Apparatuses and methods for compressing absorbent articles

Abstract

Disclosed is an apparatus for compressing a stack of compressible absorbent articles. The apparatus includes first and second press plates each having a respective contact surface for engaging the stack of compressible absorbent articles. Each of the first and second contact surfaces define an upper region and a lower region. The position of the first press plate relative to the second press plate is adjustable between a loading position and a compressing position such that the first contact surface is nearer to the second contact surface in the compressing position than in the loading position. In both the loading position and the compressing position, a minimum distance between the upper region of the first contact surface and the upper region of the second contact surface is less than a minimum distance between the lower region of the first contact surface and the lower region of the second contact surface.

Description

APPARATUSES AND METHODS FOR COMPRESSING ABSORBENT ARTICLESBACKGROUND

[0001] Many compressible absorbent articles, such as diapers, incontinent products, menstrual pad products, and the like, are packaged in flexible material. Prior to packaging, the compressible absorbent articles are often stacked and compressed by a compression apparatus. The compressed stack of compressible absorbent articles is then packaged in the flexible material (e.g., plastic wrap or bag), which maintains the stack in a compressed form.

[0002] Interruptions in the compression and packaging process can lead to both delay and packaging waste. Accordingly, there is an on-going need in the art for apparatuses and methods of compressing compressible absorbent articles that offer improved consistency and reliability to avoid delay and waste in the packaging process.SUMMARY

[0003] Various implementations relate to an apparatus for compressing a stack of compressible absorbent articles. The apparatus includes a first press plate and a second press plate. The first press plate has a first contact surface for engaging the stack of compressible absorbent articles, the first contact surface defining an upper region and a lower region. The second press plate has a second contact surface for engaging the stack of compressible absorbent articles, the second contact surface defining an upper region and a lower region. The position of the first press plate relative to the second press plate is adjustable between a loading position and a compressing position such that the first contact surface is nearer to the second contact surface in the compressing position than in the loading position. In both the loading position and the compressing position, a minimum distance between the upper region of the first contact surface and the upper region of the second contact surface is less than a minimum distance between the lower region of the first contact surface and the lower region of the second contact surface.

[0004] Various implementations relate to a method for compressing a stack of compressible absorbent articles. The method including the steps of: providing a compression apparatus including a first press plate and a second press plate; positioning the stack ofcompressible absorbent articles between the first press plate and the second press plate; and moving at least one of the first press plate and the second press plate to apply non-uniform compression to the stack of compressible absorbent articles. An upper region of the stack of compressible absorbent articles is subjected to greater compression than a lower region of the stack of compressible absorbent articles.

[0005] This summary is illustrative only and is not intended to be in any way limiting. Other aspects, features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements.BRIEF DESCRIPTION OF DRAWINGS

[0006] Various implementations are explained with reference to the following drawings. The drawings are merely exemplary and certain features may be used singularly or in combination with other features.

[0007] FIG. 1 is a perspective elevation view of a folded compressible absorbent article according to one implementation.

[0008] FIG. 2 is a side elevation view of a compression apparatus according to one implementation.

[0009] FIG. 3 is a side elevation view of a press plate included in the compression apparatus of FIG. 2 according to one implementation.

[0010] FIG. 4 is a side elevation view of the compression apparatus of FIG. 2 in a loading position with an uncompressed stack of compressible absorbent articles according to one implementation .

[0011] FIG. 5 is a side elevation view of the compression apparatus of FIG. 2 in a compressing position with a compressed stack of compressible absorbent articles according to one implementation.

[0012] FIG. 6 is a side elevation view of a press plate included in the compression apparatus of FIG. 2 and positioned adjacent to a compressible absorbent article according to one implementation.

[0013] FIG. 7 is a side elevation view of a press plate having a curvilinear medial region according to one implementation.

[0014] FIG. 8 is a side elevation view of a compression apparatus having the press plates of FIG. 7 in a loading position with an uncompressed stack of compressible absorbent articles according to one implementation.

[0015] FIG. 9 is a side elevation view of a compression apparatus having the press plates of FIG. 7 in a compressing position with a compressed stack of compressible absorbent articles according to one implementation.

[0016] FIG. 10 is a side elevation view of the press plate of FIG. 7 positioned adjacent to a compressible absorbent article according to one implementation.DETAILED DESCRIPTION

[0017] Following below are more detailed descriptions of concepts related to apparatuses and methods for compressing compressible absorbent articles. Before turning to the figures, which illustrate certain exemplary implementations in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.Definitions

[0018] As used in this application and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Thus, for example, reference to a “filament” includes aspects having two or more such filaments unless the context clearly indicates otherwise.

[0019] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises”, means “including but not limited to”, and is not intended to exclude, for example, other additives, components, integers or steps.

[0020] For the terms “for example,” “exemplary,” and “such as,” and grammatical equivalences thereof, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise.

[0021] As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0022] It will be understood that the terms “first,” “second,” etc., may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or a section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of exemplary aspects.

[0023] Ranges may be expressed herein as from one particular value to another particular value. When such a range is expressed, another aspect includes from the one particular value to the other particular value. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint. Similarly, the values listed include approximations of these values. In one non-limiting aspect the terms are defined to be within 10%. In another non-limiting aspect, the terms are defined to be within 5%. In still another non-limiting aspect, the terms are defined to be within 1%.

[0024] Throughout this disclosure, various aspects of the disclosure can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, a description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6, etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, 6 and any whole and partial increments therebetween. This applies regardless of the breadth of the range.Compressible Absorbent Article

[0025] Referring to the figures generally, the various implementations disclosed herein relate to apparatuses and methods for compressing a plurality of compressible absorbent articles. FIG. 1 is a perspective elevation view of a folded compressible absorbent article that is processed according to various implementations described herein. As shown in FIG. 1, the compressible absorbent article 100 includes a major axis 106 that passes through a majority of material. The compressible absorbent article 100 also includes a minor axis 104 that passes through a minimum amount of material, and a medium axis 102 that passes through an amount of material which is less than the major amount but which is more than the minimum amount. According to various implementations, compression of the compressible absorbent article 100 includes substantial compression in the direction parallel to the minor axis 104 and orthogonal to the plane created by the major axis 106 and the medium axis 102.

[0026] In the illustrated implementation of FIG. 1, the compressible absorbent article 100 is represented as a folded compressible absorbent article by way of non-limiting example. In some implementations, the compressible absorbent article 100 is an infant care garment or the like (e.g., a diaper), such as a HUGGIES® product made by Kimberly-Clark Worldwide Inc. In some implementations, the compressible absorbent article 100 is a childcare garment or the like, such as a PULL-UPS® product made by Kimberly-Clark Worldwide Inc. In some implementations, the compressible absorbent article 100 is an adult care garment or the like, such as a DEPEND® product made by Kimberly-Clark Worldwide Inc. In some implementations, the compressible absorbent article 100 is a feminine care article or the like, such as a KOTEX® product made by Kimberly-Clark Worldwide Inc.Compression Apparatus

[0027] FIG. 2 is a side elevation view of a compression apparatus 200 according to one implementation. The compression apparatus 200 includes a first press plate 210a and a second press plate 210b. The two press plates 210a, 210b are spaced-apart and configured to compress a plurality of compressible absorbent articles 100 positioned between the press plates 210a, b (as shown and discussed here with respect to FIGS. 4 and 5). As shown in FIG. 2, an area between the spaced-apart press plates 210a, b defines a loading zone 202 where compressible absorbent articles 100 (e.g., a stack of compressible absorbent articles 100) may be positioned on a floor

[0028] The interior faces of the press plates 210a,b define contact surfaces 214a,b. Accordingly, the first press plate 210a includes a first contact surface 214a and the second press plate 210b includes a second contact surface 214b. The contact surfaces 214a,b are the portions of the press plates 210a, b configured to engage and apply a compressive force to the compressible absorbent articles 100 disposed in the loading zone 202.

[0029] In various implementations, the press plates 210a,b are configured to move laterally toward one another and along the floor 204. In this way, the press plates 210a,b are configured to move between a loading position and a compressing position. In the illustrated implementation of FIG. 2, the press plates 210a, b and their respective contact surfaces 214a, b are oriented such that they are horizontally opposed to one another.

[0030] In the loading position, the press plates 210a, b are spaced apart to facilitate loading of a stack of compressible absorbent articles 100 between the contact surfaces 214a,b (e.g., as shown in FIG. 4). In the compressing position, the press plates 210a, b are moved toward one another to reduce the area between the contact surfaces 214a, b (e.g., as shown in FIG. 5). When the press plates 210a, b are moved from the loading position to the compressing position, the contact surfaces 214a, b engage and compress the compressible absorbent articles 100 positioned therebetween.

[0031] In the illustrated implementation, each press plate’s contact surface 214a,b defines a lower region 220 and an upper region 230. The upper region 230 of each contact surface 214a, b includes a protrusion 232, which extends inwardly into the loading zone 202. As shown in FIG. 2, the contact surfaces 214a, b are oriented to mirror one another such that each press plate’s protrusion 232 extends into the loading zone 202 in the direction of the opposing contact surface 214a, b. As will be appreciated from the description herein, various implementations of the compression apparatus 200 may be provided with a pair of press plates having contact surfaces oriented to mirror one another and having the characteristics of any of the various press plates described herein.

[0032] As shown in FIG. 2, the lower regions 220 of the contact surfaces 214a, b are separated by a distance DI, while the upper regions 230 of the contact surfaces 214a,b are separated by a distance D2. In the illustrated implementation of FIG. 2, the distance D2 is less than the distance DI due to the protrusion 232 provided in each contact surface’s upper region 230. Additionally, the distances DI, D2 are adjustable as the press plates 210a, b are movedbetween the loading position and the compressing position. For example, in the compressing position (e.g., shown in FIG. 5) each distance DI, D2 between the contact surfaces 214a, b is less than the distance DI, D2 (respectively) between the contact surfaces 214a,b in the loading position (e.g., shown in FIG. 4).

[0033] In various implementations, in both the loading position and the compressing position, a minimum distance between the upper region 230 of the first contact surface 214a and the upper region 230 of the second contact surface 214b is less than a minimum distance between the lower region 220 of the first contact surface 214a and the lower region 220 of the second contact surface. In certain implementations, in both the loading position and the compressing position, the maximum distance between the upper region 230 of the first press plate’s contact surface 214a and the upper region 230 of the second press plate’s contact surface 214b is less than the minimum distance between the lower region 220 of the first plate’s contact surface 214a and the lower region of the second press plate’s contact surface 214b.

[0034] FIG. 3 is a side elevation view of the first press plate 210a included in the compression apparatus 200 of FIG. 2. In the illustrated implementation of FIG. 2, the second press plate 210b has the same dimensions as the first press plate 210a mirrored in an opposing direction.

[0035] In the illustrated implementation of FIG. 3, the first press plate’s contact surface 214a spans a contact surface height Hl (e.g., measured from the bottom edge of the first contact surface 214a adjacent the floor 204 to the top edge of the first contact surface 214a). In the illustrated implementation, the press plate’s contact surface height Hl spans the press plate’s full height. However, in other implementations, the press plate 210a may have a height that exceeds the contact surface height Hl (e.g., such that the height of the contact surface 214a is less than the height of the press plate 210a).

[0036] As shown in FIG. 3, the upper region 230 of the first contact surface 214a extends from a top edge of the first contact surface 214a to an interface with the lower region 220 of the first contact surface 214a. Likewise, the lower region 220 of the first contact surface 214a extends from a bottom edge of the first contact surface 214a to the interface with the upper region 230 of the first contact surface 214a.

[0037] As is further depicted in FIG. 3, the press plate’s lower region 220 spans a height H2, which extends from the bottom edge of the first contact surface 214a to the bottom of theupper region 230 (e.g., the interface where the lower region 220 meets the upper region 230). The first contact surface’s upper region 230 (and thereby its protrusion 232) spans a height H3, which extends from a top edge of the first contact surface 214a to the top edge of the lower region 220 (e.g., the interface where the upper region 230 meets the lower region 220).

[0038] As shown in FIG. 3, the sum of the heights H2 and H3 is equivalent to the press plate height Hl. In certain implementations, the interface of the upper region 230 and the lower region 220 of the first contact surface 214a is located at a height from the bottom edge of the first contact surface 214a that is one-half or more of the contact surface height Hl (e.g., such that the lower region’s height H2 is greater than or equal to half of the contact surface height Hl and the upper region’s height H3 is less than or equal to half of the contact surface height Hl).

[0039] In the illustrated implementation of FIG. 3, the first press plate’s lower region 220 has a plate thickness Tl. The press plate’s upper region 230 includes the protrusion 232, which extends outwardly a distance T3 relative to the press plate’s lower region 220 (also referred to herein as a protrusion thickness T3). As a result, the press plate’s upper region 230 has a plate thickness T2 (equivalent to Tl + T3 in the illustrated implementation).

[0040] As is further depicted in the illustrated implementation of FIG. 3, the upper region 230 of the first contact surface 214a has a substantially flat surface profile. Additionally, the lower region 220 of the first contact surface 214a has a substantially flat surface profile. As shown in FIG. 2, the contact surfaces 214a, b of the first and second press plates 210a, b are also horizontally opposed to one another. Furthermore, the upper regions 230 and lower regions 220 of the contact surfaces 214a,b are parallel to one another.

[0041] In various implementations, the first contact surface 214a is configured have a contact surface height Hl between about 50 mm and 160 mm. In various implementations, the first contact surface 214a is configured to have a lower region height H2 between about 25 mm and 80 mm. In various implementations, the first contact surface 214a is configured to have an upper region protrusion height H3 between about 25 mm and 80 mm.

[0042] In various implementations, the first press plate’s lower region 220 is configured to have a thickness Tl between about 0 mm and 10 mm. In various implementations, the first press plate’s upper region 230 is configured to have a thickness T2 between about 5 mm and 20 mm. In various implementations, the first press plate’s protrusion 232 is configured to extend outwardly relative to the lower region 220 of the first contact surface 214a by a distance T3 (theprotrusion thickness) between about 5 mm and 20 mm. Tn one implementation, the first press plate 210a has a contact surface height Hl of 112 mm, a lower region height H2 of 65 mm, an upper region protrusion height H3 of 47 mm, and a protrusion thickness T3 of 12 mm.

[0043] In some implementations, the first press plate 210a is configured to have a protrusion height aspect ratio reflecting the height of the protrusion 232 relative to the height of the first contact surface 214a. In various implementations, the protrusion height aspect ratio is defined as the height of the upper region protrusion 232 (H3) divided by the height of the nonprotruding lower region 220 (H2). In various implementations, the first press plate 210a has a protrusion height aspect ratio (H3 / H2) of 1.0 or less. In one implementation, the first press plate 210a has a contact surface height (Hl) of 112mm, a lower region height (H2) of 65 mm, and a protrusion height (H3) of 47 mm, yielding a protrusion height aspect ratio (H3 / H2) of about 0.72. In another implementation, the first press plate 210a has a contact surface height (Hl) of 112 mm, a lower region height (H2) of 90mm, and a protrusion height (H3) of 22 mm, yielding a protrusion height aspect ratio (H3 / H2) of about 0.24.

[0044] In some implementations, the first press plate 210a is configured to have a protrusion thickness aspect ratio reflecting the thickness of the protrusion 232 (T3) relative to the protrusion height (H3). In various implementations, the protrusion thickness aspect ratio is defined as the protrusion thickness (T3) divided by the height of the upper region protrusion 232 (H3). In various implementations, the first press plate 210a has a protrusion thickness aspect ratio (T3 / H3) of 0.25 or more. In one implementation, the press plate’s upper region protrusion 232 has a height (H3) of 47 mm and a protrusion thickness (T3) of 12 mm, yielding a protrusion thickness aspect ratio (T3 / H3) of about 0.26. In one implementation, the first press plate’s upper region protrusion 232 has a height (H3) of 47 mm and a protrusion thickness (T3) of 18 mm, yielding a protrusion thickness aspect ratio (T3 / H3) of about 0.38. In one implementation, the first press plate’s upper region protrusion 232 has a height (H3) of 72 mm and a protrusion thickness (T3) of 18 mm, yielding a protrusion thickness aspect ratio (T3 / H3) of about 0.25.

[0045] As will be appreciated from the description herein, the foregoing description of the features and dimensions of the first press plate 210a may also be provided in the second press plate 210b. For example, in the illustrated implementation of FIG. 2, the second press plate 210b has the same dimensions as the first press plate 210a mirrored in an opposing direction.

[0046] Various implementations of the press plates described herein may be adapted for use with known compression apparatuses to compress compressible absorbent articles. For example, various implementations of the press plates described herein may be used with compression apparatuses sold by Optima Packaging Ground (e.g., the Optima LS Stacker machine).Method of Compressing Compressible Absorbent Articles

[0047] Compressible absorbent articles 100 (e.g., diapers) are manufactured with outer materials having increasing softness and improved hand feel. For example, spunbond meltblown spunbond (SMS) materials with increasing softness are being used as the outer material for compressible absorbent articles 100. As the softness and hand feel of these outer materials are improved, the product-to-product coefficient of friction between compressible absorbent articles 100 is reduced. When compressible absorbent articles 100 are arranged continuously in a stack, the reduced coefficient of friction leads to higher slippage between adjacent compressible absorbent articles 100.

[0048] When stacks of compressible absorbent articles 100 are compressed during processing (e.g., by a compression apparatus), the reduced product-to-product coefficient of friction increases the likelihood that the compressible absorbent articles 100 become misaligned or dislodged and cause the stack to lose integrity. For example, during compression, compressible absorbent article stacks can bow upward so severely that the stack falls apart. In other instances, compressible absorbent articles 100 may become dislodged from the loading zone 202 or otherwise move out of alignment with one another. When a loss of stack integrity occurs, the compression apparatus may need to be stopped to realign or remove the compressible absorbent articles 100 and, in some instances, the stack may have been deformed. These scenarios lead to manufacturing delays and waste.

[0049] In various implementations, the compression apparatus 200 may be used to implement a method for compressing compressible absorbent articles 100 that provides improved maintenance of stack integrity. FIG. 4 is a side elevation of the compression apparatus 200 and a stack of compressible absorbent articles 100 according to one implementation. In the illustrated implementation, the compression apparatus 200 includes first and second press plates210a,b having upper regions 230 that include protrusions 232 (e.g., as shown and described with respect to FIGS. 2 and 3).

[0050] As shown in FIG. 4, the compression apparatus 200 is first oriented in the loading position such that the press plates 210a, b are spaced apart. Next, a plurality of compressible absorbent articles 100 are arranged into a stack (e.g., such that each of the compressible absorbent articles are individually folded and arranged contiguously to form a stack). The stack of compressible absorbent articles 100 are then positioned on the floor 204 in the loading zone 202 between the press plates 210a,b. In the illustrated implementation, the compressible absorbent articles 100 are oriented such that their medium axis 102 (shown in FIG. 1) is substantially parallel with the contact surfaces 214a, b of the press plates 210a, b and their minor axis 104 (shown in FIG. 1) is substantially parallel to the press plates’ direction of travel (e.g., the axis along which the press plates 210a,b move between the loading position and the compressing position). In other words, the stack of compressible absorbent articles 100 is oriented horizontally between the horizontally opposed contact surfaces 214a, b of the first and second press plates 210a,b.

[0051] The press plates 210a, b are next moved from the loading position to the compressing position. As the press plates 210 move laterally toward one another, the compressible absorbent articles 100 are engaged by the contact surfaces 214a, b of the press plates 210a, b and are compressed in a direction parallel to the minor axis 104 (shown in FIG. 1) of each individual compressible absorbent article 100.

[0052] FIG. 5 is a side elevation view of the compression apparatus 200 with the press plates 210a, b in the compressing position. Directional arrows in FIG. 5 depict the lateral movement of each press plate 210a, b toward the other. As shown in FIG. 5, the press plates 210a, b apply non-uniform compression to the compressible absorbent articles 100.

[0053] In the illustrated implementation, an upper region of the stack of compressible absorbent articles 100 is subjected to greater compression than a lower region of the stack of compressible absorbent articles 100. In the compressing position, the distance D2 between the protrusions 232 of the press plates 210 is less than the distance DI between the lower regions 220 of the press plates 210. As a result, the upper regions 230 of the contact surfaces 214a, b apply higher compressive forces to the stack of compressible absorbent articles 100 than the lower regions 220. In this way, the press plates 210a, b apply non-uniform compression to thecompressible absorbent articles 100, where an upper region of the stack of compressible absorbent articles (aligned with the upper regions 230 of the contact surfaces 214a, b) is subjected to greater compression than a lower region of the stack of compressible absorbent articles (aligned with the lower regions 220 of the contact surfaces 214a,b).

[0054] During compression by the press plates 210a, b, the length of the upper region of the compressible absorbent article stack is reduced to the distance D2 between the upper region protrusions 232, while the length of the lower region of the compressible absorbent article stack is reduced to the distance DI between the lower regions 220 of the contact surfaces 214a, b. As D2 is less than DI, the upper region of the compressible absorbent article stack will become shorter than the lower region of the compressible absorbent article stack as the stack is compressed. In other words, as shown in FIG. 5, the width of the upper region of the compressed stack of compressible absorbent articles 100 is less than the width of a lower region of the compressed stack of compressible absorbent articles 100.

[0055] Due to the length differential between the upper and lower regions of the compressible absorbent article stack, the stack will begin to bow in the direction of the side of the stack that is longer. As shown in FIG. 5, by compressing an upper region of the compressible absorbent article stack more than a lower region (non-uniform compression), the compression apparatus 200 causes the compressible absorbent article stack to bow downwards under compression.

[0056] In various implementations, causing the compressible absorbent article stack to bow downwards under compression improves stack integrity during processing. For example, the downward bow of the compressible absorbent article stack (as shown in FIG. 5) counteracts any upward force that may occur when a product stack is misaligned and the compressible absorbent articles 100 slip relative to one another. Accordingly, by applying non-uniform compression to induce a downward force in the compressible absorbent article stack, various implementations of the press plates 210a,b provide for more effective maintenance of stack integrity during compression.

[0057] In certain implementations, the press plates 210a, b are configured to have protrusions 232 configured to engage a certain region of a compressible absorbent article 100. FIG. 6 is a side elevation view of the first press plate 210a positioned adjacent to a compressible absorbent article 100 according to one implementation. In the illustrated implementation, thecompressible absorbent article 100 is schematically depicted and shown with a central plane 114 extending through the center of the compressible absorbent article 100. The central plane 114 is parallel with the compressible absorbent articles’ minor axis 104 and medium axis 102 (shown in FIG. 1). As shown in FIGS. 1 and 6, the compressible absorbent article 100 is folded in half and therefore has an uncompressed folded height (HF) (e.g., the height of the compressible absorbent article when it is folded in half, uncompressed, and oriented perpendicularly to a floor 204 of the compression apparatus 200). As the central plane 114 passes through the center of the compressible absorbent article 100, the central plane 114 is located at a height that is one-half of the folded height (HF).

[0058] In various implementations, the stack of compressible absorbent articles 100 described herein may comprise a plurality of folded compressible absorbent articles 100, each having the same folded height (HF) and stacked contiguously. As such, the stack of folded compressible absorbent articles may also have an uncompressed folded height (HF) and an uncompressed stack width (e.g., equivalent to the width of a folded compressible absorbent article 100 multiplied by the number of compressible absorbent articles in the stack).

[0059] As shown in FIG. 6, the compressible absorbent article 100 is positioned on the floor 204 of the compression apparatus 200 adjacent to the first press plate 210a for reference. In the illustrated implementation, the press plate 210a is configured such that the upper region 230 of its first contact surface 214a — which includes the protrusion 232 — is positioned above the central plane 114 of the compressible absorbent article 100. As a result, when a stack of compressible absorbent articles 100 is compressed by the pressed plates 210a,b, the upper region of the stack of compressible absorbent articles (which is subjected to greater compression by the upper region 230 of the contact surfaces 214a,b) is located above a central plane extending through the center of the stack of folded compressible absorbent articles (e.g., the central plane extending through the stack being the same as the central plane 114 shown in FIG. 6). In various implementations, the press plates 210a, b may be configured such that the upper regions 230 of the contact surfaces 214a, b are located at or above the central plane 114 (e.g., at or above a height that is one-half or more of the folded height (HF)).

[0060] After the stack of compressible absorbent articles 100 have been compressed between the press plates 210a,b, the compression apparatus 200 pushes the compressed stack of compressible absorbent articles 100 out of the loading zone 202. For example, in someimplementations, the compression apparatus 200 pushes the compressed stack of compressible absorbent articles 100 in a machine direction out of the loading zone 202 (e.g., out of the plane of the figure after the compression process) to be packaged. In some implementations, the compressed stack of compressible absorbent articles 100 is then placed into a flexible container (e.g., a flexible, sealed plastic bag holding the compressible absorbent articles 100 in their compressed form).Additional Press Plate and Compression Apparatus Configurations

[0061] Various additional implementations of the compression apparatus and methods of using the same may also include additional press plate configurations that provide non-uniform compression of the compressible absorbent articles 100.

[0062] FIG. 7 is a side elevation view of a first press plate 710a according to another implementation. As shown in FIG. 7, the first press plate 710a includes a first contact surface 714a having a lower region 720, an upper region 730, and a medial region 725. The medial region 725 is positioned between the lower region 720 and the upper region 730. The upper region 730 includes a protrusion 732, which extends inwardly into the loading zone 202 when the first press plate 710a is used in a compression apparatus 700 (shown in FIGS. 8 and 9).

[0063] As shown in FIG. 7, the first contact surface 714a has a contact surface height Hl (e.g., measured from the bottom edge of the first contact surface 714a adjacent the compression apparatus floor to the top edge of the first contact surface 714a). In the illustrated implementation, the press plate’s contact surface 714a spans the press plate’s full height. However, in other implementations, the press plate 710 may have a height that exceeds the height (Hl) of the first contact surface 714a.

[0064] As shown in FIG. 7, the first contact surface’s lower region 720 spans a height H2, which extends from the bottom edge of the first contact surface 714a to the bottom edge of the medial region 725 (e.g., the interface where the lower region 720 meets the medial region 725). The first contact surface’s medial region 725 spans a height H4, which extends from the top edge of the bottom region 720 (e.g., the interface where the lower region 220 meets the medial region 725) to the bottom edge of the upper region 730 (e.g., the interface where the upper region 730 meets the medial region 725). The first contact surface’s upper region 730 (and thereby the protrusion 732) spans a height H3, which extends from the top edge of the firstcontact surface 714a to the top of the medial region 725 (e.g., the interface where the upper region 730 meets the medial region 725).

[0065] As shown in FIG. 7, the sum of the heights H2, H4, and H3 is equivalent to the press plate height Hl. In certain implementations, the interface of the upper region 730 and the medial region 725 of the first contact surface 214a is located at a height from the bottom edge of the first contact surface 214a that is one-half or more of the contact surface height Hl (e.g., such that the sum of the lower region’s height H2 and medial region’s height H4 (i.e., H2+H4) is greater than or equal to half of the contact surface height Hl and the upper region’s height H3 is less than or equal to half of the contact surface height Hl).

[0066] In the illustrated implementation of FIG. 7, the first press plates’ lower region 720 has a plate thickness Tl. The first press plate’s upper region 730 includes the protrusion 732, which extends outwardly a distance T3 relative to the press plate’s lower region 720 (also referred to herein as a protrusion thickness T3). As a result, the press plate’s upper region 730 has a plate thickness T2 (equivalent to Tl + T3 in the illustrated implementation).

[0067] As depicted in FIG. 7, the press plate’s medial region 725 has a variable plate thickness. The bottom of the medial region 725 has a plate thickness Tl equivalent to the thickness of the lower region 720 (e.g., at the interface of the medial region 725 and lower region 720). The plate thickness of the medial region 725 gradually increases as it approaches the upper region 730 such that the top of the medial region 725 has a plate thickness T2 equivalent to the thickness of the upper region 730 (e.g., at the interface of the medial region 725 and upper region 730). As a result, the medial region 725 has a gradually increasing plate thickness, which increases from Tl to T2 between the lower region 720 and the upper region 730.

[0068] In the illustrated implementation, the surface profile of the first contact surface 714a is substantially flat in both the upper region 730 and the lower region 720. As shown in FIG. 8, the contact surfaces 714a,b of first and second press plates 710a, b are also horizontally opposed to one another. In the illustrated implementation of FIG. 8, the upper regions 730 and lower regions 720 of the contact surfaces 214a, b are therefore parallel to one another.

[0069] In the medial region 725, the surface profile of the first contact surface 714a is curved. For example, in the illustrated implementation of FIG. 7, the medial region 725 defines a curvilinear surface (e.g., having a sigmoidal or S-shaped cross-section). In other implementations, the medial region 725 may define a curved surface having an arcuate shape orconstant radius curve. In other implementations, the medial region 725 may be defined by an angled flat surface.

[0070] In various implementations, the first contact surface 714a is configured have a contact surface height Hl between about 50 mm and 160 mm. In various implementations, the first contact surface 714a is configured to have a lower region height H2 between about 0 mm and 10 mm. In various implementations, the first contact surface 714a is configured to have an upper region protrusion height H3 between about 5 mm and 80 mm. In various implementations, the first contact surface 714a is configured to have a medial region height H4 between about 45 mm and 155 mm.

[0071] In various implementations, the press plate’s lower region 720 is configured to have a thickness T1 between about 0 mm and 10 mm. In various implementations, the press plate’s upper region 730 is configured to have a thickness T2 between about 5 mm and 20 mm. In various implementations, the press plate’s protrusion 732 is configured to extend outwardly relative to the lower region portion of the contact surface 714a by a distance T3 (the protrusion thickness) between about 5 mm and 25 mm. In one implementation, the first contact surface 714a has a contact surface height Hl of 112 mm, a lower region height H2 of 5 mm, an upper region protrusion height H3 of 20 mm, a medial region height H4 of 87 mm, and a protrusion thickness T3 of 25 mm.

[0072] In some implementations, the press plate 710 is configured to have a protrusion height aspect ratio reflecting the height of the protrusion 732 relative to the height of the contact surface 714. In various implementations, the protrusion height aspect ratio is defined as the height of the upper region protrusion 732 (H3) divided by the sum of the height of the nonprotruding lower region 720 (H2) and the height of the less-protruding medial region 725 (H4). In various implementations, the press plate 710 has a protrusion height aspect ratio (H3 / (H2+H4)) of 1.0 or less. In one implementation, the press plate 710 has a contact surface height (Hl) of 112 mm, a lower region height (H2) of 5 mm, a medial region height (H4) of 60 mm, and a protrusion height (H3) of 47 mm, yielding a protrusion height aspect ratio (H3 / (H2+H4)) of about 0.72.

[0073] In some implementations, the press plate 710 is configured to have a protrusion thickness aspect ratio reflecting the thickness of the protrusion 732 (T3) relative to the protrusion height (H3). In various implementations, the protrusion thickness aspect ratio is defined as theprotrusion thickness (T3) divided by the height of the upper region protrusion 732 (H3). Tn various implementations, the press plate 710 has a protrusion thickness aspect ratio (T3 / H3) of 0.06 or more. In one implementation, the press plate’s upper region protrusion 732 has a height (H3) of 20 mm and a protrusion thickness (T3) of 25 mm, yielding a protrusion thickness aspect ratio (T3 / H3) of about 1.25.

[0074] As will be appreciated from the description herein, the foregoing description of the features and dimensions of the first press plate 710a may also be provided in the second press plate 710b. For example, in the illustrated implementation of FIGS. 8 and 9, the second press plate 710b has the same dimensions as the first press plate 710a mirrored in an opposing direction.

[0075] FIG. 8 is a side elevation of a compression apparatus 700 according to one implementation. The compression apparatus 700 has the features of the compression apparatus 200 described herein but uses press plates 710a,b with alternative contact surfaces. Accordingly, the compression apparatus 700 includes a first press plate 710a and a second press plate 710b. The two press plates 710a, 710b are spaced-apart and configured to compress a plurality of compressible absorbent articles 100 positioned between the press plates 710a,b.

[0076] The interior faces of the press plates 710a, b define a first contact surface 714a and a second contact surface 714b, respectively. In various implementations, the press plates 710a,b each have the dimensions and features of the first press plate 710a shown and described with respect to FIG. 7. As can be appreciated from FIG. 8, the second press plate 710b has the same dimensions as the first press plate 710a mirrored in an opposing direction.

[0077] The press plates 710a,b are configured to move laterally between a loading position and a compressing position. As shown in FIG. 8, the press plates 710a,b and their respective contact surfaces 714a,b are oriented such that they are horizontally opposed to one another. FIG. 8 shows the press plates 710a,b in the loading position with a stack of compressible absorbent articles 100 disposed between the contact surfaces 714a,b.

[0078] As shown in FIG. 8, the contact surfaces 714a,b are oriented to mirror one another such that each press plate’s protrusion 732 extends into the loading zone in the direction of the opposing contact surface 714a, b. In the illustrated implementation of FIGS. 7-9, in both the loading position and the compression position, the distance between the upper regions 730 of the contact surfaces 714a,b is less than the distance between the medial regions 725 of the contactsurfaces 714a,b, and the distance between the medial regions 725 of the contact surfaces is less than the distance between the lower regions 720 of the contact surfaces 714a,b. In various implementations, in both the loading position and the compressing position, a minimum distance between the upper region 730 of the first contact surface 714a and the upper region 730 of the second contact surface 714b is less than a minimum distance between the medial region 725 of the first contact surface 714a and the medial region 725 of the second contact surface 714b. Additionally, in both the loading position and the compressing position, a minimum distance between the medial region 725 of the first contact surface 714a and the medial region 725 of the second contact surface 714b is less than a minimum distance between the lower region 720 of the first contact surface 714a and the lower region 720 of the second contact surface 714b. In certain implementations, in both the loading position and the compressing position, the maximum distance between the upper region 730 of the first contact surface 714a and the upper region 730 of the second contact surface 714b is less than the minimum distance between the medial region 725 of the first contact surface 214a and the medial region 725 of the second contact surface 714b, and the maximum distance between the medial region 725 of the first contact surface 714a and the medial region 725 of the second contact surface 714b is less than the minimum distance between the lower region 720 of the first contact surface 714a and the lower region 720 of the second contact surface 714b.

[0079] FIG. 9 is a side elevation view of the compression apparatus 700 showing the press plates 710a,b in a compressing position. Directional arrows in FIG. 9 depict the lateral movement of each press plate 710a,b toward the other. As shown in FIG. 9, the contact surfaces 714a,b engage and apply non-uniform compression to the stack of compressible absorbent articles 100.

[0080] As depicted in FIG. 9, an upper region of the stack of compressible absorbent articles 100 is subjected to greater compression than medial and lower regions of the stack of compressible absorbent articles. In the compressing position, the distance between the protrusions 732 of the contact surfaces 714a,b is less than the distance between the medial regions 725 and lower regions 720 of the contact surfaces 714a,b. As a result, the upper regions 730 of the contact surfaces 714a,b apply higher compressive forces to the stack of compressible absorbent articles 100 than the medial regions 725 and lower regions 720. In this way, the press plates 710a,b apply a non-uniform compression to the compressible absorbent articles 100,where an upper region of the stack of compressible absorbent articles (aligned with the upper regions 730 of the contact surfaces 714a,b) is subjected to greater compression than the medial and lower regions of the stack of compressible absorbent articles (aligned with the medial regions 725 and lower regions 720 of the contact surfaces 714a,b).

[0081] During compression by the press plates 710a,b, the length of the upper region of the compressible absorbent article stack is reduced to the distance between the upper region protrusions 732, the length of the medial region of the compressible absorbent article stack is reduced to the distance between the medial regions 725 of the contact surfaces 714a,b, and the length of the lower region of the compressible absorbent article stack is reduced to the distance between the lower regions 720 of the contact surfaces 714a,b. As a result, the upper region of the compressible absorbent article stack will become shorter than the medial region and lower region of the compressible absorbent article stack as the stack is compressed. In other words, as shown in FIG. 9, the width of the upper region of the compressed stack of compressible absorbent articles 100 is less than the width of a medial region and lower region of the compressed stack of compressible absorbent articles 100.

[0082] Due to the length differential between the upper and medial / lower regions of the compressible absorbent article stack, the stack will begin to bow in the direction of the side of the stack that is longer. As shown in FIG. 9, by compressing an upper region of the compressible absorbent article stack more than a medial / lower region (non-uniform compression), the compression apparatus 700 causes the compressible absorbent article stack to bow downwards under compression. As discussed above with respect to FIG. 5, this downward bow of the stack provides for more effective maintenance of stack integrity during compression.

[0083] In certain implementations, the press plates 710a,b are configured to have protrusions 232 configured to engage a certain region of a compressible absorbent article 100. FIG. 10 is a side elevation view of the first press plate 710a positioned adjacent to a compressible absorbent article 100 having the features described with respect to FIG. 6. Accordingly, the compressible absorbent article 100 is schematically depicted with a central plane 114 and uncompressed folded height (HF). As the central plane 114 passes through the center of the compressible absorbent article 100, the central plane 114 is located at a height that is one-half of the folded height (HF).

[0084] As shown in FTG. 10, the compressible absorbent article 100 is positioned on the floor 204 of the compression apparatus 700 adjacent to the first press plate 710a for reference. In the illustrated implementation, the press plate 710a is configured such that the upper region 730 of its first contact surface 214a — which includes the protrusion 732 — is positioned above the central plane 114 of the compressible absorbent article 100. As a result, when a stack of compressible absorbent articles is compressed by the pressed plates 710a, b, the upper region of the stack of compressible absorbent articles (which is subjected to greater compression by the upper region 730 of the contact surfaces 714a, b) is located above a central plane extending through the center of the stack of folded compressible absorbent articles (e.g., the central plane extending through the stack being the same as the central plane 114 shown in FIG. 6). In various implementations, the press plates 710a,b may be configured such that the upper regions 730 of the contact surfaces 714a,b are located at or above the central plane 114 (e.g., at or above a height that is one-half or more of the folded height (HF)).Examples

[0085] To further illustrate the principles of the present disclosure, the following examples are provided for the purpose of additional illustration only and are not intended to limit the scope of the present disclosure in any manner whatsoever.

[0086] Stacks of compressible absorbent articles were subjected to compression by a compression apparatus under varying conditions. A conventional compression apparatus was used having the features of the compression apparatus 200 shown and described with respect to FIGS. 2-5. The compression apparatus’ press plates 210a, b were configured such that the distance D2 between the press plates’ contact surfaces 214a, b (measured at the minimum distance between the protrusions 232) was 456 mm in the loading position and 160 mm in the compression position.

[0087] The compression apparatus 200 was used in nine different configurations. The press plates 210a,b were tested with three different protrusion thicknesses (T3): 6 mm, 12 mm, and 18 mm. For each protrusion thickness (T3), the press plates 210a, b were configured with lower region heights (H2) of 40 mm, 65 mm, and 90 mm.

[0088] The compression apparatus 200 was loaded with stacks of Huggies® Snug &Dry™ Diapers having spunbond meltblown spunbond outer material. The loaded diapers wereeach size 4 having a folded height (HF) of 1 12 mm. When press plates 210a,b having a protrusion thickness (T3) of 6 mm were used, a stack of 35 diapers was loaded into the compression apparatus 200. When press plates 210a, b having a protrusion thickness (T3) of 12 mm were used, a stack of 34 diapers was loaded into the compression apparatus 200. When press plates 210a, b having a protrusion thickness (T3) of 18 mm was used, a stack of 33 diapers were loaded into the compression apparatus 200.

[0089] In each of the nine test configurations, the diaper stacks were compressed as the press plates 210a,b were moved from the loading position (FIG. 4) to the compressing position (FIG. 5). After compression, the diaper stacks were evaluated for integrity. Where the diapers remained aligned in a single stack under compression, the result was rated “CSI” for Complete Stack Integrity. Where the diapers were partially misaligned in a stack under compression, the result was rated “PSI” for Partial Stack Integrity. Where the diaper stack lost integrity (e.g., by one or more diapers blowing out of the stack under compression), the result was rated “LSI” for Loss of Stack Integrity. The results of the tests in each of the nine configurations are shown in Table 1.Table 1*CSI = Complete Stack Integrity maintained under compression *PSI = Partial Stack Integrity maintained under compression *LSI = Loss of Stack Integrity under compression

[0090] As reflected in results shown in Table 1 , complete stack integrity was maintained in all examples where the protrusion thickness (T3) was 18 mm. In other words, where the protrusions 232 extend beyond the lower regions 220 of the contact surfaces 214a,b by 18 mm, the stacks of absorbent compressible articles remained intact under compression.

[0091] When the protrusion thickness (T3) was reduced to 12 mm, complete stack integrity was maintained where the lower region height (H2) was 65 mm and partial stack integrity was maintained when the lower region height (H2) was 90 mm. However, when the lower region height (H2) was reduced to 40 mm, the 12 mm protrusion thickness resulted in a loss of stack integrity. For the tested diapers under compression, the folded height (HF) was 112 mm and, thus, the diapers had a central plane 114 located at a height of 56 mm. Accordingly, where the upper region protrusions 232 of the press plates 210a, b were positioned above the central plane 114 of the diapers (i.e., a lower region height H2 of 56 mm or more), the compression apparatus exhibited improved maintenance of stack integrity.

[0092] In various implementations, thinner protrusion thicknesses (T3) may improve the aesthetic appearance of compressed absorbent articles in comparison to thicker protrusion thicknesses (e.g., by reducing creases or other physical deformation of the compressible absorbent articles). The results in Table 1 therefore indicate that, where the upper region protrusions 232 are positioned above the central plane of the folded compressible absorbent articles, a thinner protrusion thickness (T3) may be used while still maintaining stack integrity under compression.Conclusion

[0093] For purposes of this description, certain advantages and novel features of the aspects and configurations of this disclosure are described herein. The described methods, systems, and apparatus should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed aspects, alone and in various combinations and sub-combinations with one another. The disclosed methods, systems, and apparatus are not limited to any specific aspect, feature, or combination thereof, nor do the disclosed methods, systems, and apparatus require that any one or more specific advantages be present or problems be solved.

[0094] Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above. Such variation may depend, for example, on the software and hardware systems chosen and on designer choice. All such variations are within thescope of the disclosure. Likewise, software implementations of the described methods could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps, and decision steps.

[0095] Features disclosed in this specification (including any accompanying claims, abstract, and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The claimed features extend to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract, and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0096] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description is presented for purposes of illustration and is not intended to be exhaustive or limiting. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure.Example Implementations

[0097] Various example implementations of the disclosure are described below for convenience. These implementations are provided as examples, and do not limit the subject technology.

[0098] Example 1: An apparatus for compressing a stack of compressible absorbent articles, the apparatus comprising: a first press plate having a first contact surface for engaging the stack of compressible absorbent articles, the first contact surface defining an upper region and a lower region; a second press plate having a second contact surface for engaging the stack of compressible absorbent articles, the second contact surface defining an upper region and a lower region; wherein the position of the first press plate relative to the second press plate is adjustable between a loading position and a compressing position such that the first contact surface is nearer to the second contact surface in the compressing position than in the loading position; and wherein, in both the loading position and the compressing position, a minimum distance between the upper region of the first contact surface and the upper region of the secondcontact surface is less than a minimum distance between the lower region of the first contact surface and the lower region of the second contact surface.

[0099] Example 2: The apparatus of Example 1, wherein the maximum distance between the upper region of the first press plate’s contact surface and the upper region of the second press plate’s contact surface is less than the minimum distance between the lower region of the first plate’s contact surface and the second press plate’s contact surface.

[0100] Example 3: The apparatus of Example 1, wherein the first press plate and the second press plate are each configured to move toward and away from one another between the loading position and the compressing position.

[0101] Example 4: The apparatus of Example 1, wherein the upper region of the first contact surface extends from a top edge of the first contact surface to an interface with the lower region of the first contact surface, and the lower region of the first contact surface extends from a bottom edge of the first contact surface to the interface with the upper region of the first contact surface; and wherein the upper region of the second contact surface extends from a top edge of the second contact surface to an interface with the lower region of the second contact surface, and the lower region of the second contact surface extends from a bottom edge of the second contact surface to the interface with the upper region of the second contact surface.

[0102] Example 5 : The apparatus of Example 4, wherein the first contact surface and the second contact surface each span a contact surface height; wherein the interface of the upper region and the lower region of the first contact surface is located at a height from the bottom edge of the first contact surface that is one-half or more of the contact surface height; and wherein the interface of the upper region and the lower region of the second contact surface is located at a height from the bottom edge of the second contact surface that is one-half or more of the contact surface height.

[0103] Example 6: The apparatus of Example 5, wherein the contact surface height is between approximately 50 mm and 160 mm.

[0104] Example 7: The apparatus of Example 6, wherein the height of the first contact surface’s upper region from the top edge of the first contact surface to the interface with the lower region of the first contact surface is between approximately 25 mm and 80 mm; and wherein the height of the second contact surface’s upper region from the top edge of the secondcontact surface to the interface with the lower region of the second contact surface is between approximately 25 mm and 80 mm.

[0105] Example 8: The apparatus of Example 1, wherein the upper region of the first contact surface is substantially flat and the upper region of the second contact surface is substantially flat.

[0106] Example 9: The apparatus of Example 8, wherein the first contact surface and the second contact surface are horizontally opposed; and wherein the upper region of the first contact surface is parallel to the upper region of the second contact surface.

[0107] Example 10: The apparatus of Example 9, wherein the first contact surface further defines a medial region between its upper region and lower region; wherein the second contact surface defines a medial region between its upper region and lower region; wherein, in both the loading position and the compressing position, a minimum distance between the upper region of the first contact surface and the upper region of the second contact surface is less than a minimum distance between the medial region of the first contact surface and the medial region of the second contact surface; and wherein, in both the loading position and the compressing position, a minimum distance between the medial region of the first contact surface and the medial region of the second contact surface is less than a minimum distance between the lower region of the first contact surface and the lower region of the second contact surface.

[0108] Example 11 : The apparatus of Example 10, wherein the upper region of the first contact surface extends from a top edge of the first contact surface to an interface with the medial region of the first contact surface, the medial region of the first contact surface extends from an interface with the upper region of the first contact surface to an interface with the lower region of the first contact surface, and the lower region of the first contact surface extends from a bottom edge of the first contact surface to the interface with the medial region of the first contact surface; and wherein the upper region of the second contact surface extends from a top edge of the second contact surface to an interface with the medial region of the second contact surface, the medial region of the second contact surface extends from an interface with the upper region of the second contact surface to an interface with the lower region of the second contact surface, and the lower region of the second contact surface extends from a bottom edge of the second contact surface to the interface with the medial region of the second contact surface.

[0109] Example 12: The apparatus of Example 11 , wherein the first contact surface and the second contact surface each span a contact surface height; wherein the interface of the upper region and the medial region of the first contact surface is located at a height from the bottom edge of the first contact surface that is one-half or more of the contact surface height; and wherein the interface of the upper region and the medial region of the second contact surface is located at a height from the bottom edge of the second contact surface that is one-half or more of the contact surface height.

[0110] Example 13: The apparatus of Example 10, wherein the medial region of the first contact surface has a curvilinear surface profile and the medial region of the second contact surface has a curvilinear surface profile.

[0111] Example 14: A method for compressing a stack of compressible absorbent articles, the method comprising the steps of: providing a compression apparatus comprising a first press plate and a second press plate; positioning the stack of compressible absorbent articles between the first press plate and the second press plate; and moving at least one of the first press plate and the second press plate to apply non-uniform compression to the stack of compressible absorbent articles, wherein an upper region of the stack of compressible absorbent articles is subjected to greater compression than a lower region of the stack of compressible absorbent articles.

[0112] Example 15: The method of Example 14, wherein a width of the upper region of the compressed stack of absorbent articles is less than a width of a lower region of the compressed stack of absorbent articles.

[0113] Example 16: The method of Example 14, wherein the stack of compressible absorbent articles comprises a plurality of folded absorbent articles stacked contiguously and each having a folded height; and wherein the upper region of the stack of compressible absorbent articles is located above a central plane extending through the center of the folded compressible absorbent articles at a height that is one-half or more of the folded height.

[0114] Example 17: The method of Example 14, wherein the first press plate has a first contact surface for engaging the stack of compressible absorbent articles, the first contact surface defining an upper region and a lower region; wherein the second press plate has a second contact surface for engaging the stack of compressible absorbent articles, the second contact surface defining an upper region and a lower region; wherein the step of moving at least one of the firstpress plate and the second press plate to apply non-uniform compression to the stack of compressible absorbent articles comprises moving the first press plate’s contact surface and the second press plate’s contact surface toward one another to apply non-uniform compression to the stack of compressible absorbent articles.

[0115] Example 18: The method of Example 17, wherein the upper region of the first contact surface and the upper region of the second contact surface apply greater compression to the stack of compressible absorbent articles than the lower region of the first contact surface and the lower region of the second contact surface.

[0116] Example 19: The method of Example 14, wherein the non-uniform compression applied to the stack of compressible absorbent articles causes the stack to bow downwards under compression.

[0117] Example 20: The method of Example 1 , further comprising the step of placing the compressed stack of absorbent articles into a flexible container.

Claims

CLAIMS1. An apparatus for compressing a stack of compressible absorbent articles, the apparatus comprising: a first press plate having a first contact surface for engaging the stack of compressible absorbent articles, the first contact surface defining an upper region and a lower region; a second press plate having a second contact surface for engaging the stack of compressible absorbent articles, the second contact surface defining an upper region and a lower region; wherein the position of the first press plate relative to the second press plate is adjustable between a loading position and a compressing position such that the first contact surface is nearer to the second contact surface in the compressing position than in the loading position; and wherein, in both the loading position and the compressing position, a minimum distance between the upper region of the first contact surface and the upper region of the second contact surface is less than a minimum distance between the lower region of the first contact surface and the lower region of the second contact surface.

2. The apparatus of claim 1, wherein the maximum distance between the upper region of the first press plate’s contact surface and the upper region of the second press plate’s contact surface is less than the minimum distance between the lower region of the first plate’s contact surface and the second press plate’s contact surface.

3. The apparatus of claim 1, wherein the first press plate and the second press plate are each configured to move toward and away from one another between the loading position and the compressing position.

4. The apparatus of claim 1, wherein the upper region of the first contact surface extends from a top edge of the first contact surface to an interface with the lower region of the first contact surface, and the lower region of the first contact surface extends from a bottom edge of the first contact surface to the interface with the upper region of the first contact surface; andwherein the upper region of the second contact surface extends from a top edge of the second contact surface to an interface with the lower region of the second contact surface, and the lower region of the second contact surface extends from a bottom edge of the second contact surface to the interface with the upper region of the second contact surface.

5. The apparatus of claim 4, wherein the first contact surface and the second contact surface each span a contact surface height; wherein the interface of the upper region and the lower region of the first contact surface is located at a height from the bottom edge of the first contact surface that is one-half or more of the contact surface height; and wherein the interface of the upper region and the lower region of the second contact surface is located at a height from the bottom edge of the second contact surface that is one-half or more of the contact surface height.

6. The apparatus of claim 5, wherein the contact surface height is between approximately 50 mm and 160 mm.

7. The apparatus of claim 6, wherein the height of the first contact surface’s upper region from the top edge of the first contact surface to the interface with the lower region of the first contact surface is between approximately 25 mm and 80 mm; and wherein the height of the second contact surface’s upper region from the top edge of the second contact surface to the interface with the lower region of the second contact surface is between approximately 25 mm and 80 mm.

8. The apparatus of claim 1, wherein the upper region of the first contact surface is substantially flat and the upper region of the second contact surface is substantially flat.

9. The apparatus of claim 8, wherein the first contact surface and the second contact surface are horizontally opposed; and wherein the upper region of the first contact surface is parallel to the upper region of the second contact surface.

10. The apparatus of claim 9, wherein the first contact surface further defines a medial region between its upper region and lower region; wherein the second contact surface defines a medial region between its upper region and lower region; wherein, in both the loading position and the compressing position, a minimum distance between the upper region of the first contact surface and the upper region of the second contact surface is less than a minimum distance between the medial region of the first contact surface and the medial region of the second contact surface; and wherein, in both the loading position and the compressing position, a minimum distance between the medial region of the first contact surface and the medial region of the second contact surface is less than a minimum distance between the lower region of the first contact surface and the lower region of the second contact surface.

11. The apparatus of claim 10, wherein the upper region of the first contact surface extends from a top edge of the first contact surface to an interface with the medial region of the first contact surface, the medial region of the first contact surface extends from an interface with the upper region of the first contact surface to an interface with the lower region of the first contact surface, and the lower region of the first contact surface extends from a bottom edge of the first contact surface to the interface with the medial region of the first contact surface; and wherein the upper region of the second contact surface extends from a top edge of the second contact surface to an interface with the medial region of the second contact surface, the medial region of the second contact surface extends from an interface with the upper region of the second contact surface to an interface with the lower region of the second contact surface, and the lower region of the second contact surface extends from a bottom edge of the second contact surface to the interface with the medial region of the second contact surface.

12. The apparatus of claim 11, wherein the first contact surface and the second contact surface each span a contact surface height;wherein the interface of the upper region and the medial region of the first contact surface is located at a height from the bottom edge of the first contact surface that is one-half or more of the contact surface height; and wherein the interface of the upper region and the medial region of the second contact surface is located at a height from the bottom edge of the second contact surface that is one-half or more of the contact surface height.

13. The apparatus of claim 10, wherein the medial region of the first contact surface has a curvilinear surface profile and the medial region of the second contact surface has a curvilinear surface profile.

14. A method for compressing a stack of compressible absorbent articles, the method comprising the steps of: providing a compression apparatus comprising a first press plate and a second press plate; positioning the stack of compressible absorbent articles between the first press plate and the second press plate; and moving at least one of the first press plate and the second press plate to apply non- uniform compression to the stack of compressible absorbent articles, wherein an upper region of the stack of compressible absorbent articles is subjected to greater compression than a lower region of the stack of compressible absorbent articles.

15. The method of claim 14, wherein a width of the upper region of the compressed stack of absorbent articles is less than a width of a lower region of the compressed stack of absorbent articles.

16. The method of claim 14, wherein the stack of compressible absorbent articles comprises a plurality of folded absorbent articles stacked contiguously and each having a folded height; and wherein the upper region of the stack of compressible absorbent articles is located above a central plane extending through the center of the folded compressible absorbent articles at a height that is one-half or more of the folded height.

17. The method of claim 14, wherein the first press plate has a first contact surface for engaging the stack of compressible absorbent articles, the first contact surface defining an upper region and a lower region; wherein the second press plate has a second contact surface for engaging the stack of compressible absorbent articles, the second contact surface defining an upper region and a lower region; wherein the step of moving at least one of the first press plate and the second press plate to apply non-uniform compression to the stack of compressible absorbent articles comprises moving the first press plate’s contact surface and the second press plate’s contact surface toward one another to apply non-uniform compression to the stack of compressible absorbent articles.

18. The method of claim 17, wherein the upper region of the first contact surface and the upper region of the second contact surface apply greater compression to the stack of compressible absorbent articles than the lower region of the first contact surface and the lower region of the second contact surface.

19. The method of claim 14, wherein the non-uniform compression applied to the stack of compressible absorbent articles causes the stack to bow downwards under compression.

20. The method of claim 14, further comprising the step of placing the compressed stack of absorbent articles into a flexible container.

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