] SUMMARY OF THE INVENTION It is an object of the present invention to provide a closure element which overcomes the problems of the prior art.

[0017] According to the invention, this object is achieved by a closure element having the features forming the subject matter of claim 1.

[0018] According to another aspect, the invention relates to a method for producing absorbent sanitary articles having the features forming the subject matter of claim 7 and to a machine for producing absorbent sanitary articles according to claim 10.

[0019] Preferred embodiments form the subject matter of the dependent claims.

[0020] The claims form an integral part of the disclosure provided herein regarding the invention. [Brief explanation of the drawings]

[0021] The invention will now be described in detail with reference to the accompanying drawings, given by way of non-limiting example only, in which: [Figure 1] 1 is a perspective view of a closure element according to the invention; [Figure 2] FIG. 2 is a schematic front view of the closure element of FIG. 1. [Figure 3] 1A-1D are schematic plan views illustrating steps in a method for producing absorbent sanitary articles. [Figure 4] 4A-4D are schematic front views of the portion indicated by arrow IV in FIG. 3 in two successive stages of a method for producing an absorbent sanitary article. [Figure 5] 4A-4D are schematic front views of the portion indicated by arrow IV in FIG. 3 in two successive stages of a method for producing an absorbent sanitary article. [Figure 6] 1 is a schematic plan view of an absorbent sanitary article with side closures in a closed position. FIG. [Figure 7] 1 is a schematic plan view of an absorbent sanitary article with side closures in an open position. FIG. [Figure 8] FIG. 8 is a schematic cross-sectional view taken along line VIII-VIII in FIG. 7. [Figure 9] 8 is a schematic plan view showing an embodiment of a side closure indicated by arrow IX in FIG. 7. [Figure 10] 8 is a schematic plan view showing an embodiment of a side closure indicated by arrow IX in FIG. 7. [Figure 11] 8 is a schematic plan view showing an embodiment of a side closure indicated by arrow IX in FIG. 7. [Figure 12] 8 is a schematic plan view showing an embodiment of a side closure indicated by arrow IX in FIG. 7. [Figure 13] 8 is a schematic plan view showing an embodiment of a side closure indicated by arrow IX in FIG. 7. DETAILED DESCRIPTION OF THE INVENTION

[0022] With reference to these figures, the numeral 10 designates a closure element for producing a reclosable absorbent sanitary article.

[0023] As explained in EP 1 523 968 by the same applicant, the closure elements 10 are intended to be fixed at spaced positions on a continuous elastic band in a process for producing absorbent sanitary articles according to the technique known as transverse.

[0024] The closure element 10 comprises a web of nonwoven fabric 12 folded according to a general omega-shaped configuration to form a base 14 , two intermediate flaps 18 and two distal flaps 24 .

[0025] The base 14 is generally flat and is divided into two sections 16 located on either side of a central plane X perpendicular to the base 14 .

[0026] Two intermediate flaps 18 are parallel to the base 14 and lie on either side of the central plane X. The intermediate flaps 18 are connected to respective ends of the base 14 by respective first folds 20. The intermediate flaps 18 have respective surfaces 40 that face the base 14 and are permanently secured to corresponding surfaces 42 of the base 14, for example, by respective adhesive layers 22 or, alternatively, by heat or ultrasonic welding.

[0027] Two distal flaps 24 are parallel to each intermediate flap 18 and are located on either side of the central plane X. The distal flaps 24 are connected to the respective ends of the intermediate flaps 18 by respective second folds 26.

[0028] The closure element 10 includes a surface fastening element 30 disposed on a surface 44 of the distal flap 24 facing the respective intermediate flap 18 .

[0029] The surface fastening elements 30 may be micro-hook fastening elements designed to form a Velcro® type surface connection with a corresponding micro-loop fastening element.

[0030] The surface fasteners 30 may be attached to the surface 44 of the distal flap 24 by adhesive or by heat or ultrasonic welding.

[0031] The surface fasteners 30 may be integrally formed on the surface 44 of the distal flap 24 by, for example, ultrasonic equipment of the type described in commonly assigned patent application EP4108220.

[0032] For each distal flap 24, the surface fastening elements 30 may be continuous along a direction parallel to the central plane X.

[0033] Alternatively, for each distal flap 24, the surface fastening elements 30 may be discontinuous along a direction parallel to the central plane X.

[0034] The surface fastening elements 30 can releasably engage with the surface 46 of each intermediate flap 18 facing away from the base 14. This is particularly useful in cases where the surface fasteners 30 are microhook fasteners that engage with the surface 46 of the intermediate flap 18 made of a nonwoven fabric.

[0035] Each of the surface fastening elements 30 is contained between a respective first folded portion 20 and a respective second folded portion 26. The surface fastening elements 30 therefore do not protrude laterally beyond the respective first folded portion 20, thus avoiding any contact between the surface fastening elements 30 and elements external to the closure element 10.

[0036] The distal flaps 24 may have respective ends 48 that project laterally beyond the corresponding outer ends 50 of the respective surface fasteners 30, thereby facilitating grasping the ends 48 with the fingers to open the closure element 10.

[0037] In possible embodiments, the ends 48 of the distal flaps 24 may project laterally outward beyond the respective second folds 26 to further facilitate grasping the ends 48 with the fingers.

[0038] FIG. 3 shows diagrammatically the steps of a method for producing absorbent sanitary articles.

[0039] The method involves forming a continuous composite tape 60 that advances in a machine direction A. The continuous composite tape 60 is formed from a continuous array of absorbent sanitary article blanks 66.

[0040] The continuous composite tape 60 includes a continuous waistband 62 that is parallel to the machine direction A. The continuous waistband 62 is typically elastic and may include a plurality of elastic threads attached between two nonwoven webs.

[0041] The continuous composite tape 60 includes a plurality of absorbent cores 64 having respective ends attached to a continuous waistband 62. The absorbent cores 64 extend perpendicular to the longitudinal direction A and are spaced apart from one another in the longitudinal direction A.

[0042] The absorbent hygienic article blanks 66 each include an absorbent core 64 and a respective continuous waistband section 62 .

[0043] The method involves forming a plurality of fastening elements 10, each having the structure shown in Figures 1 and 2. The fastening elements 10 can be produced starting from a continuous nonwoven web with two lateral regions attached or integrally formed with respective continuous or intermittent strips of microhook material that form the fastening elements 30. An adhesive layer 22 is also applied to the continuous nonwoven web. The continuous nonwoven web is folded into an omega shape to assume the shape shown in Figures 1 and 2. The continuous nonwoven web is then cut transversely to form the fastening elements 10.

[0044] As shown in Figures 3 and 4, the bases 14 of the fasteners 10 are attached to the surface of the continuous waistband 62 at spaced apart locations along the longitudinal direction A. As shown schematically in Figure 4, attachment of the bases 14 of the fasteners 10 to the continuous waistband 62 may be achieved, for example, by an adhesive layer 68 applied intermittently to the continuous waistband 62.

[0045] The fastening elements 10 are oriented with their respective central planes X perpendicular to the longitudinal direction A. The fastening elements 10 are attached to the continuous waistband 62 such that the central plane X of each closure element 10 is aligned with the separation line between each pair of adjacent absorbent hygienic article blanks 66.

[0046] 3, the continuous waistband 62 may have a smooth inner edge 80 that is contoured to conform to the wearer's legs. The inner edge 80 may be cut flush with the inner edge of the surface fasteners 30.

[0047] As shown in Figures 4 and 5, after installation of the fasteners 10, the continuous waistband 62 is transversely cut along cut lines 70 that are substantially aligned with the midplane X of the fasteners 10. This transverse cutting of the continuous waistband 62 along the cut lines 70 forms absorbent hygienic articles 72 having the shape shown schematically in Figure 6. Each cut line 70 divides the respective closure element 10 into two symmetrical sections that each form a side closure 74 of the absorbent hygienic article 72.

[0048] As shown in FIG. 5, after cutting the continuous waistband 62, the portions of the continuous waistband 62 adjacent the cut line 70 elastically contract against the respective side closures 74.

[0049] During the forming, securing, and cutting steps of the fastener 10, the surface fastener 30 is enclosed between the respective distal flap 24 and intermediate flap 18 and releasably engages the surface 46 of the respective intermediate flap 18 facing away from the base 14.

[0050] This avoids problems that may arise from adhesion of the surface fastening elements 30 to materials or components used in the manufacturing or packaging process of the absorbent sanitary article 72 .

[0051] At the end of the manufacturing process, an absorbent hygienic article 72 is obtained, each comprising a waistband 62, an absorbent core 64 having one end fixed to the waistband 62, and two side closures 74 attached to opposite ends of the waistband 62, wherein the side closures 74 are formed by respective sections of the closure element 10.

[0052] At the end of the production process, the absorbent sanitary article 72 is folded and wrapped to create the product package.

[0053] The absorbent sanitary article 72 is packaged with the side closures 74 of the absorbent sanitary article 72 in a closed configuration in which the surface fastening elements 30 are enclosed between the respective distal and intermediate flaps 24 and 18 .

[0054] When in use, the surface fasteners 30 are hidden and do not adhere to clothing or other fabric articles when the article is worn.

[0055] In use, the side closures 74 are open as shown in Figures 7 and 8. In this configuration, the surface fasteners 30 couple with the side flaps 76 or front panel 78 to close the absorbent sanitary article 72 around the waist of the user.

[0056] Referring to FIG. 9, the surface fastening elements 30 may have a width equal to the width of each distal flap 24 .

[0057] Alternatively, as shown in FIG. 10, the surface fasteners 30 may have a width less than the width of each distal flap 24 and may be surrounded on four sides by the material of the distal flap 24.

[0058] 11, the distal flap 24 of each side closure 74 may be shaped to have a width that is less than the width of the respective intermediate flap 18. The shape may be asymmetrical (which results in scrap cuts) as shown in FIG.

[0059] 12 and 13, the distal flap 24 of each side closure 74 may be cut symmetrically to form two side closures 74 having complementary shapes, thus avoiding the formation of scrap.

[0060] To realize the embodiments of Figures 11, 12 and 13, it may be advantageous for the base 14 to be formed by two or more webs extending from either side of the central plane X and joined together along joining lines parallel to the central plane X.

[0061] Naturally, without prejudice to the principles of the invention, the details of construction and embodiment may be varied in various ways with respect to those described and illustrated, without thereby departing from the scope of the invention as defined by the following claims. (Other possible items) (Item 1) A closure element for producing a reclosable absorbent sanitary article, comprising a nonwoven web (12), said nonwoven web (12) comprising: a base (14) divided into two sections (16), the two sections (16) being located on either side of a central plane (X) perpendicular to the base (14); two intermediate flaps (18) parallel to the base (14) and located on either side of the central plane (X), wherein the intermediate flaps (18) are connected to respective ends of the base (14) by respective first folds (20) and have respective surfaces permanently fixed to the base (14); two distal flaps (24) parallel to each of the intermediate flaps (18) and located on either side of the central plane (X), wherein the distal flaps (24) are connected to the respective ends of the intermediate flaps (18) by respective second folds (26); It folds in the general omega configuration to form wherein the closure element (10) comprises a surface fastening element (30) disposed on a surface (44) of each of the distal flaps (24) facing a respective intermediate flap (18); Closure element. (Item 2) Item 2. The closure element according to item 1, wherein the surface fastening element (30) is a microhook surface fastener. (Item 3) 3. The closure element according to claim 1, wherein the surface fastening element (30) engages with a releasable surface (46) of each intermediate flap (18) facing away from the base (14). (Item 4) 4. The closure element according to any one of items 1 to 3, wherein each of the surface fastening elements (30) is contained between a respective first folded portion (20) and a respective second folded portion (26). (Item 5) 5. The closure element of any one of items 1 to 4, wherein the distal flaps (24) include respective ends (48) that protrude laterally beyond the corresponding outer ends (50) of the respective surface-fastening elements (30). (Item 6) Item 6. The closure element according to item 5, wherein the end (48) of the distal flap (24) protrudes laterally outward beyond each first fold (20). (Item 7) 1. An absorbent hygienic article comprising a waistband (62), an absorbent core (64) having one end attached to the waistband (62), and two side closures (74) attached to opposite ends of the waistband (62), wherein the side closures (74) are formed by respective sections of a closure element (10) according to any one of items 1 to 6. (Item 8) forming a continuous composite tape (60) advancing in a machine direction (A) formed by a continuous array of absorbent hygienic article blanks (66), wherein said continuous composite tape (60) comprises a continuous waistband (62) parallel to said machine direction (A) and a plurality of absorbent cores (64) with respective ends secured to said continuous waistband (62); forming a plurality of closure elements (10) according to any one of items 1 to 6; attaching the base portions (14) of the closure elements (10) onto the surface of the continuous waistband (62) in spaced apart locations along the longitudinal direction (A); and cutting said continuous waistband (62) transversely along a cutting line (70) substantially aligned with said central plane (X) of said closure element (10). A method for producing absorbent sanitary articles comprising: (Item 9) 9. The method according to claim 8, wherein the surface fastening element (30) is enclosed between each distal flap (24) and intermediate flap (18) during the forming, securing, and cutting steps of the closure element (10). (Item 10) A machine for producing absorbent sanitary articles configured to implement the method according to item 8 or 9.

Claims

1. A closure element for producing a reclosable absorbent sanitary article, comprising a nonwoven web, said nonwoven web comprising: a base divided into two sections, the two sections being located on opposite sides of a central plane perpendicular to the base; two intermediate flaps parallel to the base and positioned on either side of the central plane, the intermediate flaps being connected to respective ends of the base by respective first folds and having respective surfaces permanently fixed to the base; two distal flaps parallel to each of the intermediate flaps and located on either side of the central plane, the distal flaps being connected to respective ends of the intermediate flaps by respective second folds; It folds in the general omega configuration to form wherein the closure element comprises a surface fastening element disposed on a surface of each of the distal flaps facing a respective intermediate flap; Closure element.

2. The closure element of claim 1 , wherein the surface fastening element is a microhook surface fastener.

3. The closure element of claim 1 , wherein the surface fastening element engages a releasable surface of each intermediate flap facing away from the base.

4. The closure element of claim 1 , wherein each of the surface fastening elements is contained between a respective first folded portion and a respective second folded portion.

5. The closure element of claim 1 , wherein the distal flaps include respective ends that project laterally beyond corresponding outer ends of respective surface-fastening elements.

6. The closure element of claim 5 , wherein the ends of the distal flaps project laterally outward beyond their respective first folds.

7. 10. An absorbent hygienic article comprising a waistband, an absorbent core having one end attached to the waistband, and two side closures attached to opposite ends of the waistband, wherein the side closures are formed by a closure element according to any one of claims 1 to 6 in each section.

8. forming a longitudinally advancing continuous composite tape formed by a continuous array of absorbent hygienic article blanks, wherein the continuous composite tape includes a continuous waistband parallel to the longitudinal direction and a plurality of absorbent cores with respective ends secured to the continuous waistband. forming a plurality of closure elements according to any one of claims 1 to 6; attaching the bases of the closure elements onto a surface of the continuous waistband in spaced locations along the longitudinal direction; and cutting the continuous waistband transversely along a cutting line substantially aligned with the central plane of the closure element. A method for producing absorbent sanitary articles comprising:

9. 9. The method of claim 8, wherein the surface fastening elements are enclosed between respective distal and medial flaps during the forming, securing, and cutting steps of the closure element.

10. A machine for producing absorbent sanitary articles configured to implement the method of claim 8.

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