The Procter Gamble Company

The Proctor 'gamble Company

Gerald M Weber

James W Richardson

Osman Polat

Thomas Allen Desmarais

William Willhite, Jr

Daniel Joseph Valerio

Kofi Aduwusu

Godfrey Retier

Kenneth B Buell

Gerald A Young

Douglas Herrin Benson

William Robert Vinnage, Jr

Gregory Wade Taylor

Godfrey Reiter

David Albert Sabatelli

Gary Dean La Von

Leonard C Hooper

James R Mick

A method and several exemplary apparatus for capillary dewatering of foam materials. The apparatus may include felt which is applied to an exposed face of the foam material, or a double felt arrangement applied to two opposed surfaces of the foam material. The apparatus may provide a temperature differential between the two exposed surfaces of the foam material. An alternative embodiment utilizes a roll having a capillary dewatering medium. The capillary dewatering medium may be maintained at a vacuum either above or below the breakthrough vacuum of the capillaries. The disclosed apparatus and method is particularly useful for dewatering foams having relatively fine open capillaries.

Process for capillary dewatering of foam materials and foam materials produced thereby

This invention relates to a method and several exemplary apparatus for capillary dewatering of foam materials. The apparatus may include felt which is applied to an exposed face of the foam material, or a double felt arrangement applied to two opposed surfaces of the foam material. The apparatus may provide a temperature differential between the two exposed surfaces of the foam material. An alternative embodiment utilizes a roll having a capillary dewatering medium. The capillary dewatering medium may be maintained at a vacuum either above or below the breakthrough vacuum of the capillaries. The disclosed apparatus and method are particularly useful for dewatering foams having relatively fine open capillaries.

Process for capillary dewatering of foam materials and foam materials

Disclosed is a shaped absorbent core suitable for absorbing and retaining aqueous body fluids. The absorbent cores comprise a front panel and a back panel. The front and back panels are made from fluid absorbent material, and each has an inner end, an outer end, and two sides. The inner and outer ends of each front and back panel have a length, with the inner end of each being shorter than the outer length of each. The front and back panels may comprise multiple layers of absorbent material. The absorbent cores also comprise a center section made from fluid absorbent material having first and second ends. The first end of the center section is in fluid communication with the front panel by overlapping the front panel intermediate the front inner and outer ends, and the second end is in fluid communication with the back panel by overlapping the back panel intermediate the back inner and outer ends. A method of preparing a shaped absorbent core comprises the steps of providing at least one continuous rectilinear web of first absorbent material having a longitudinal axis and a pair of lateral edges defining a first width. A continuous rectilinear web of second absorbent material having a longitudinal axis and a pair of lateral edges defining a second width wider than the first width of the first absorbent material is formed with opposing generally arcuate notched areas in the lateral edges at spaced intervals along the web of second absorbent material. The web of second absorbent material is severed transversely along a line intersecting the opposed generally arcuate notched areas at spaced intervals to form sections having opposed notched ends The sections are then positioned such that the notched ends are spaced apart and overlap the continuous rectilinear web of first absorbent material, forming layers of absorbent material. Then the layers of absorbent material are severed transversely at a point intermediate the notched ends.

Shaped absorbent cores comprising multiple pieces of absorbent material

An improved method and apparatus for incrementally stretching 'zero strain' stretch laminate webs to impart elasticity thereto in the direction of initial stretching, at least up to the point of initial stretching. The 'zero strain' stretch laminate material is formed of at least two plies of material which are either intermittently or substantially continuously secured to one another along at least a portion of their coextensive surfaces while in a substantially untensioned ('zero strain') condition. One of the plies is stretchable and elastomeric, while the second ply is elongatable, but not necessarily elastomeric. The second ply will, upon stretching of the laminate, be at least to a degree permanently elongated so that, upon release of the applied tensile forces, it will not return to its original undistorted configuration. This results in z-direction bulking of the laminate web when the applied tension is released as well as subsequent elastic extensibility in the direction of initial stretching, at least up to the point of initial stretching. In a particularly preferred embodiment of the present invention the opposed peripheral edge portions of the laminate web to be incrementally stretched are subjected to restraint to substantially prevent inwardly directed slippage or contraction thereof in a direction parallel to the direction of stretching. This maximizes the effectiveness of the incremental web stretching operation by forcing the 'zero strain' stretch laminate web to undergo the fullest possible degree of elongation during the incremental stretching operation.

Method for incrementally stretching a zero strain stretch laminate web

A 'zero strain' stretch laminate web exhibiting a non-uniform degree of elasticity, as measured in the direction of elasticization at various points along an axis oriented substantially perpendicular to the direction of elasticization. Improved method and apparatus for non-uniformly stretching 'zero strain' stretch laminate webs to impart elasticity thereto in the direction of stretching, at least up to the point of initial stretching are also disclosed. The 'zero strain' stretch laminate material is formed of at least two plies of material which are either intermittently or substantially continuously secured to one another along at least a portion of their coextensive surfaces while in a substantially untensioned ('zero strain') condition. One of the plies is stretchable and elastomeric, while the second ply is elongatable, but not necessarily elastomeric. The second ply will, upon stretching of the laminate, be at least to a degree permanently elongated so that, upon release of the applied tensile forces, it will not return to its original undistorted configuration. This results in z-direction bulking of the laminate web when the applied tension is released as well as elastic extensibility in the direction of initial stretching, at least up to the point of initial stretching. In a particularly preferred embodiment of the present invention, the mechanical stretching of said laminate web is carried out by passing said laminate web between at least one pair of meshing corrugated rolls, the degree of meshing between said corrugated rolls being non-uniform about the periphery of said rolls, whereby said laminate web is subjected to non-uniform incremental stretching as it passes therebetween to produce a varying degree of elasticity in the resultant web.

Method for incrementally stretching zero strain stretch laminate web in

An improved method and apparatus for incrementally stretching 'zero strain' stretch laminate webs to impart elasticity thereto in the direction of stretching, at least up to the point of initial stretching. The 'zero strain' stretch laminate material is formed of at least two plies of material which are either intermittently or substantially continuously secured to one another along at least a portion of their coextensive surfaces while in a substantially untensioned ('zero strain') condition. One of the plies is stretchable and elastomeric, while the second ply is elongatable, but not necessarily elastomeric. The second ply will, upon stretching of the laminate, be at least to a degree permanently elongated so that, upon release of the applied tensile forces, it will not return to its original undistorted configuration. This results in z-direction bulking of the laminate web when the applied tension is released as well as subsequent elastic extensibility in the direction of initial stretching, at least up to the point of initial stretching. In a particularly preferred embodiment of the present invention, the mechanical stretching operation is carried out by passing said laminate web between multiple pairs of meshing corrugated rolls, each pair of rolls exhibiting a greater degree of meshing than the preceding pair, to sequentially stretch said web in stages. Sequentially stretching the web in the foregoing manner minimizes damage to the web.

Method for sequentially stretching zero strain stretch laminate web to

Method and apparatus for ultrasonically bonding continuously moving webs to one another using a stationary vibrating horn and a relatively slick, non-thermally softenable moving slip layer interposed between the webs to be bonded and the horn to prevent web damage. Interposing the slip layer between the webs to be bonded and the ultrasonic horn improves both the quality and efficiency of web bonding. It reduces friction between the travelling webs and the substantially stationary ultrasonic horn not only due to its relatively slick surface, but also due to the compressive force which the slip layer exerts upon the webs to be bonded. This in turn minimizes jamming and hangups in the very limited clearance existing between the rotating anvil roll and the substantially stationary vibrating ultrasonic horn. In addition, the slip layer maximizes retention of heat either generated in the laminate web by the ultrasonic horn or transferred to the laminate web structure by preheating one or more of the webs. If desired, the slip layer may be comprised of a continuous belt which rotates about the ultrasonic horn. In addition, a secondary slip layer may be provided intermediate the webs to be bonded and the rotating anvil roll to minimize heat transfer from the webs to the anvil roll and to prevent sticking of the webs to the anvil roll. In a particularly preferred embodiment the peripheral edges of the raised anvil bosses are relieved slightly to minimize web tearing and to enhance bond strength. In still another preferred embodiment the anvil roll is heated to a temperature approximating the maximum temperature achieved by the webs being bonded to minimize heat transfer from the webs to the anvil roll during the boding operation. Novel laminate products bonded on-the-fly without the use of an ancillary adhesive may also be produced.

Adhesive-free bonding of continuously moving webs to form laminate web

Method and apparatus for ultrasonically bonding continuously moving webs to one another using a stationary vibrating horn and a relatively slick, non-thermally softenable moving slip layer interposed between the webs to be bonded and the horn to prevent web damage. Interposing the slip layer between the webs to be bonded and the ultrasonic horn improves both the quality and efficiency of web bonding. It reduces friction between the travelling webs and the substantially stationary ultrasonic horn not only due to its relatively slick surface, but also due to the compressive force which the slip layer exerts upon the webs to be bonded. This in turn minimizes jamming and hangups in the very limited clearance existing between the rotating anvil roll and the substantially stationary vibrating ultrasonic horn. In addition, the slip layer maximizes retention of heat either generated in the laminate web by the ultrasonic horn or transferred to the laminate web structure by preheating one or more of the webs. If desired, the slip layer may be comprised of a continuous belt which rotates about the ultrasonic horn. In addition, a secondary slip layer may be provided intermediate the webs to be bonded and the rotating anvil roll to minimize heat transfer from the webs to the anvil roll and to prevent sticking of the webs to the anvil roll. In a particularly preferred embodiment the peripheral edges of the raised anvil bosses are relieved slightly to minimize web tearing and to enhance bond strength. In still another preferred embodiment the anvil roll is heated to a temperature approximating the maximum temperature achieved by the webs being bonded to minimize heat transfer from the webs to the anvil roll during the bonding operation. Novel laminate products bonded on-the-fly without the use of an ancillary adhesive may also be produced.

An apparatus for unwinding a roll of web material which is prone to blocking: for example, an elastomeric film which, while rolled, is prone to having the convolutions of the roll stick together. The apparatus induces a sufficiently high rate of strain in a short span adjacent the roll to effect continuously peeling the outermost convolution from the roll. Additionally, the apparatus is of such a geometry that, in the event blocking precipitates circumferential shifting of the point of web separation from the roll, the stripping angle is increased. This, in turn, increases the effectiveness of the rate of strain induced peeling force on the web whereby more positive peeling occurs.

Apparatus for unwinding a roll of blocking-prone web material

An interconnected web of disposable diapers containing a pair of continuous, stretched strands of elastic aligned generally parallel to the direction of web travel, is folded along its length from a substantially flat condition to produce a C-shaped, transverse cross-section by means of a conventional board and guide folder. The C-folded web is maintained under tension during the longitudinal folding operation to keep the continuous elastic strands in a stretched condition, and the web is cut transverse to the direction of web travel without releasing the tension in either the individual diapers cut from the web or in the advancing web. Means are provided for transversely folding the individual diapers cut from the web about their midpoints while maintaining the elastic strands associated therewith in a stretched condition and the diaper under positive control. Because the advancing web of interconnected diapers is maintained under positive control at all times, the individual diapers severed from the web are cut in register with respect to one another. This is of critical importance in situations where the web of interconnected disposable diapers is comprised of a plurality of discrete, interconnected diaper segments rather than a continuous web of disposable diaper material having a uniform cross-section throughout its length.

Growing community of inventors

Loveland, OH, United States of America

Gerald M Weber