Mcneil-ppc, Inc.

Personal Products Company

Johnson & Johnson Gmbh

Michael J Menard

Dennis C Holtman

Thomas J Helmstetter

David E Johnson

Paul Y Fung

Henri Brisebois

Peter W Jackson

John D Spano

Philip Joseph Marbach

James C Johns

An absorbent article is provided for use in the perineal area of the body. Compliant sealing gaskets are pre-formed to extend outward from the central portion of the article. The gaskets may be formed by looping a strip of material so as to form a compliant cuff which bears against the user's body in a comfortable manner. An elastic member placed in tension so as to impart an arcuate shape to the article may be placed inside a cavity formed by the cuff. The gaskets may be applied to an article having wings attached to the central portion so as to form pockets for retaining the elasticized portions of the panty crotch. The proximal ends of the gaskets are disposed outward of the pockets and the distance between the pockets is less than the width of the panty crotch so that the body facing said of the article is placed in tension.

Absorbent article having pre-formed compliant gaskets

A method and apparatus is provided for forming and attaching tabs to an absorbent article worn in the perineal portion of the body, such as sanitary napkins. A strip of tab material is cut into two tab strips by making an approximately sinusoidal shaped longitudinal cut using a rotary die. The tab strips are then inverted so the tabs face outward and aligned so that the tabs are in-line. The tab strips are then cut into tab pairs and attached to a strip of absorbent article using an adhesive. In an alternate embodiment, the tab pairs are first attached to a layer of material which is then attached to a second layer of material on which an absorbent core is disposed, thereby enclosing the absorbent core. An absorbent article made by the aforementioned method and apparatus is also provided. The article has a central portion and tabs attached to the portions of the longitudinally extending sides of the central portion which are adjacent the body facing said of the article, thereby preferentially creating tension in the pervious cover forming the body facing side and inducing compressive forces acting on the absorbent core which aid it in resisting lateral deformation. The central portion has an article release strip covering pressure sensitive adhesive strips on its garment facing side and the tabs have tab release strips covering pressure sensitive adhesive strips on their garment facing sides. The tabs are disposed over the garment facing side of the central portion and adhesive is applied between the article release strip and tab release strips, attaching each to the other so that both the article release strip and the tab release strips can be removed by a single pull on the article release strip.

Absorbent article with attached tabs and method and apparatus for making same

A novel method for manufacturing a layer of a laminated, disposable absorbent product, such as a fluid-permeable cover layer, an absorbent core layer or a fluid-impervious backing layer thereof, with a comparatively small amount of waste matter. The method comprises the steps of longitudinally cutting a continuous web of starting material according to a cyclic pattern constructed with line segments corresponding to the edge contour of the disposable absorbent product. The cutting operation divides the continuous web in two strips, each strip having a patterned longitudinal edge whose outline corresponds to the cyclic pattern. The strips are crossed and joined to one another in a parallel and in a phase relationship to form a compound web having longitudinal edges producing repeatedly the edge contour of the disposable absorbent product. The invention extends to integrating this method into an operation for manufacturing disposable absorbent products, and to a novel apparatus for carrying out the methods according to the invention and the resulting products.

Method of making a no waste absorbent product

An absorbent article is provided for use in the perineal area of the body having an absorbent core having an upper body facing surface, a lower garment facing surface, first and second longitudinal sides, and first and second transverse ends. A body fluid impervious sealing wrapper, having upper and lower portions each having longitudinally and transversely extending edges along which said portions are joined, is formed around the absorbent core so as to enclose at least the entirety of the garment facing surface, the longitudinal sides and the transverse ends, thereby forming a seal. A centrally disposed opening is formed in the upper portion of the sealing wrapper thereby forming a window on the body facing surface of the absorbent core that exposes it to fluid flow. A fluid pervious layer covers at least the portion of the body facing surface on which the window is formed. The upper portion of the sealing wrapper and the pervious layer are joined so as to form a laminated layer. In another embodiment, the window is formed in a fibrous non-woven fabric that covers the longitudinal sides of the absorbent core and the window is covered by an apertured plastic film.

Method of making an absorbent article having strike window

Absorbent article having strike window

An absorbent article is provided having an apparatus attached to its garment facing side which allows the article to be attached to, and yet float on, an undergarment and which also serves to distribute the forces imposed on the article by the user's body over a large portion of the article and to transmit the forces to the undergarment, thereby increasing the geometric stability and shape maintenance of the article. The apparatus comprises a semi-rigid elastic frame formed from a thin plastic sheet and having two longitudinally extending members connected by at least one transversely extending member. Inwardly extending tabs for attaching the article to an undergarment are disposed at the mid-point of each longitudinally extending member. The longitudinally and transversely extending members may be pre-formed to give the article an arcuate shape. When applied to a winged article, the frame may also have outwardly extending tabs, disposed opposite each of the inwardly extending tabs, for properly positioning the wings.

Absorbent article having a deformation resisting apparatus

Improved methods and apparatus for forming absorbent products and the improved absorbent products formed thereby are disclosed. In a first embodiment of the present invention, a rotary die is used to cut ellipsoidal and hyperbolic-shaped from a single sheet of material and these shapes are overlaid to form an absorbent structure. The shapes are chosen such that there is no waste of the material and yet the resulting absorbent structure is of a useful shape. Methods are also disclosed whereby two sets of rotary dies are used to simultaneously cut two sheets of material into an arcuate segment and the arcuate segments are overlaid atop each other to form useful absorbent structures. In either embodiment, powders such as superabsorbents may be added to one or more of the surfaces of the components used to construct the absorbent structures.

Methods and apparatus for making multi-layer absorbent products

A method for making an absorbent article, such as a sanitary napkin, having tabs. A first series of patches of a hot melt type pressure sensitive adhesive are applied to one side of a double-sided release strip. The release strip is then placed against the central portion of the absorbent article so that the first adhesive patches bond to the central portion. A second series of patches of the adhesive are applied to the other side of the double-sided release strip and tabs are folded over the central portion so that the second adhesive patches bond to the tabs. Since the release strip has been coated with a release agent, such as silicone, on both of its sides, the first and second patches of adhesive bond to the central portion and the tabs, respectively, with greater tenacity than they did to the release strip. When the user removes the release strip prior to use, the first and second adhesive patches remain on the central portion and the tabs. Thus, a hot melt type of pressure sensitive adhesive is applied to the central portion and the tabs without danger that they will be scorched by the heat of the hot melt adhesive as it leaves the glue gun.

Method of attaching adhesive to a tabbed absorbent article

A method and apparatus for producing fibrous web pieces by die cutting the pieces from a continuous web. In the method, a fibrous web is provided having adjacent corrugations usually filled with a powder, and the powder-filled web is passed through a matched cutting die set intermittently which cuts and punches out the individual web pieces. Following the web cut out step, the web pieces are transferred downwardly onto a shuttle conveyor, and the pieces moved forward and simultaneously spread apart to permit subsequent convenient placement of the pieces. The cutting die apparatus includes matched punch and body die units which closely interfit with less than about 0.001 inch total clearance, so as to cut and punch out the fibrous web pieces from the continuous web.

Method and apparatus for producing fibrous web pieces

A method and apparatus for incorporating a powder into a continuous fibrous web containing multiple corrugations. In the method, a fibrous web provided with multiple parallel corrugations is continuously passed over a curved surface having an arc with a radius to web thickness ratio of 0.5-3 and the corrugations are opened at their upper side, while any bonded fibers connecting adjacent corrugations together are broken apart. A powder having 50-1000 micron particle size is deposited by gravity into the opened spaces between adjacent corrugations of the web. The deposited powder is then compacted into the fibrous corrugated web by rubbing with a pad moved in an oscillating motion generally perpendicular to the corrugations. The powder filled web is bent in the opposite direction around a roller to break the fibers between the corrugations on the opposite side of the web. The second roller can be made vertically movable so as to convert the web continuous forward motion to an intermittent forward motion.

Method and apparatus for providing powder into fibrous web structures

An improved method and apparatus for rapidly forming plastic foam shells from a flexible foam sheet. The foam sheet is intermittently passed through a radiant heating unit and is rapidly heated on both sides to 130.degree.-250.degree. F. to soften the foam. The heated foam sheet is immediately passed through a forming die unit in which the foam sheet is deformed partly into the die cavity by withdrawal of air from the cavity, and a die plug descends and final forms a shell while rapidly cooling the foam shell to below its plastic deformation temperature. By this forming method and apparatus, ethylene-containing foam shells having a depth 10-25 times the foam sheet initial thickness are rapidly formed at 10-30 cycles/minute.

Thermoforming flexible plastic foam shells

A method and apparatus for incorporating a powder into a continuous fibrous web containing multiple corrugations. In the method, a fibrous web provided with multiple parallel corrugations is continuously passed over a curved surface having an arc with a radius to web thickness ratio of 0.5-3 and the corrugations are opened at their upper side. While any bonded fibers connecting adjacent corrugations together are broken apart. A powder having 50-1000 micron particle size is deposited by gravity into the opened spaces between adjacent corrugations of the web. The deposited powder is then compacted into the fibrous corrugated web by rubbing with a pad moved in an oscillating motion generally perpendicular to the corrugations. The powder filled web is bent in the opposite direction around a roller to break the fibers between the corrugations on the opposite side of the web. The second roller can be made vertically movable so as to convert the web continuous forward motion to an intermittent forward motion.

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Doylestown, PA, United States of America

Michael J Menard