CA2233236C - A method for selectively aperturing a nonwoven web - Google Patents
A method for selectively aperturing a nonwoven web Download PDFInfo
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- CA2233236C CA2233236C CA002233236A CA2233236A CA2233236C CA 2233236 C CA2233236 C CA 2233236C CA 002233236 A CA002233236 A CA 002233236A CA 2233236 A CA2233236 A CA 2233236A CA 2233236 C CA2233236 C CA 2233236C
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- nonwoven web
- web
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- weakened
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Classifications
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/24—Perforating by needles or pins
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
- A61F13/15731—Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F3/00—Severing by means other than cutting; Apparatus therefor
- B26F3/002—Precutting and tensioning or breaking
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
- Y10T428/24331—Composite web or sheet including nonapertured component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24826—Spot bonds connect components
Landscapes
- Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Mechanical Engineering (AREA)
- Forests & Forestry (AREA)
- Public Health (AREA)
- Epidemiology (AREA)
- Biomedical Technology (AREA)
- Heart & Thoracic Surgery (AREA)
- Vascular Medicine (AREA)
- Animal Behavior & Ethology (AREA)
- General Health & Medical Sciences (AREA)
- Veterinary Medicine (AREA)
- Manufacturing & Machinery (AREA)
- Absorbent Articles And Supports Therefor (AREA)
- Orthopedics, Nursing, And Contraception (AREA)
- Treatment Of Fiber Materials (AREA)
- Nonwoven Fabrics (AREA)
Abstract
The present invention provides a method for selectively aperturing a nonwove n web (102). A nonwoven web (102) is weakened along a plurality of locations a nd then a tensioning force is applied to the nonweven web (102) causing the nonwoven web (102) to rupture at the plurality of weakened location creating a plurality of apertures in the nonwoven web (102) coincident with the weakene d locations.
Description
2 PCT/US96/14643 ,, A METHOD FOR SELECTIVELY
s APERTURING A NONWOVEN WEB
~o FIELD OF INVENTION
The present invention relates to apertured nonwoven webs and a method of making the same. Apertured nonwoven webs are particularly well suited for use in is disposable absorbent articles such as diapers, incontinence briefs, training pants, feminine hygiene garments, and the like.
BACKGROUND OF THE INVENTION
Nonwoven webs formed by nonwoven extrusion processes such as, for 2o example, meltblowing processes and spunbonding processes may be manufactured into products and components of products so inexpensively that the products could be viewed as disposable after only one or a few uses. Representatives of such products include disposable absorbent articles, such as diapers, incontinence briefs, training pants, feminine hygiene garments, and the like.
is Infants and other incontinent individuals wear disposable absorbent articles such as diapers to receive and contain urine and other body exudates.
Absorbent articles function both to contain the discharged materials and to isolate these materials from the body of the wearer and from the wearer's garments and bed clothing. Disposable absorbent articles having many different basic designs are 3o known to the art.
A typical absorbent article includes a liquid pervious topsheet, a liquid impervious backsheet joined to the topsheet, and an absorbent core positioned between the topsheet and the backsheet. Nonwoven webs are often used as the topsheet because they are liquid pervious and provide a skin friendly surface.
3s However, in certain uses nonwoven webs do not function all that well as a topsheet as body exudates sometimes hang-up or get caught in the nonwoven web and thus, become trapped against the wearer's skin. One solution to the aforementioned problem is to provide apertures in the nonwoven web so that body exudates may readily penetrate through the nonwoven web and into the underlying absorbent core.
Unfortunately. certain techniques used to form apertured nonwoven webs are either costly, create an undesirable harsh feeling against the wearer's skin, or are subject to tearing, particularly when the apertured nonwoven web is to be used as a topsheet on .
s a disposable absorbent article.
As used herein, the term "nonwoven web", refers to a web that has a structure of individual fibers or threads which are interlaid, but not in any regular, repeating manner. Nonwoven webs have been, in the past. formed by a variety of processes, such as, for example, meltblowing processes, spunbonding processes and ~ o bonded carded web processes.
As used herein, the term "microfibers", refers to small diameter fibers having an average diameter not greater than about 100 microns.
As used herein, the term "meltblown fibers", refers to fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually is circular, die capillaries as molten threads or filaments into a high velocity gas (e.g., air) stream which attenuates the filaments of molten thermoplastic material to reduce their diameter, which may be to a microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers.
2o As used herein, the term "spunbonded fibers", refers to small diameter fibers which are formed by extruding a molten thermoplastic material as filaments from a plurality of fine, usually circular, capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced as by, for example, eductive drawing or other well-known spunbonding mechanisms.
zs As used herein, the term "polymer" generally includes, but is not limited to, hompolymers, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof.
Furthermore, unless otherwise specifically limited, the term "polymer" shall include all possible geometrical configurations of the material. These configurations 3o include, but are not limited to, isotactic, syndiaotactic and random symmetries.
As used herein, the term "elastic" refers to any material which, upon application of a biasing force, is stretchable, that is, elongatable, at least about 60 percent (i.e., to a stretched, biased length, which is at least about 160 percent of its relaxed unbiased length), and which, will recover at least 55 percent of its elongation ss upon release of the stretching, elongation force. A hypothetical example would be a one ( 1 ) inch sample of a material which is elongatable to at least 1.60 inches, and WO 97/11662 PC'lC/US96/14643 which, upon being elongated to 1.60 inches and released, will recover to a length of not more than 1.27 inches. Many elastic materials may be elongated by more than 60 percent (i.e., much more than 160 percent of their relaxed length), for example, elongated 100 percent or more, and many of these materials will recover to s substantially their initial relaxed length, for example, to within 105 percent of their initial relaxed length, upon release of the stretch force.
As used herein, the term "nonelastic" refers to any material which does not fall within the definition of "elastic" above.
As used herein, the term "extensible" refers to any material which, upon io application of a biasing force, is elongatable, at least about 50 percent without experiencing catastrophic failure.
As used herein, the term "melt-stabilized" refers to portions of a nonwoven web which have been subjected to localized heating and/or localized pressure to substantially consolidate the fibers of the nonwoven web into a stabilized film-like ~ s form.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a method for selectively aperturing a nonwoven web comprising the steps of-.
2o providing a nonwoven web;
weakening the nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations; and applying a tensioning force to the nonwoven web to cause the nonwoven web to rupture at the plurality of weakened, melt-stabilized locations creating a plurality of 2s apertures in the nonwoven web coincident with said weakened, melt-stabilized locations.
The nonwoven web may include bonded carded webs, spunbonded webs, or meltblown webs. The meltblown web may include meltblown microfibers. The nonwoven web may also have multiple layers such as, for example, multiple 3o spunbonded layers and/or multiple meltblown layers. The nonwoven material may be made of polymers such as, for example, polyolefins. Exemplary polyolefins include polypropylene, polyethylene, ethylene copolymers and propylene copolymers. The nonwoven web may be an elastic nonwoven web. a nonelastic nonwoven web or an extensible nonwoven web.
s APERTURING A NONWOVEN WEB
~o FIELD OF INVENTION
The present invention relates to apertured nonwoven webs and a method of making the same. Apertured nonwoven webs are particularly well suited for use in is disposable absorbent articles such as diapers, incontinence briefs, training pants, feminine hygiene garments, and the like.
BACKGROUND OF THE INVENTION
Nonwoven webs formed by nonwoven extrusion processes such as, for 2o example, meltblowing processes and spunbonding processes may be manufactured into products and components of products so inexpensively that the products could be viewed as disposable after only one or a few uses. Representatives of such products include disposable absorbent articles, such as diapers, incontinence briefs, training pants, feminine hygiene garments, and the like.
is Infants and other incontinent individuals wear disposable absorbent articles such as diapers to receive and contain urine and other body exudates.
Absorbent articles function both to contain the discharged materials and to isolate these materials from the body of the wearer and from the wearer's garments and bed clothing. Disposable absorbent articles having many different basic designs are 3o known to the art.
A typical absorbent article includes a liquid pervious topsheet, a liquid impervious backsheet joined to the topsheet, and an absorbent core positioned between the topsheet and the backsheet. Nonwoven webs are often used as the topsheet because they are liquid pervious and provide a skin friendly surface.
3s However, in certain uses nonwoven webs do not function all that well as a topsheet as body exudates sometimes hang-up or get caught in the nonwoven web and thus, become trapped against the wearer's skin. One solution to the aforementioned problem is to provide apertures in the nonwoven web so that body exudates may readily penetrate through the nonwoven web and into the underlying absorbent core.
Unfortunately. certain techniques used to form apertured nonwoven webs are either costly, create an undesirable harsh feeling against the wearer's skin, or are subject to tearing, particularly when the apertured nonwoven web is to be used as a topsheet on .
s a disposable absorbent article.
As used herein, the term "nonwoven web", refers to a web that has a structure of individual fibers or threads which are interlaid, but not in any regular, repeating manner. Nonwoven webs have been, in the past. formed by a variety of processes, such as, for example, meltblowing processes, spunbonding processes and ~ o bonded carded web processes.
As used herein, the term "microfibers", refers to small diameter fibers having an average diameter not greater than about 100 microns.
As used herein, the term "meltblown fibers", refers to fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually is circular, die capillaries as molten threads or filaments into a high velocity gas (e.g., air) stream which attenuates the filaments of molten thermoplastic material to reduce their diameter, which may be to a microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers.
2o As used herein, the term "spunbonded fibers", refers to small diameter fibers which are formed by extruding a molten thermoplastic material as filaments from a plurality of fine, usually circular, capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced as by, for example, eductive drawing or other well-known spunbonding mechanisms.
zs As used herein, the term "polymer" generally includes, but is not limited to, hompolymers, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof.
Furthermore, unless otherwise specifically limited, the term "polymer" shall include all possible geometrical configurations of the material. These configurations 3o include, but are not limited to, isotactic, syndiaotactic and random symmetries.
As used herein, the term "elastic" refers to any material which, upon application of a biasing force, is stretchable, that is, elongatable, at least about 60 percent (i.e., to a stretched, biased length, which is at least about 160 percent of its relaxed unbiased length), and which, will recover at least 55 percent of its elongation ss upon release of the stretching, elongation force. A hypothetical example would be a one ( 1 ) inch sample of a material which is elongatable to at least 1.60 inches, and WO 97/11662 PC'lC/US96/14643 which, upon being elongated to 1.60 inches and released, will recover to a length of not more than 1.27 inches. Many elastic materials may be elongated by more than 60 percent (i.e., much more than 160 percent of their relaxed length), for example, elongated 100 percent or more, and many of these materials will recover to s substantially their initial relaxed length, for example, to within 105 percent of their initial relaxed length, upon release of the stretch force.
As used herein, the term "nonelastic" refers to any material which does not fall within the definition of "elastic" above.
As used herein, the term "extensible" refers to any material which, upon io application of a biasing force, is elongatable, at least about 50 percent without experiencing catastrophic failure.
As used herein, the term "melt-stabilized" refers to portions of a nonwoven web which have been subjected to localized heating and/or localized pressure to substantially consolidate the fibers of the nonwoven web into a stabilized film-like ~ s form.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a method for selectively aperturing a nonwoven web comprising the steps of-.
2o providing a nonwoven web;
weakening the nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations; and applying a tensioning force to the nonwoven web to cause the nonwoven web to rupture at the plurality of weakened, melt-stabilized locations creating a plurality of 2s apertures in the nonwoven web coincident with said weakened, melt-stabilized locations.
The nonwoven web may include bonded carded webs, spunbonded webs, or meltblown webs. The meltblown web may include meltblown microfibers. The nonwoven web may also have multiple layers such as, for example, multiple 3o spunbonded layers and/or multiple meltblown layers. The nonwoven material may be made of polymers such as, for example, polyolefins. Exemplary polyolefins include polypropylene, polyethylene, ethylene copolymers and propylene copolymers. The nonwoven web may be an elastic nonwoven web. a nonelastic nonwoven web or an extensible nonwoven web.
3~
3a In accordance with one embodiment of the present invention, there is provided a method for selectively aperturing a nonwoven web comprising the steps of a) providing a nonwoven web;
b) weakening the nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations;
c) providing an incremental stretching means; and d) subjecting the nonwoven web to incremental stretching by the incremental stretching means causing the nonwoven web to rupture at the plurality of weakened, melt-stabilized locations creating a plurality of apertures in the nonwoven web coincident with the plurality of weakened, melt-stabilized locations.
In accordance with another embodiment of the present invention, there is provided a method for selectively aperturing a bonded nonwoven web comprising the steps of a) providing a nonwoven web;
b) weakening the nonwoven web without rupturing the nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations;
c) providing an incremental stretching means; and d) subjecting the nonwoven web to incremental stretching by the incremental stretching means causing the nonwoven web to rupture at the plurality of weakened, melt-stabilized locations creating a plurality of apertures in the nonwoven web coincident with the plurality of weakened, melt-stabilized locations.
In accordance with another embodiment of the present invention, there is provided a nonwoven web made according to a method comprising the steps of:
a) providing a nonwoven web, wherein the nonwoven web is provided with a 3b patterned plurality of spaced apart discrete bonds to form a coherent web structure;
b) weakening the nonwoven web at a plurality of locations to create a plurality S of weakened, melt-stabilized locations, wherein a portion of the spaced apart descrete bonds are separated from the melt-stabilized locations; and c) applying a tensioning force to the nonwoven web to cause the nonwoven web to rupture at the plurality of weakened, melt-stabilized locations so as to create a plurality of apertures in the nonwoven web coincident with the plurality of weakened, melt-stabilized locations, the apertures having a circumferential edge, a portion of which edge is defined by a remnant of the melt stabilized locations, without substantially rupturing any of the spaced apart discrete separated bonds that are from the melt stabilized locations.
In accordance with another embodiment of the present invention, there is provided a fibrous nonwoven web comprising a plurality of apertures formed by application of a tensioning force, the apertures coincident with a plurality of weakened, melt-stabilized locations, the apertures having a circumferential edge, a portion of the circumferential edge being defined by a remnant of the melt-stabilized locations and further comprising a patterned plurality of spaced apart discrete bonds, wherein the spaced apart discrete bonds are separated from the melt stabilized locations, and further wherein the fibers are joined by the spaced apart discrete bonds to form a coherent web structure, the spaced apart discrete bonds being substantially unruptured by the application of the tensioning force.
3a In accordance with one embodiment of the present invention, there is provided a method for selectively aperturing a nonwoven web comprising the steps of a) providing a nonwoven web;
b) weakening the nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations;
c) providing an incremental stretching means; and d) subjecting the nonwoven web to incremental stretching by the incremental stretching means causing the nonwoven web to rupture at the plurality of weakened, melt-stabilized locations creating a plurality of apertures in the nonwoven web coincident with the plurality of weakened, melt-stabilized locations.
In accordance with another embodiment of the present invention, there is provided a method for selectively aperturing a bonded nonwoven web comprising the steps of a) providing a nonwoven web;
b) weakening the nonwoven web without rupturing the nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations;
c) providing an incremental stretching means; and d) subjecting the nonwoven web to incremental stretching by the incremental stretching means causing the nonwoven web to rupture at the plurality of weakened, melt-stabilized locations creating a plurality of apertures in the nonwoven web coincident with the plurality of weakened, melt-stabilized locations.
In accordance with another embodiment of the present invention, there is provided a nonwoven web made according to a method comprising the steps of:
a) providing a nonwoven web, wherein the nonwoven web is provided with a 3b patterned plurality of spaced apart discrete bonds to form a coherent web structure;
b) weakening the nonwoven web at a plurality of locations to create a plurality S of weakened, melt-stabilized locations, wherein a portion of the spaced apart descrete bonds are separated from the melt-stabilized locations; and c) applying a tensioning force to the nonwoven web to cause the nonwoven web to rupture at the plurality of weakened, melt-stabilized locations so as to create a plurality of apertures in the nonwoven web coincident with the plurality of weakened, melt-stabilized locations, the apertures having a circumferential edge, a portion of which edge is defined by a remnant of the melt stabilized locations, without substantially rupturing any of the spaced apart discrete separated bonds that are from the melt stabilized locations.
In accordance with another embodiment of the present invention, there is provided a fibrous nonwoven web comprising a plurality of apertures formed by application of a tensioning force, the apertures coincident with a plurality of weakened, melt-stabilized locations, the apertures having a circumferential edge, a portion of the circumferential edge being defined by a remnant of the melt-stabilized locations and further comprising a patterned plurality of spaced apart discrete bonds, wherein the spaced apart discrete bonds are separated from the melt stabilized locations, and further wherein the fibers are joined by the spaced apart discrete bonds to form a coherent web structure, the spaced apart discrete bonds being substantially unruptured by the application of the tensioning force.
4 BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the invention will be better understood from the s following description which is taken in conjunction with the accompanying drawings in which like designations are used to designate substantially identical elements, and in which:
FIG. 1 is a plan view of a disposable diaper embodiment of the present invention having portions cut away to reveal underlying structure, the inner surface io of the diaper is facing the viewer;
FIG. 2 is a schematic representation of an exemplary process for selectively aperturing a nonwoven web of the present invention;
FIG. 3 is an enlarged perspective illustration of a web weakening arrangement of the present invention;
Is FIG. 4 is an enlarged perspective illustration of an incremental stretching system of the present invention;
FIG. 5 is a schematic representation of another process for selectively aperturing a nonwoven web of the present invention;
FIG. 6 is an enlarged perspective illustration of another web weakening zo arrangement of the present invention;
FIG. 7 is an enlarged plan view photograph of a nonwoven web prior to being weakened;
FIG. 8 is an enlarged plan view photograph of a nonwoven web of the present invention after the nonwoven web has been weakened at a plurality of 2s locations; and FIG. 9 is an enlarged plan view photograph of a nonwoven web of the present invention after tension has been applied to rupture the nonwoven web at the weakened locations to create apertures in the nonwoven.
3o DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term "absorbent article" refers to devices which absorb ' and contain body exudates, and, more specifically, refers to devices which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. The term "disposable" is used herein to 3s describe absorbent articles which are not intended to be laundered or otherwise restored or reused as an absorbent article (i.e., they are intended to be discarded after a single use and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner). A "unitary" absorbent article refers to absorbent articles which are formed of separate parts united together to form a coordinated entity so that they do not require separate manipulative parts like a s separate holder and liner. A preferred embodiment of an absorbent article of the present invention is the unitary disposable absorbent article, diaper 20, shown in Figure I. As used herein, the term "diaper" refers to an absorbent article generally worn by infants and incontinent persons that is worn about the lower torso of the wearer. It should be understood, however, that the present invention is also ~o applicable to other absorbent articles such as incontinence briefs, incontinence undergarments, diaper holders and liners, feminine hygiene garments, training pants, and the like.
Figure 1 is a plan view of the diaper 20 of the present invention in its flat out, uncontracted state (i.e., with elastic induced contraction pulled out) with is portions of the structure being cut-away to more clearly show the construction of the diaper 20 and with the portion of the diaper 20 which faces the wearer, the inner surface 40, facing the viewer. As shown in Figure l, the diaper 20 preferably comprises a containment assembly 22 comprising a liquid pervious topsheet 24;
a liquid impervious backsheet 26 joined to the topsheet; and an absorbent core 2o positioned between the topsheet 24 and the backsheet 26. The diaper preferably further comprises elasticized side panels 30; elasticized leg cuffs 32;
elasticized waistbands 34; and a fastening system 36 preferably comprising a pair of securement members 37 and a landing member, (not shown).
The diaper 20 is shown in Figure I to have an inner surface 40 (facing the 2s viewer in Figure 1), an outer surface 42 opposed to the inner surface 40, a rear waist region 44, a front waist region 46 opposed to the rear waist region 44, a crotch region 48 positioned between the rear waist region 44 and the front waist region 46, and a periphery which is defined by the outer perimeter or edges of the diaper 20 in which the longitudinal edges are designated 50 and the end edges are designated 52.
3o The inner surface 40 of the diaper 20 comprises that portion of the diaper 20 which is positioned adjacent to the wearer's body during use (i.e., the inner surface 40 generally is formed by at least a portion of the topsheet 24 and other components joined to the topsheet 24). The outer surface 42 comprises that portion of the diaper 20 which is positioned away from the wearer's body (i.e., the outer surface 42 is 3s generally formed by at least a portion of the backsheet 26 and other components joined to the backsheet 26). As used herein, the term "joined" encompasses configurations whereby an element is directly secured to the other element by affixing the element directly to the other element, and configurations whereby the element is indirectly secured to the other element by affixing the element to intermediate members) which in turn are affixed to the other element. The rear s waist region 44 and the front waist region 46 extend from the end edges 52 of the periphery to the crotch region 48.
The diaper 20 also has two centerlines, a longitudinal centerline 90 and a transverse centerline 92. The term "longitudinal", as used herein, refers to a line, axis, or direction in the plane of the diaper 20 that is generally aligned with (e.g.
io approximately parallel with) a vertical plane which bisects a standing wearer into left and right halves when the diaper 20 is worn. The terms "transverse" and "lateral", as used herein, are interchangeable and refer to a line, axis or direction which lies within the plane of the diaper that is generally perpendicular to the longitudinal direction (which divides the wearer into front and back body halves).
is The containment assembly 22 of the diaper 20 is shown in Figure 1 as comprising the main body (chassis) of the diaper 20. The containment assembly comprises at least topsheet 24, backsheet 26 and absorbent core 28. When the absorbent article comprises a separate holder and a liner, the containment assembly 22 generally comprises the holder and the liner (i.e., the containment assembly 22 2o comprises one or more layers of material to define the holder while the liner comprises an absorbent composite such as a topsheet, a backsheet, and an absorbent core.) For unitary absorbent articles, the containment assembly 22 comprises the main structure of the diaper with other features added to form the composite diaper structure. Thus, the containment assembly 22 for the diaper 20 generally comprises is the topsheet 24, the backsheet 26, and the absorbent core 28.
Figure 1 shows a preferred embodiment of the containment assembly 22 in which the topsheet 24 and the backsheet 26 have length and width dimensions generally larger than those of the absorbent core 28. The topsheet 24 and the backsheet 26 extend beyond the edges of the absorbent core 28 to thereby form the 3o periphery of the diaper 20. While the topsheet 24, the backsheet 26, and the absorbent core 28 may be assembled in a variety of well known configurations, w exemplary containment assembly configurations are described generally in U.S.
' Patent 3,860,003 entitled "Contractible Side Portions for Disposable Diaper"
which issued to Kenneth B. Buell on January 14, 1975; and U.S. Patent 5,151,092 entitled ss "Absorbent Article With Dynamic Elastic Waist Feature Having A Predisposed Resilient Flexural Hinge" which issued to Kenneth B. Buell et al., on September 29, 19930.
The absorbent core 28 may be any absorbent member which is generally compressible. conformable, non-imitating to the . wearer's skin. and capable of absorbing and retaining liquids such as urine and other certain body exudates.
As s shown in Figure 1, the absorbent core 28 has a garment-facing side, a body-facing side, a pair of side edges, nerd a pair of waist edges. The absorbent con 28 may be manufactured in a wide variety of sizes and shapes (e.g.. rectangular, hourglass.
"T"-shaped, asymmetric. etc.) and from a wide variety of liquid-absorbent materials commonly used in disposable diapers and other absorbent articles such as lo comminuted wood pulp wbicb is generally referred to as airfeit. Examples of other suitable absorbent materials include creped cellulose wadding; meltblown polymers including coform; chemically stiffened, rnodifced or cross~linked cellulosic fibers;
tissue including tissue wraps and tissue iamircatrs; absorbent foams;
absorbent sponges; supaabsorbent polymers; absorbent gelling materials; or any equivalent l s maxarial or cornbinationa of a~rial<s.
The configuration and corrsn of the absorbent core 28 may vary (e.g., the absorbent core may have varying caliper zones, a hydrophilic gradient, a superabsorbent" gradient, or Power aveta~e density and lower average basis weight acquisition zones; or may comprise one or more layers or structures). Further.
the lo size and absorbent capacity of the abaorbant core 28 may also be varied to accommodate wearers ranging from infarcts through adults. However, the total absorbent capacity of the absorbaat core 28 should be compatible with the design loading and the int~de~d use of the diaper 20.
One embodiment of the diaper 20 has an asymmetric, modified T-shaped is absorbent core 28 having ears in t!~ front waist region but a generally rectangular shape in the rear waist region. "lrxerrcplary absorbent sttucucres for use as the absotbera core 28 of tt~ pt~at invention that have achieved W de acceptance and comrneccial success art described in U.S. ,Patent 4.610,6?8 entitled "High-Density Aicsorbact Structures" isaur~d to Weisman et al. op September 9, 1986; U.S.
Patent 30 4,6?3,402 entitled "Absorbent Articles With Dual-Layered Cores" issued to Weistrcan et al. on June 16, 198?; U.S. Patent 4,888,231 entitled "Absorbent Core Having A Dusting Layez" issued to Angstadt on Decexnba 19, 1989; and U.S.
Patent 4,834,?35, entitled "High Density Absorbent Members Having Lowcr Density and Lower Basis Weight Acquisition Zones", issued to Alemany et al. on 3s May 30, 1989. The absorbent core may fureher comprise the dual core system ~n~ining an acquisitionldistribution core of chemically stiffened fibers positioned g over an absorbent storage core as detailed in U.S. Patent 5.23~x.423. entitled "Absorbent Article With ;Mastic Waist Feature and Enhanced Absorbency" issued to Aleman~ et al., on August 10, 1993: and in U.S. Patent 5.14?.345, entitled "High Efficiency Absorbent Articles For Incontinence Management" issued to Young, s LaVon and Taylor on September. 15, 1992.
The backsheet 2b is positioned adjacent the garment-facing surface of the absorbent core 28 and is preferably joined thereto by attachment means (not shown) such as those well known in the art. For example, the backslsert 26 may be secured vo to the absorbent core 28 by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines, spirals, or spots of adhesive.
Adhesives which have been found to be satisfactory are manufactured by H. 8. Fuller Company of St. Paul, Minnesota and marketed as HL-1258. An example of a suitable attachment means comprising an open pattern network of filaments of adhesive is is disclosed in U.S. Patent 4,S?3,98b entitled "Diapoaable Way-Containment Garment", which issued to Minetola et al. on March 4, 1986. Another . suitable attachment means comprisnn~g several lines of adhesive filammta swirled into a spiral pattern i~ illu~rated by flee apparatus and metkmds shown in U.S.
Patent 3,911,1 ?3 issued to Spe~agtse, 3r. on October ?, 19?5; U.S. Patent 4,?85,99b issued to io Ziecker, et al. on November 22, 19?8; sad U.S. Patent 4,842,666 issued to Werenicz on June 27, 1989.
Alternatively, the att~:hm~ent means may comprise heat bonds, praswr bonds, ulvasonic .bonds, dynamic mechanical bonds, or any otkter suitable auachment means or combinations of these atta~chm~mt means as are known in the art.
is Embodiments of the pceaant invention see also conteerpiated vvlacrreia the absorbent core is not joined to the backshsaet 2b, the topalseet 24, or Goth in order to provide greater ability in the fret waist region 4b aaxi tlwe rear waist region 44.
The backsheet 2b is impervious,to.liquids (e.g., urine) and is preferably manufacttued fmm a thin plastic film, although other flexible liquid impervious 3o materials may also be used. As usod herein. the term "flexible" refers to materials which are compliant and will readily confoem co the general shape and contours of the human body. The backs~t 2b prevents the exudaaes absorbed and contained in the absorbent core 28 from wetting articles which contact the diaper 20 such as bedsheets and uodergatments, however, the backsheet 2b may permit vapors to 3s escape fronn the absorbent core 28 (i.e., is breathable). Thus, the backsheet 26 preferably comprises a polymeric film such as themtopfLtstic films of polyethylcna or polypropylene. A suitable material for the backsheet 26 is a thermoplastic film having a thickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils).
The topsheet 24 is positioned adjacent the body-facing surface of the absorbent core 28 and is preferably joined thereto and to the backsheet 26 by s attachment means (not shown) such as those well known in the art. Suitable attachment means are described with respect to joining the backsheet 26 to the absorbent core 28. In a preferred embodiment of the present invention, the topsheet 24 and the backsheet 26 are joined directly to each other in the diaper periphery and are indirectly joined together by directly joining them to the absorbent core 28 by io the attachment means (not shown).
The topsheet 24 is preferably compliant, soft feeling, and non-irritating to the wearer's skin. Further, the topsheet 24 is preferably liquid pervious permitting liquids (e.g., urine) to readily penetrate through its thickness. A suitable topsheet 24 is manufactured from a nonwoven web of synthetic fibers (e.g., polyester, ~s polyethylene, or polypropylene fibers or bicomponent fibers). Other suitable fibers include natural fibers such as wood, cotton, or rayon, or combinations of natural and synthetic fibers.
The topsheet 24 of the present invention preferably comprises an apertured nonwoven web. Referring to FIG. 2 there is schematically illustrated at 100 a zo process for selectively aperturing a nonwoven web suitable for use as a topsheet on a disposable absorbent article.
According to the present invention, a nonwoven web 102 is unwound from a supply roll 104 and travels in a direction indicated by the arrows associated therewith as the supply roll 104 rotates in the direction indicated by the arrows zs associated therewith. The nonwoven material 102 passes through a nip 106 of the web weakening roller arrangement 108 formed by rollers 110 and 112.
The nonwoven material 102 may be formed by known nonwoven extrusion processes, such as, for example, known meltblowing processes or known spunbonding processes, and passed directly through the nip 106 without first being 3o bonded and/or stored on a supply roll.
The nonwoven web 102 may be extensible, elastic, or nonelastic. The nonwoven web 102 may be a spunbonded web, a meltblown web, or a bonded carded web. If the nonwoven web is a web of meltblown fibers, it may include meltblown microfibers. The nonwoven web 102 may be made of fiber forming 3s polymers such as, for example, polyolefins. Exemplary polyolefins include one or more of polypropylene, polyethylene, ethylene copolymers, propylene copolymers, and butene copolymers.
In another embodiment. the nonwoven web 102 may be a multilayer material having, for example, at least one layer of a spunbonded web joined to at least one layer of a meltblown web, a bonded carded web, or other suitable material. For s example, the nonwoven web 102 may be a multilayer web having a first layer of spunbonded polypropylene having a basis weight from about 0.2 to about 8 ounces per square yard, a layer of meltblown polypropylene having a basis weight from about 0.2 to about 4 ounces per square yard, and a second layer of spunbonded polypropylene having a basis weight from about 0.2 to about 8 ounces per square ~o yard. Alternatively, the nonwoven web may be a single layer of material, such as, for example, a spunbonded web having a basis weight from about 0.2 to about 10 ounces per square yard or a meltblown web having a basis weight from about 0.2 to about 8 ounces per square yard.
The nonwoven web may be joined to a polymeric film to form a laminate.
is Suitable polymeric film materials include but are not limited to polyolefins, such as polyethylenes, polypropylene, ethylene copolymers, propylene copolymers, and butene copolymers; nylon (polyamide); metallocene catalyst-based polymers;
cellulose esters; poly (methyl methacrylate); polystyrene; poly (vinyl chloride);
polyester; polyurethane; compatible polymers; compatible copolymers; and blends, laminates and/or combinations thereof.
The nonwoven web 102 may also be a composite made up of a mixture of two or more different fibers or a mixture of fibers and particles. Such mixtures may be formed by adding fibers and/or particulates to the gas stream in which the meltblown fibers or spunbond fibers are carried so that an intimate entangled co-ts mingling of fibers and other materials, e.g., wood pulp, staple fibers and particles occurs prior to collection of the fibers.
The nonwoven web of fibers should be joined by bonding to form a coherent web structure. Suitable bonding techniques include, but are not limited to, chemical bonding, thermobonding, such as point calendering, hydroentangling, and needling.
so Referring now to FIG. 7 there is shown a photograph of a coherent nonwoven web 102 prior to entering nip 106. As can be seen in FIG. 7 the coherent ' nonwoven web comprises a plurality of fibers joined together by point calendered bonds 200 to form a coherent web structure. a Referring to FIGS. 2 and 3, the nonwoven web weakening roller arrangement 3s 108 preferably comprises a patterned calendar roller 110 and a smooth anvil roller 112. One or both of the patterned calendar roller 110 and the smooth anvil roller 112 may be heated and the pressure between the two rollers may be adjusted by well known means to provide the desired temperature, if any, and pressure to concurrently weaken and melt-stabilize the nonwoven web 102 at a plurality of locations.
s' The patterned calendar roller 110 is configured to have a circular cylindrical surface 114, and a plurality of protuberances or pattern elements 116 which extend outwardly from surface 114. The protuberances 116 are disposed in a predetermined pattern with each protuberance 116 being configured and disposed to precipitate a weakened, melt-stabilized location in the nonwoven web 102 to effect a ~o predetermined pattern of weakened, melt-stabilized locations in the nonwoven web 102. As shown in FIG. 3, patterned calendar roller 110 has a repeating pattern of protuberances 116 which extend about the entire circumference of surface 114.
Alternatively, the protuberances 116 may extend around a portion, or portions of the circumference of surface 114.
1 s The protuberances 116 are preferably truncated conical shapes which extend radially outwardly from surface 114 and which have elliptical distal end surfaces 117. Although it is not intended to thereby limit the scope of the present invention to protuberances of only this configuration. Other suitable shapes for distal ends 117 include, but are not limited to circular, square, rectangular, etc. The roller 110 zo is finished so that all of the end surfaces 117 lie in an imaginary right circular cylinder which is coaxial with respect to the axis of rotation of roller 110.
The protuberances 116 are disposed in a regular predetermined pattern of rows and columns in the embodiment shown in FIG. 3, although it is not intended to thereby limit the scope of the present invention to the pattern of protuberances of is only this configuration. The protuberances may be disposed in any predetermined ' pattern about patterned calendar roll 110.
Anvil roller 112, is preferably a smooth surfaced, right circular cylinder of steel.
FIG. 8 is a photograph of the nonwoven web 102 after having passed through 3o the weakening roller arrangement 108, and prior to passing through the nip 130 of ~ the incremental stretching system 132. As can be seen in the photograph, the nonwoven web 102 includes a plurality of weakened, melt-stabilized locations 202.
- Weakened, melt-stabilized locations 202 generally correspond to the pattern of protuberances 116 extending from the surface 114 of patterned calendar roller 110.
3s As seen in FIG. 8, the nonwoven web 102 also includes coherent web forming point calendered bonds 200 which serve to maintain the structural integrity of the WO 97/11662 ' PCT/US96/14643 nonwoven web 102.
From the weakening roller arrangement 108, the nonwoven web 102 passes , through nip 130 formed by the incremental stretching system 132 employing opposed pressure applicators having three-dimensional surfaces which at least to a s degree are complementary to one another.
Referring now to FIG. 4, there is shown a fragmentary enlarged view of the incremental stretching system 132 comprising incremental stretching rollers 134 and 136. The incremental stretching roller 134 includes a plurality of teeth 160 and corresponding grooves 161 which extend about the entire circumference of roller io 134. Incremental stretching roller 136 includes a plurality of teeth 162 and a plurality of corresponding grooves 163. The teeth 160 on roller 134 intermesh with or engage the grooves 163 on roller 136, while the teeth 162 on roller 136 intermesh with or engage the grooves 161 on roller 134. As the nonwoven web 102 having weakened, melt-stabilized locations 202 passes through the incremental stretching ~s system 132 the nonwoven web 102 is subjected to tensioning in the CD or cross-machine direction causing the nonwoven web 102 to be extended in the CD
direction. Alternatively, or additionally the nonwoven web 102 may be tensioned in the MD or machine direction. The tensioning force placed on the nonwoven web 102 is adjusted such that it causes the weakened, melt-stabilized locations 202 to 2o rupture creating a plurality of apertures 204 coincident with the weakened melt stabilized locations 202 in the nonwoven web 102. However, the bonds of the nonwoven web 102 are preferably strong enough such that they do not rupture during tensioning, thereby maintaining the nonwoven web in a coherent condition even as the weakened, melt-stabilized locations rupture. However, it may be zs desirable to have some of the bonds rupture during tensioning.
Refernng now to FIG. 9 there is shown a photograph of the nonwoven web 102 after having been subjected to the tensioning force applied by the incremental stretching system 132. As can be seen in the photograph, the nonwoven web 102 now includes a plurality of apertures 204 which are coincident with the weakened, 3o melt-stabilized locations 202 of the nonwoven web shown in FIG. 8. A
portion of the circumferential edges of apertures 204 include remnants 205 of the melt-stabilized locations 202. It is believed that the remnants 205 help to resist further tearing of the nonwoven web particularly when the nonwoven web is used as a topsheet on a disposable absorbent article.
3s Other exemplary structures of incremental stretching mechanisms suitable for incrementally stretching or tensioning the nonwoven web are described in . 13 International Patent Publication No. WO 95/0376, published February 9, 1995, in the name of Chappell, et al., the disclosure of which is incorporated herein by reference.
The selectively apertured nonwoven web may also be used as a topsheet on - s' other disposable absorbent articles such as for example, incontinence briefs, training pants, feminine hygiene garments and the like. The selectively apertured nonwoven web may also be used in other portions of a disposable absorbent article such as, for example, as an acquisition layer positioned between the topsheet and the absorbent core, as part of the absorbent core, or as portions of other components of the ~o disposable absorbent article.
The nonwoven web 102 is preferably taken up on wind-up roll 180 and stored. Alternatively, the nonwoven web 102 may be fed directly to a production line where it is used to form a topsheet on a disposable absorbent article.
Referring to FIG. 5 there is schematically illustrated at 300 another process is for selectively aperturing a nonwoven web of the present invention. A
nonwoven web 302 is unwound from a supply roll 304 and travels in a direction indicated by the arrows associated therewith as the supply roll 304 rotates in the direction indicated by the arrows associated therewith. The nonwoven material 302 is forwarded through the web weakening arrangement 308.
2o The nonwoven material 302 may be formed by known extrusion processes, such as, for example, known melt-blowing processes or known spunbonding processes, and passed directly through the web weakening arrangement 308.
The nonwoven web 302 may be extensible, elastic or non-elastic. The nonwoven web 302 may be a spunbonded web, a meltblown web, or a bonded is carded web. If the nonwoven web is a web of meltblown fibers, it may include meltblown microfibers. The nonwoven web 302 may be made of fiber forming polymers such as, for example, polyolefins. Exemplary polyolefins include one or more of polypropylene, polyethylene, ethylene copolymers, propylene copolymers, and butene copolymers.
3o In another embodiment, the nonwoven web 302 may be a multilayer material , having, for example, at least one layer of a spunbonded web joined to at least one layer of a meltblown web, a bonded carded web, or other suitable material.
- The nonwoven web may be joined to a polymeric film to form a laminate.
Suitable polymeric film materials include but are not limited to polyolefins, such as 3s polyethylenes, polypropylene, ethylene copolymers, propylene copolymers, and butene copolymers; nylon (polyamide); metallocene catalyst-based polymers;
cellulose esters; poly (methyl methacrylate); polystyrene; poly (vinyl chloride);
polyester; polyurethane; compatible polymers; compatible copolymers; and blends, laminates and/or combinations thereof.
The nonwoven web 302 may also be a composite made up of a mixture of s two or more different fibers or a mixture of fibers and particles. Such mixtures may be formed by adding fibers and/or particles to the gas stream in which the meltblown fibers or spunbond fibers are carried so that an intimate entangled co-mingling of fibers and other materials, e.g., wood pulp, staple fibers and particles occurs prior to collection of the fibers.
The nonwoven web of fibers should be joined by bonding to form a coherent web structure. Suitable bonding techniques, include, but are not limited to, chemical bonding, thermobonding, such as point calendering, hydroentangling, and needling.
Referring to FIGS. 5 and 6, the nonwoven web weakening arrangement 308 preferably comprises an ultrasonic transducer 306 and a cylinder 310. As the is nonwoven material 302 is forwarded between the ultrasonic transducer 306 and the anvil cylinder 310, the nonwoven web 302 is subjected to ultrasonic vibrational energy whereupon predetermined pattern locations of the nonwoven web 302 are weakened and melt-stabilized. Anvil 310 has a multiplicity of discrete pattern protuberances which are generally designated 316 disposed on its outwardly facing zo surface 314 in a predetermined pattern which extends about the entire circumference of the anvil cylinder. The protuberances 316 are disposed in a predetermined pattern with each protuberance 316 being configured and disposed to precipitate a weakened, melt-stabilized location 304 in the nonwoven web 302 to effect a predetermined pattern of weakened, melt-stabilized locations in the nonwoven web 2s 302. As shown in FIG. 6, anvil 310 has a repeating pattern of protuberances which extend about the entire circumference of surface 314. Alternatively, the protuberances 316 may extend around a portion, or portions of the circumference of surface 314.
The protuberances 316 are preferably truncated conical shapes which extend 3o radially outward from the surface 314 and which have elliptical distal end surfaces.
Other suitable shapes for the distal end include, but are not limited to, circular, square, rectangular, etc. The anvil 310 is finished so that all of the end surfaces lie in an imaginary right circular cylinder which is coaxial with respect to the axis of rotation of anvil 310.
3s After having passed through the weakening arrangement 308, and prior to passing through the nip 330 of the incremental stretching system 332, the nonwoven WO 97/11662 ' PCT/US96/14643 web 302 includes a plurality of weakened, melt-stabilized locations 304 which generally correspond to the pattern of protuberances 316 extending from the surface 314 of anvil 310.
From the weakening arrangement 308, the nonwoven web 102 passes s ° through nip 330 formed by the incremental stretching system 332 employing opposed pressure applicators having three-dimensional surfaces which at least to a degree are complementary to one another. The incremental stretching system 332 preferably comprises incremental stretching rollers 334 and 336. The incremental stretching roller 334 includes a plurality of teeth and corresponding grooves which io extend about the entire circumference of the roller 334. Incremental stretching roller 336 includes a plurality of teeth and a plurality of corresponding grooves.
Teeth on roller 334 intermesh or engage with the grooves on roller 136, while the teeth on roller 336 intermesh with or engage with the grooves on the roller 334. As the nonwoven web 302 having weakened, melt-stabilized locations 304 passes through ~s the incremental stretching system 332, the nonwoven web is subjected to tensioning causing the web to be extended. The tensioning force placed on the nonwoven web is adjusted such that it causes the weakened, melt-stabilized locations 304 to rupture creating a plurality of apertures in the nonwoven web which are coincident with the weakened melt-stabilized locations.
2o The nonwoven web 302 is preferably taken up on wind-up roll 380 and stored. Alternatively, the nonwoven web 302 may be fed directly to a production line where it is used to form a topsheet on a disposable absorbent article.
The diaper 20 preferably further comprises elasticized leg cuffs 32 for providing improved containment of liquids and other body exudates. Each as elasticized leg cuff 32 may comprise several different embodiments for reducing the leakage of body exudates in the leg regions. (The leg cuff can be and is sometimes also referred to as leg bands, side flaps, barrier cuffs, or elastic cuffs.) U.S. Patent 3,860,003 describes a disposable diaper which provides a contractible leg opening having a side flap and one or more elastic members to provide an elasticized leg cuff 30 (gasketing cuff). U.S. Patent 4,909,803 entitled "Disposable Absorbent Article Having Elasticized Flaps" issued to Aziz et al. on March 20, 1990, describes a disposable diaper having "stand-up" elasticized flaps (burner cuffs) to improve the containment of the leg regions. U.S. Patent 4,695,278 entitled "Absorbent Article Having Dual Cuffs" issued to Lawson on September 22, 1987, describes a 3s disposable diaper having dual cuffs including a gasketing cuff and a barrier cuff.
U.S. Patent 4,704,115 entitled "Disposable Waist Containment Garment" issued to Buell on November 3, 1987. discloses a disposable diaper or incontinence garment having side-edge-leakage-guard gutters configured to contain free liquids within the garnnent.~ While each . elasticized leg cuff 32 may be configured so as to be similar to any of the leg bands, s side flaps. barrier cuffs, or elastic cuffs described above, it is preferred that each elasticized leg cuff 32 comprise at lest an inner barrier cuff comprising a battier flap and a spacing element such as described in the above-referenced U.S. Pat.
No.
4,909,803. In a preferred embodiment, the elasticized leg cuts 32 additionally comprises an elastic gasketing cuff with one or more elastic strands, positioned ~o outboard of the barrio cuff such as described in the above-referred U.S.
Pat. No.
4,695278.
The diaper 20 preferably funirer comprises an elasticized waistband 34 that provides improved fit and cantairurtent. The elasdcizai waistband 34 is that.
portion or zone of the diaper 20 which is intended to elastically expand and contract to is dynamically fit the wearer's waist. 'Tile elasticized waiatbar>d 34 preferably extends longitudinally outwardly from at least one of the waist edges of the absorbent core 28 and generally forms at least a portion of the end edge of the diaper 20.
Disposable digs are gsneraliy cona~r~ted so as to have tvvo elasticized waistbands, one positioned in the rest waist region and one positioned in the front Io waist region, although diapers can be constructed with a single elasticized waistband. Further, while the etasticizsd waistband 34 or any of its constituent elements can comprise a separate element affixed to the diaper 20, the elasticized waistband 34 may be consnuctad as an acde~on of other elements of the diaper such as the baakshaet 26 or the 24, preferably bath the backsiaert 26 and the zs topsheet 24. The elate w~tbe~ 34 may be conswcted ui a number of di$er~ent configurations including tl~e described in U.S. Patent 4,5 i 5.595 entitled "Dispoasble Diapers with Elastically Contractible Waistbands" issued to Kievit et al.
on May ~, 1985 and the above refixresraed L1.S. Patent 5,151,092 issued to Huell.
so In a preferred embodies. ~ ' 20 also ccsaprises elasticized side panels 30 disposed in tt~e rear waist region 44. (As used hcp~ein, the tens "disposed"
is used to mean that an elks) of the di4per is forntod (joined and positioned) in a particular plue or position as a unitary structure with otixr elements of the diaper or as a separate element joined to another element of the diaper.) The elasticized as side panels 30 provide an elastically extensible featmr that provides a more comfortable and contouring fit by initially conformably fitting the, diaper to the wearer and sustaining this fit throughout the -time of wear well passed when the diaper has been loaded with exndatcs since the elasticizced side panels allow the sides of the diaper to expand and contract. The elasticized side panels 30 further provide more effective application of the diaper 20 sitsce even if the diaperer pulls one s elasticized side panel 30 ,farther than the other during the application (asymmetrically), the diaper 20 will "self adjust" during wear. While the diaper 20 of the present invention preferably has the elasticized side panels 30 disposed in the rear waist region 44; alternatively, the diaper 20 may also be provided with elasticized side panels disposed in the front waist region 46 and the rear waist region ~0 44. While the elasticized side panels 30 may lx consuucted in a number of configurations. examples of diapers with elasticized side parcels arc disclosed in U.S.
Pat. No. 4,857.067, entitled "Disposable Diaper Having Shined Ears" issued to Wood, et al. on August 15, 1989; U.S. Pat. No. 4,381.781 issued to Sciaraffa, et al.
on May 3. 1983: U.S. Pat. No. 4,938,753 issued to Van Gampel, et al. on July 3, ~ s 1990; and in U.S. Pat. No. 5,151,092 issued to Buell et al. on September 29, 1992.
Suitable elastic materials for use as the elasticized side panels itxlwde clastomaic foams, synthetic or natural rubber, synthetic or natural rubber foams, elastatrueric films, elastomeric scrim, elastomeric viroven or nonwoven webs, elastomeric compositta such as elastomeric :o nonwovcn larrtinates, or the like.
The diaper 20 also comprises a fastening sysd~m 3b which forms a side ctosure which maintains the rear waist region 44 and the firarit waist region 46 in as overlapping configuration s~h that lateral tensions an maintained around the circumferemx of the diaper to maintain the diaper on the wcara- Exemplary a fastening systems ace disclosed in U,S. Pat. No. 4,8b9,724 issued to Scripps on September 2b, 1989; U,S. Pat. Nor 4,846.815 issued to Script on July 11, 1989;
U.S. Pat' No. 4,894,060 issued to Nesugard an January Ib, 19'90; U.S. Pat. No.
4,946,52? issued to Battrell on August 7t ,1990; U.S. Pat. No. 3,848,594 issued to Buell on November 19, 1974; and U.S. Pat.'No. 4.bb2,8?5 issurd to Hirotsu and 30 Robertson on May 5, 1987.
While particular embodiments of tttee ptes~nt invctttion have been illustrated and described, it would be obvious to those sltilled in the art that various other changes and modifications can be made without departing fiam the spirit and scope 3s of the invention. It is tlxrcfore intrreded to cover in the agperukd claims all such changes and modifications that ace within the scope of this invention._
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the invention will be better understood from the s following description which is taken in conjunction with the accompanying drawings in which like designations are used to designate substantially identical elements, and in which:
FIG. 1 is a plan view of a disposable diaper embodiment of the present invention having portions cut away to reveal underlying structure, the inner surface io of the diaper is facing the viewer;
FIG. 2 is a schematic representation of an exemplary process for selectively aperturing a nonwoven web of the present invention;
FIG. 3 is an enlarged perspective illustration of a web weakening arrangement of the present invention;
Is FIG. 4 is an enlarged perspective illustration of an incremental stretching system of the present invention;
FIG. 5 is a schematic representation of another process for selectively aperturing a nonwoven web of the present invention;
FIG. 6 is an enlarged perspective illustration of another web weakening zo arrangement of the present invention;
FIG. 7 is an enlarged plan view photograph of a nonwoven web prior to being weakened;
FIG. 8 is an enlarged plan view photograph of a nonwoven web of the present invention after the nonwoven web has been weakened at a plurality of 2s locations; and FIG. 9 is an enlarged plan view photograph of a nonwoven web of the present invention after tension has been applied to rupture the nonwoven web at the weakened locations to create apertures in the nonwoven.
3o DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term "absorbent article" refers to devices which absorb ' and contain body exudates, and, more specifically, refers to devices which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. The term "disposable" is used herein to 3s describe absorbent articles which are not intended to be laundered or otherwise restored or reused as an absorbent article (i.e., they are intended to be discarded after a single use and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner). A "unitary" absorbent article refers to absorbent articles which are formed of separate parts united together to form a coordinated entity so that they do not require separate manipulative parts like a s separate holder and liner. A preferred embodiment of an absorbent article of the present invention is the unitary disposable absorbent article, diaper 20, shown in Figure I. As used herein, the term "diaper" refers to an absorbent article generally worn by infants and incontinent persons that is worn about the lower torso of the wearer. It should be understood, however, that the present invention is also ~o applicable to other absorbent articles such as incontinence briefs, incontinence undergarments, diaper holders and liners, feminine hygiene garments, training pants, and the like.
Figure 1 is a plan view of the diaper 20 of the present invention in its flat out, uncontracted state (i.e., with elastic induced contraction pulled out) with is portions of the structure being cut-away to more clearly show the construction of the diaper 20 and with the portion of the diaper 20 which faces the wearer, the inner surface 40, facing the viewer. As shown in Figure l, the diaper 20 preferably comprises a containment assembly 22 comprising a liquid pervious topsheet 24;
a liquid impervious backsheet 26 joined to the topsheet; and an absorbent core 2o positioned between the topsheet 24 and the backsheet 26. The diaper preferably further comprises elasticized side panels 30; elasticized leg cuffs 32;
elasticized waistbands 34; and a fastening system 36 preferably comprising a pair of securement members 37 and a landing member, (not shown).
The diaper 20 is shown in Figure I to have an inner surface 40 (facing the 2s viewer in Figure 1), an outer surface 42 opposed to the inner surface 40, a rear waist region 44, a front waist region 46 opposed to the rear waist region 44, a crotch region 48 positioned between the rear waist region 44 and the front waist region 46, and a periphery which is defined by the outer perimeter or edges of the diaper 20 in which the longitudinal edges are designated 50 and the end edges are designated 52.
3o The inner surface 40 of the diaper 20 comprises that portion of the diaper 20 which is positioned adjacent to the wearer's body during use (i.e., the inner surface 40 generally is formed by at least a portion of the topsheet 24 and other components joined to the topsheet 24). The outer surface 42 comprises that portion of the diaper 20 which is positioned away from the wearer's body (i.e., the outer surface 42 is 3s generally formed by at least a portion of the backsheet 26 and other components joined to the backsheet 26). As used herein, the term "joined" encompasses configurations whereby an element is directly secured to the other element by affixing the element directly to the other element, and configurations whereby the element is indirectly secured to the other element by affixing the element to intermediate members) which in turn are affixed to the other element. The rear s waist region 44 and the front waist region 46 extend from the end edges 52 of the periphery to the crotch region 48.
The diaper 20 also has two centerlines, a longitudinal centerline 90 and a transverse centerline 92. The term "longitudinal", as used herein, refers to a line, axis, or direction in the plane of the diaper 20 that is generally aligned with (e.g.
io approximately parallel with) a vertical plane which bisects a standing wearer into left and right halves when the diaper 20 is worn. The terms "transverse" and "lateral", as used herein, are interchangeable and refer to a line, axis or direction which lies within the plane of the diaper that is generally perpendicular to the longitudinal direction (which divides the wearer into front and back body halves).
is The containment assembly 22 of the diaper 20 is shown in Figure 1 as comprising the main body (chassis) of the diaper 20. The containment assembly comprises at least topsheet 24, backsheet 26 and absorbent core 28. When the absorbent article comprises a separate holder and a liner, the containment assembly 22 generally comprises the holder and the liner (i.e., the containment assembly 22 2o comprises one or more layers of material to define the holder while the liner comprises an absorbent composite such as a topsheet, a backsheet, and an absorbent core.) For unitary absorbent articles, the containment assembly 22 comprises the main structure of the diaper with other features added to form the composite diaper structure. Thus, the containment assembly 22 for the diaper 20 generally comprises is the topsheet 24, the backsheet 26, and the absorbent core 28.
Figure 1 shows a preferred embodiment of the containment assembly 22 in which the topsheet 24 and the backsheet 26 have length and width dimensions generally larger than those of the absorbent core 28. The topsheet 24 and the backsheet 26 extend beyond the edges of the absorbent core 28 to thereby form the 3o periphery of the diaper 20. While the topsheet 24, the backsheet 26, and the absorbent core 28 may be assembled in a variety of well known configurations, w exemplary containment assembly configurations are described generally in U.S.
' Patent 3,860,003 entitled "Contractible Side Portions for Disposable Diaper"
which issued to Kenneth B. Buell on January 14, 1975; and U.S. Patent 5,151,092 entitled ss "Absorbent Article With Dynamic Elastic Waist Feature Having A Predisposed Resilient Flexural Hinge" which issued to Kenneth B. Buell et al., on September 29, 19930.
The absorbent core 28 may be any absorbent member which is generally compressible. conformable, non-imitating to the . wearer's skin. and capable of absorbing and retaining liquids such as urine and other certain body exudates.
As s shown in Figure 1, the absorbent core 28 has a garment-facing side, a body-facing side, a pair of side edges, nerd a pair of waist edges. The absorbent con 28 may be manufactured in a wide variety of sizes and shapes (e.g.. rectangular, hourglass.
"T"-shaped, asymmetric. etc.) and from a wide variety of liquid-absorbent materials commonly used in disposable diapers and other absorbent articles such as lo comminuted wood pulp wbicb is generally referred to as airfeit. Examples of other suitable absorbent materials include creped cellulose wadding; meltblown polymers including coform; chemically stiffened, rnodifced or cross~linked cellulosic fibers;
tissue including tissue wraps and tissue iamircatrs; absorbent foams;
absorbent sponges; supaabsorbent polymers; absorbent gelling materials; or any equivalent l s maxarial or cornbinationa of a~rial<s.
The configuration and corrsn of the absorbent core 28 may vary (e.g., the absorbent core may have varying caliper zones, a hydrophilic gradient, a superabsorbent" gradient, or Power aveta~e density and lower average basis weight acquisition zones; or may comprise one or more layers or structures). Further.
the lo size and absorbent capacity of the abaorbant core 28 may also be varied to accommodate wearers ranging from infarcts through adults. However, the total absorbent capacity of the absorbaat core 28 should be compatible with the design loading and the int~de~d use of the diaper 20.
One embodiment of the diaper 20 has an asymmetric, modified T-shaped is absorbent core 28 having ears in t!~ front waist region but a generally rectangular shape in the rear waist region. "lrxerrcplary absorbent sttucucres for use as the absotbera core 28 of tt~ pt~at invention that have achieved W de acceptance and comrneccial success art described in U.S. ,Patent 4.610,6?8 entitled "High-Density Aicsorbact Structures" isaur~d to Weisman et al. op September 9, 1986; U.S.
Patent 30 4,6?3,402 entitled "Absorbent Articles With Dual-Layered Cores" issued to Weistrcan et al. on June 16, 198?; U.S. Patent 4,888,231 entitled "Absorbent Core Having A Dusting Layez" issued to Angstadt on Decexnba 19, 1989; and U.S.
Patent 4,834,?35, entitled "High Density Absorbent Members Having Lowcr Density and Lower Basis Weight Acquisition Zones", issued to Alemany et al. on 3s May 30, 1989. The absorbent core may fureher comprise the dual core system ~n~ining an acquisitionldistribution core of chemically stiffened fibers positioned g over an absorbent storage core as detailed in U.S. Patent 5.23~x.423. entitled "Absorbent Article With ;Mastic Waist Feature and Enhanced Absorbency" issued to Aleman~ et al., on August 10, 1993: and in U.S. Patent 5.14?.345, entitled "High Efficiency Absorbent Articles For Incontinence Management" issued to Young, s LaVon and Taylor on September. 15, 1992.
The backsheet 2b is positioned adjacent the garment-facing surface of the absorbent core 28 and is preferably joined thereto by attachment means (not shown) such as those well known in the art. For example, the backslsert 26 may be secured vo to the absorbent core 28 by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines, spirals, or spots of adhesive.
Adhesives which have been found to be satisfactory are manufactured by H. 8. Fuller Company of St. Paul, Minnesota and marketed as HL-1258. An example of a suitable attachment means comprising an open pattern network of filaments of adhesive is is disclosed in U.S. Patent 4,S?3,98b entitled "Diapoaable Way-Containment Garment", which issued to Minetola et al. on March 4, 1986. Another . suitable attachment means comprisnn~g several lines of adhesive filammta swirled into a spiral pattern i~ illu~rated by flee apparatus and metkmds shown in U.S.
Patent 3,911,1 ?3 issued to Spe~agtse, 3r. on October ?, 19?5; U.S. Patent 4,?85,99b issued to io Ziecker, et al. on November 22, 19?8; sad U.S. Patent 4,842,666 issued to Werenicz on June 27, 1989.
Alternatively, the att~:hm~ent means may comprise heat bonds, praswr bonds, ulvasonic .bonds, dynamic mechanical bonds, or any otkter suitable auachment means or combinations of these atta~chm~mt means as are known in the art.
is Embodiments of the pceaant invention see also conteerpiated vvlacrreia the absorbent core is not joined to the backshsaet 2b, the topalseet 24, or Goth in order to provide greater ability in the fret waist region 4b aaxi tlwe rear waist region 44.
The backsheet 2b is impervious,to.liquids (e.g., urine) and is preferably manufacttued fmm a thin plastic film, although other flexible liquid impervious 3o materials may also be used. As usod herein. the term "flexible" refers to materials which are compliant and will readily confoem co the general shape and contours of the human body. The backs~t 2b prevents the exudaaes absorbed and contained in the absorbent core 28 from wetting articles which contact the diaper 20 such as bedsheets and uodergatments, however, the backsheet 2b may permit vapors to 3s escape fronn the absorbent core 28 (i.e., is breathable). Thus, the backsheet 26 preferably comprises a polymeric film such as themtopfLtstic films of polyethylcna or polypropylene. A suitable material for the backsheet 26 is a thermoplastic film having a thickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils).
The topsheet 24 is positioned adjacent the body-facing surface of the absorbent core 28 and is preferably joined thereto and to the backsheet 26 by s attachment means (not shown) such as those well known in the art. Suitable attachment means are described with respect to joining the backsheet 26 to the absorbent core 28. In a preferred embodiment of the present invention, the topsheet 24 and the backsheet 26 are joined directly to each other in the diaper periphery and are indirectly joined together by directly joining them to the absorbent core 28 by io the attachment means (not shown).
The topsheet 24 is preferably compliant, soft feeling, and non-irritating to the wearer's skin. Further, the topsheet 24 is preferably liquid pervious permitting liquids (e.g., urine) to readily penetrate through its thickness. A suitable topsheet 24 is manufactured from a nonwoven web of synthetic fibers (e.g., polyester, ~s polyethylene, or polypropylene fibers or bicomponent fibers). Other suitable fibers include natural fibers such as wood, cotton, or rayon, or combinations of natural and synthetic fibers.
The topsheet 24 of the present invention preferably comprises an apertured nonwoven web. Referring to FIG. 2 there is schematically illustrated at 100 a zo process for selectively aperturing a nonwoven web suitable for use as a topsheet on a disposable absorbent article.
According to the present invention, a nonwoven web 102 is unwound from a supply roll 104 and travels in a direction indicated by the arrows associated therewith as the supply roll 104 rotates in the direction indicated by the arrows zs associated therewith. The nonwoven material 102 passes through a nip 106 of the web weakening roller arrangement 108 formed by rollers 110 and 112.
The nonwoven material 102 may be formed by known nonwoven extrusion processes, such as, for example, known meltblowing processes or known spunbonding processes, and passed directly through the nip 106 without first being 3o bonded and/or stored on a supply roll.
The nonwoven web 102 may be extensible, elastic, or nonelastic. The nonwoven web 102 may be a spunbonded web, a meltblown web, or a bonded carded web. If the nonwoven web is a web of meltblown fibers, it may include meltblown microfibers. The nonwoven web 102 may be made of fiber forming 3s polymers such as, for example, polyolefins. Exemplary polyolefins include one or more of polypropylene, polyethylene, ethylene copolymers, propylene copolymers, and butene copolymers.
In another embodiment. the nonwoven web 102 may be a multilayer material having, for example, at least one layer of a spunbonded web joined to at least one layer of a meltblown web, a bonded carded web, or other suitable material. For s example, the nonwoven web 102 may be a multilayer web having a first layer of spunbonded polypropylene having a basis weight from about 0.2 to about 8 ounces per square yard, a layer of meltblown polypropylene having a basis weight from about 0.2 to about 4 ounces per square yard, and a second layer of spunbonded polypropylene having a basis weight from about 0.2 to about 8 ounces per square ~o yard. Alternatively, the nonwoven web may be a single layer of material, such as, for example, a spunbonded web having a basis weight from about 0.2 to about 10 ounces per square yard or a meltblown web having a basis weight from about 0.2 to about 8 ounces per square yard.
The nonwoven web may be joined to a polymeric film to form a laminate.
is Suitable polymeric film materials include but are not limited to polyolefins, such as polyethylenes, polypropylene, ethylene copolymers, propylene copolymers, and butene copolymers; nylon (polyamide); metallocene catalyst-based polymers;
cellulose esters; poly (methyl methacrylate); polystyrene; poly (vinyl chloride);
polyester; polyurethane; compatible polymers; compatible copolymers; and blends, laminates and/or combinations thereof.
The nonwoven web 102 may also be a composite made up of a mixture of two or more different fibers or a mixture of fibers and particles. Such mixtures may be formed by adding fibers and/or particulates to the gas stream in which the meltblown fibers or spunbond fibers are carried so that an intimate entangled co-ts mingling of fibers and other materials, e.g., wood pulp, staple fibers and particles occurs prior to collection of the fibers.
The nonwoven web of fibers should be joined by bonding to form a coherent web structure. Suitable bonding techniques include, but are not limited to, chemical bonding, thermobonding, such as point calendering, hydroentangling, and needling.
so Referring now to FIG. 7 there is shown a photograph of a coherent nonwoven web 102 prior to entering nip 106. As can be seen in FIG. 7 the coherent ' nonwoven web comprises a plurality of fibers joined together by point calendered bonds 200 to form a coherent web structure. a Referring to FIGS. 2 and 3, the nonwoven web weakening roller arrangement 3s 108 preferably comprises a patterned calendar roller 110 and a smooth anvil roller 112. One or both of the patterned calendar roller 110 and the smooth anvil roller 112 may be heated and the pressure between the two rollers may be adjusted by well known means to provide the desired temperature, if any, and pressure to concurrently weaken and melt-stabilize the nonwoven web 102 at a plurality of locations.
s' The patterned calendar roller 110 is configured to have a circular cylindrical surface 114, and a plurality of protuberances or pattern elements 116 which extend outwardly from surface 114. The protuberances 116 are disposed in a predetermined pattern with each protuberance 116 being configured and disposed to precipitate a weakened, melt-stabilized location in the nonwoven web 102 to effect a ~o predetermined pattern of weakened, melt-stabilized locations in the nonwoven web 102. As shown in FIG. 3, patterned calendar roller 110 has a repeating pattern of protuberances 116 which extend about the entire circumference of surface 114.
Alternatively, the protuberances 116 may extend around a portion, or portions of the circumference of surface 114.
1 s The protuberances 116 are preferably truncated conical shapes which extend radially outwardly from surface 114 and which have elliptical distal end surfaces 117. Although it is not intended to thereby limit the scope of the present invention to protuberances of only this configuration. Other suitable shapes for distal ends 117 include, but are not limited to circular, square, rectangular, etc. The roller 110 zo is finished so that all of the end surfaces 117 lie in an imaginary right circular cylinder which is coaxial with respect to the axis of rotation of roller 110.
The protuberances 116 are disposed in a regular predetermined pattern of rows and columns in the embodiment shown in FIG. 3, although it is not intended to thereby limit the scope of the present invention to the pattern of protuberances of is only this configuration. The protuberances may be disposed in any predetermined ' pattern about patterned calendar roll 110.
Anvil roller 112, is preferably a smooth surfaced, right circular cylinder of steel.
FIG. 8 is a photograph of the nonwoven web 102 after having passed through 3o the weakening roller arrangement 108, and prior to passing through the nip 130 of ~ the incremental stretching system 132. As can be seen in the photograph, the nonwoven web 102 includes a plurality of weakened, melt-stabilized locations 202.
- Weakened, melt-stabilized locations 202 generally correspond to the pattern of protuberances 116 extending from the surface 114 of patterned calendar roller 110.
3s As seen in FIG. 8, the nonwoven web 102 also includes coherent web forming point calendered bonds 200 which serve to maintain the structural integrity of the WO 97/11662 ' PCT/US96/14643 nonwoven web 102.
From the weakening roller arrangement 108, the nonwoven web 102 passes , through nip 130 formed by the incremental stretching system 132 employing opposed pressure applicators having three-dimensional surfaces which at least to a s degree are complementary to one another.
Referring now to FIG. 4, there is shown a fragmentary enlarged view of the incremental stretching system 132 comprising incremental stretching rollers 134 and 136. The incremental stretching roller 134 includes a plurality of teeth 160 and corresponding grooves 161 which extend about the entire circumference of roller io 134. Incremental stretching roller 136 includes a plurality of teeth 162 and a plurality of corresponding grooves 163. The teeth 160 on roller 134 intermesh with or engage the grooves 163 on roller 136, while the teeth 162 on roller 136 intermesh with or engage the grooves 161 on roller 134. As the nonwoven web 102 having weakened, melt-stabilized locations 202 passes through the incremental stretching ~s system 132 the nonwoven web 102 is subjected to tensioning in the CD or cross-machine direction causing the nonwoven web 102 to be extended in the CD
direction. Alternatively, or additionally the nonwoven web 102 may be tensioned in the MD or machine direction. The tensioning force placed on the nonwoven web 102 is adjusted such that it causes the weakened, melt-stabilized locations 202 to 2o rupture creating a plurality of apertures 204 coincident with the weakened melt stabilized locations 202 in the nonwoven web 102. However, the bonds of the nonwoven web 102 are preferably strong enough such that they do not rupture during tensioning, thereby maintaining the nonwoven web in a coherent condition even as the weakened, melt-stabilized locations rupture. However, it may be zs desirable to have some of the bonds rupture during tensioning.
Refernng now to FIG. 9 there is shown a photograph of the nonwoven web 102 after having been subjected to the tensioning force applied by the incremental stretching system 132. As can be seen in the photograph, the nonwoven web 102 now includes a plurality of apertures 204 which are coincident with the weakened, 3o melt-stabilized locations 202 of the nonwoven web shown in FIG. 8. A
portion of the circumferential edges of apertures 204 include remnants 205 of the melt-stabilized locations 202. It is believed that the remnants 205 help to resist further tearing of the nonwoven web particularly when the nonwoven web is used as a topsheet on a disposable absorbent article.
3s Other exemplary structures of incremental stretching mechanisms suitable for incrementally stretching or tensioning the nonwoven web are described in . 13 International Patent Publication No. WO 95/0376, published February 9, 1995, in the name of Chappell, et al., the disclosure of which is incorporated herein by reference.
The selectively apertured nonwoven web may also be used as a topsheet on - s' other disposable absorbent articles such as for example, incontinence briefs, training pants, feminine hygiene garments and the like. The selectively apertured nonwoven web may also be used in other portions of a disposable absorbent article such as, for example, as an acquisition layer positioned between the topsheet and the absorbent core, as part of the absorbent core, or as portions of other components of the ~o disposable absorbent article.
The nonwoven web 102 is preferably taken up on wind-up roll 180 and stored. Alternatively, the nonwoven web 102 may be fed directly to a production line where it is used to form a topsheet on a disposable absorbent article.
Referring to FIG. 5 there is schematically illustrated at 300 another process is for selectively aperturing a nonwoven web of the present invention. A
nonwoven web 302 is unwound from a supply roll 304 and travels in a direction indicated by the arrows associated therewith as the supply roll 304 rotates in the direction indicated by the arrows associated therewith. The nonwoven material 302 is forwarded through the web weakening arrangement 308.
2o The nonwoven material 302 may be formed by known extrusion processes, such as, for example, known melt-blowing processes or known spunbonding processes, and passed directly through the web weakening arrangement 308.
The nonwoven web 302 may be extensible, elastic or non-elastic. The nonwoven web 302 may be a spunbonded web, a meltblown web, or a bonded is carded web. If the nonwoven web is a web of meltblown fibers, it may include meltblown microfibers. The nonwoven web 302 may be made of fiber forming polymers such as, for example, polyolefins. Exemplary polyolefins include one or more of polypropylene, polyethylene, ethylene copolymers, propylene copolymers, and butene copolymers.
3o In another embodiment, the nonwoven web 302 may be a multilayer material , having, for example, at least one layer of a spunbonded web joined to at least one layer of a meltblown web, a bonded carded web, or other suitable material.
- The nonwoven web may be joined to a polymeric film to form a laminate.
Suitable polymeric film materials include but are not limited to polyolefins, such as 3s polyethylenes, polypropylene, ethylene copolymers, propylene copolymers, and butene copolymers; nylon (polyamide); metallocene catalyst-based polymers;
cellulose esters; poly (methyl methacrylate); polystyrene; poly (vinyl chloride);
polyester; polyurethane; compatible polymers; compatible copolymers; and blends, laminates and/or combinations thereof.
The nonwoven web 302 may also be a composite made up of a mixture of s two or more different fibers or a mixture of fibers and particles. Such mixtures may be formed by adding fibers and/or particles to the gas stream in which the meltblown fibers or spunbond fibers are carried so that an intimate entangled co-mingling of fibers and other materials, e.g., wood pulp, staple fibers and particles occurs prior to collection of the fibers.
The nonwoven web of fibers should be joined by bonding to form a coherent web structure. Suitable bonding techniques, include, but are not limited to, chemical bonding, thermobonding, such as point calendering, hydroentangling, and needling.
Referring to FIGS. 5 and 6, the nonwoven web weakening arrangement 308 preferably comprises an ultrasonic transducer 306 and a cylinder 310. As the is nonwoven material 302 is forwarded between the ultrasonic transducer 306 and the anvil cylinder 310, the nonwoven web 302 is subjected to ultrasonic vibrational energy whereupon predetermined pattern locations of the nonwoven web 302 are weakened and melt-stabilized. Anvil 310 has a multiplicity of discrete pattern protuberances which are generally designated 316 disposed on its outwardly facing zo surface 314 in a predetermined pattern which extends about the entire circumference of the anvil cylinder. The protuberances 316 are disposed in a predetermined pattern with each protuberance 316 being configured and disposed to precipitate a weakened, melt-stabilized location 304 in the nonwoven web 302 to effect a predetermined pattern of weakened, melt-stabilized locations in the nonwoven web 2s 302. As shown in FIG. 6, anvil 310 has a repeating pattern of protuberances which extend about the entire circumference of surface 314. Alternatively, the protuberances 316 may extend around a portion, or portions of the circumference of surface 314.
The protuberances 316 are preferably truncated conical shapes which extend 3o radially outward from the surface 314 and which have elliptical distal end surfaces.
Other suitable shapes for the distal end include, but are not limited to, circular, square, rectangular, etc. The anvil 310 is finished so that all of the end surfaces lie in an imaginary right circular cylinder which is coaxial with respect to the axis of rotation of anvil 310.
3s After having passed through the weakening arrangement 308, and prior to passing through the nip 330 of the incremental stretching system 332, the nonwoven WO 97/11662 ' PCT/US96/14643 web 302 includes a plurality of weakened, melt-stabilized locations 304 which generally correspond to the pattern of protuberances 316 extending from the surface 314 of anvil 310.
From the weakening arrangement 308, the nonwoven web 102 passes s ° through nip 330 formed by the incremental stretching system 332 employing opposed pressure applicators having three-dimensional surfaces which at least to a degree are complementary to one another. The incremental stretching system 332 preferably comprises incremental stretching rollers 334 and 336. The incremental stretching roller 334 includes a plurality of teeth and corresponding grooves which io extend about the entire circumference of the roller 334. Incremental stretching roller 336 includes a plurality of teeth and a plurality of corresponding grooves.
Teeth on roller 334 intermesh or engage with the grooves on roller 136, while the teeth on roller 336 intermesh with or engage with the grooves on the roller 334. As the nonwoven web 302 having weakened, melt-stabilized locations 304 passes through ~s the incremental stretching system 332, the nonwoven web is subjected to tensioning causing the web to be extended. The tensioning force placed on the nonwoven web is adjusted such that it causes the weakened, melt-stabilized locations 304 to rupture creating a plurality of apertures in the nonwoven web which are coincident with the weakened melt-stabilized locations.
2o The nonwoven web 302 is preferably taken up on wind-up roll 380 and stored. Alternatively, the nonwoven web 302 may be fed directly to a production line where it is used to form a topsheet on a disposable absorbent article.
The diaper 20 preferably further comprises elasticized leg cuffs 32 for providing improved containment of liquids and other body exudates. Each as elasticized leg cuff 32 may comprise several different embodiments for reducing the leakage of body exudates in the leg regions. (The leg cuff can be and is sometimes also referred to as leg bands, side flaps, barrier cuffs, or elastic cuffs.) U.S. Patent 3,860,003 describes a disposable diaper which provides a contractible leg opening having a side flap and one or more elastic members to provide an elasticized leg cuff 30 (gasketing cuff). U.S. Patent 4,909,803 entitled "Disposable Absorbent Article Having Elasticized Flaps" issued to Aziz et al. on March 20, 1990, describes a disposable diaper having "stand-up" elasticized flaps (burner cuffs) to improve the containment of the leg regions. U.S. Patent 4,695,278 entitled "Absorbent Article Having Dual Cuffs" issued to Lawson on September 22, 1987, describes a 3s disposable diaper having dual cuffs including a gasketing cuff and a barrier cuff.
U.S. Patent 4,704,115 entitled "Disposable Waist Containment Garment" issued to Buell on November 3, 1987. discloses a disposable diaper or incontinence garment having side-edge-leakage-guard gutters configured to contain free liquids within the garnnent.~ While each . elasticized leg cuff 32 may be configured so as to be similar to any of the leg bands, s side flaps. barrier cuffs, or elastic cuffs described above, it is preferred that each elasticized leg cuff 32 comprise at lest an inner barrier cuff comprising a battier flap and a spacing element such as described in the above-referenced U.S. Pat.
No.
4,909,803. In a preferred embodiment, the elasticized leg cuts 32 additionally comprises an elastic gasketing cuff with one or more elastic strands, positioned ~o outboard of the barrio cuff such as described in the above-referred U.S.
Pat. No.
4,695278.
The diaper 20 preferably funirer comprises an elasticized waistband 34 that provides improved fit and cantairurtent. The elasdcizai waistband 34 is that.
portion or zone of the diaper 20 which is intended to elastically expand and contract to is dynamically fit the wearer's waist. 'Tile elasticized waiatbar>d 34 preferably extends longitudinally outwardly from at least one of the waist edges of the absorbent core 28 and generally forms at least a portion of the end edge of the diaper 20.
Disposable digs are gsneraliy cona~r~ted so as to have tvvo elasticized waistbands, one positioned in the rest waist region and one positioned in the front Io waist region, although diapers can be constructed with a single elasticized waistband. Further, while the etasticizsd waistband 34 or any of its constituent elements can comprise a separate element affixed to the diaper 20, the elasticized waistband 34 may be consnuctad as an acde~on of other elements of the diaper such as the baakshaet 26 or the 24, preferably bath the backsiaert 26 and the zs topsheet 24. The elate w~tbe~ 34 may be conswcted ui a number of di$er~ent configurations including tl~e described in U.S. Patent 4,5 i 5.595 entitled "Dispoasble Diapers with Elastically Contractible Waistbands" issued to Kievit et al.
on May ~, 1985 and the above refixresraed L1.S. Patent 5,151,092 issued to Huell.
so In a preferred embodies. ~ ' 20 also ccsaprises elasticized side panels 30 disposed in tt~e rear waist region 44. (As used hcp~ein, the tens "disposed"
is used to mean that an elks) of the di4per is forntod (joined and positioned) in a particular plue or position as a unitary structure with otixr elements of the diaper or as a separate element joined to another element of the diaper.) The elasticized as side panels 30 provide an elastically extensible featmr that provides a more comfortable and contouring fit by initially conformably fitting the, diaper to the wearer and sustaining this fit throughout the -time of wear well passed when the diaper has been loaded with exndatcs since the elasticizced side panels allow the sides of the diaper to expand and contract. The elasticized side panels 30 further provide more effective application of the diaper 20 sitsce even if the diaperer pulls one s elasticized side panel 30 ,farther than the other during the application (asymmetrically), the diaper 20 will "self adjust" during wear. While the diaper 20 of the present invention preferably has the elasticized side panels 30 disposed in the rear waist region 44; alternatively, the diaper 20 may also be provided with elasticized side panels disposed in the front waist region 46 and the rear waist region ~0 44. While the elasticized side panels 30 may lx consuucted in a number of configurations. examples of diapers with elasticized side parcels arc disclosed in U.S.
Pat. No. 4,857.067, entitled "Disposable Diaper Having Shined Ears" issued to Wood, et al. on August 15, 1989; U.S. Pat. No. 4,381.781 issued to Sciaraffa, et al.
on May 3. 1983: U.S. Pat. No. 4,938,753 issued to Van Gampel, et al. on July 3, ~ s 1990; and in U.S. Pat. No. 5,151,092 issued to Buell et al. on September 29, 1992.
Suitable elastic materials for use as the elasticized side panels itxlwde clastomaic foams, synthetic or natural rubber, synthetic or natural rubber foams, elastatrueric films, elastomeric scrim, elastomeric viroven or nonwoven webs, elastomeric compositta such as elastomeric :o nonwovcn larrtinates, or the like.
The diaper 20 also comprises a fastening sysd~m 3b which forms a side ctosure which maintains the rear waist region 44 and the firarit waist region 46 in as overlapping configuration s~h that lateral tensions an maintained around the circumferemx of the diaper to maintain the diaper on the wcara- Exemplary a fastening systems ace disclosed in U,S. Pat. No. 4,8b9,724 issued to Scripps on September 2b, 1989; U,S. Pat. Nor 4,846.815 issued to Script on July 11, 1989;
U.S. Pat' No. 4,894,060 issued to Nesugard an January Ib, 19'90; U.S. Pat. No.
4,946,52? issued to Battrell on August 7t ,1990; U.S. Pat. No. 3,848,594 issued to Buell on November 19, 1974; and U.S. Pat.'No. 4.bb2,8?5 issurd to Hirotsu and 30 Robertson on May 5, 1987.
While particular embodiments of tttee ptes~nt invctttion have been illustrated and described, it would be obvious to those sltilled in the art that various other changes and modifications can be made without departing fiam the spirit and scope 3s of the invention. It is tlxrcfore intrreded to cover in the agperukd claims all such changes and modifications that ace within the scope of this invention._
Claims (31)
1. A method for selectively aperturing a nonwoven web comprising the steps of:
a) providing a nonwoven web;
b) weakening said nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations;
c) providing an incremental stretching means; and d) subjecting said nonwoven web to incremental stretching by said incremental stretching means causing said nonwoven web to rupture at said plurality of weakened, melt-stabilized locations creating a plurality of apertures in said nonwoven web coincident with said plurality of weakened, melt-stabilized locations.
a) providing a nonwoven web;
b) weakening said nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations;
c) providing an incremental stretching means; and d) subjecting said nonwoven web to incremental stretching by said incremental stretching means causing said nonwoven web to rupture at said plurality of weakened, melt-stabilized locations creating a plurality of apertures in said nonwoven web coincident with said plurality of weakened, melt-stabilized locations.
2. The method of claim 1 further comprising selecting said nonwoven web from the group consisting of a bonded carded web of fibers, a web of spunbonded fibers, a web of meltblown fibers, and a multilayer material including at least one of said webs.
3. The method of claim 2 further comprising including meltblown microfibers in said meltblown web.
4. The method of claim 2 further comprising selecting a polymer from said fibers from the group consisting of polyolefins, polyesters, and polyamides.
5. The method of claim 4 further comprising selecting said polyolefin from the group consisting of one or more of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
6. The method of claim 5 further comprising selecting said nonwoven web as a composite material comprising a mixture of fibers and one or more other materials from the group consisting of wood pulp, staple fibers, particulates and superabsorbent materials.
7. The method of claim 1 further comprising providing said nonwoven web as an elastic nonwoven web.
8. The method of claim 1 further comprising providing said nonwoven web as a nonelastic nonwoven web.
9. The method of claim 1 further comprising providing said nonwoven web as an extensible nonwoven web.
10. The method of claim 1 further comprising forming said nonwoven web as a laminate with a polymeric film.
11. The method of claim 1 further comprising weakening said nonwoven web in a pattern.
12. The method of claim 1 further comprising weakening said nonwoven web using heat.
13. The method of claim 1 further comprising weakening said nonwoven web using pressure.
14. The method of claim 1 wherein said incremental stretching comprises feeding said nonwoven web through a nip formed by a pair of incremental stretching rollers.
15. The method of claim 14 further comprising providing said incremental stretching roller with a plurality of teeth and a plurality of grooves.
16. A method for selectively aperturing a bonded nonwoven web comprising the steps of:
a) providing a nonwoven web;
b) weakening said nonwoven web without rupturing said nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations;
c) providing an incremental stretching means; and d) subjecting said nonwoven web to incremental stretching by said incremental stretching means causing said nonwoven web to rupture at said plurality of weakened, melt-stabilized locations creating a plurality of apertures in said nonwoven web coincident with said plurality of weakened, melt-stabilized locations.
a) providing a nonwoven web;
b) weakening said nonwoven web without rupturing said nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations;
c) providing an incremental stretching means; and d) subjecting said nonwoven web to incremental stretching by said incremental stretching means causing said nonwoven web to rupture at said plurality of weakened, melt-stabilized locations creating a plurality of apertures in said nonwoven web coincident with said plurality of weakened, melt-stabilized locations.
17. The method of claim 16 wherein said incremental stretching comprises feeding said nonwoven web through a nip formed by a pair of incremental stretching rollers.
18. The method of claim 17 further comprising providing said incremental stretching roller with a plurality of teeth and a plurality of grooves.
19. A nonwoven web made according to a method comprising the steps of:
a) providing a nonwoven web, wherein said nonwoven web is provided with a patterned plurality of spaced apart discrete bonds to form a coherent web structure;
b) weakening said nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations, wherein a portion of said spaced apart descrete bonds are separated from said melt-stabilized locations; and c) applying a tensioning force to said nonwoven web to cause said nonwoven web to rupture at said plurality of weakened, melt-stabilized locations so as to create a plurality of apertures in said nonwoven web coincident with said plurality of weakened, melt-stabilized locations, said apertures having a circumferential edge, a portion of which edge is defined by a remnant of the melt stabilized locations, without substantially rupturing any of said spaced apart discrete separated bonds that are from said melt stabilized locations.
a) providing a nonwoven web, wherein said nonwoven web is provided with a patterned plurality of spaced apart discrete bonds to form a coherent web structure;
b) weakening said nonwoven web at a plurality of locations to create a plurality of weakened, melt-stabilized locations, wherein a portion of said spaced apart descrete bonds are separated from said melt-stabilized locations; and c) applying a tensioning force to said nonwoven web to cause said nonwoven web to rupture at said plurality of weakened, melt-stabilized locations so as to create a plurality of apertures in said nonwoven web coincident with said plurality of weakened, melt-stabilized locations, said apertures having a circumferential edge, a portion of which edge is defined by a remnant of the melt stabilized locations, without substantially rupturing any of said spaced apart discrete separated bonds that are from said melt stabilized locations.
20. A fibrous nonwoven web comprising a plurality of apertures formed by application of a tensioning force, said apertures coincident with a plurality of weakened, melt-stabilized locations, said apertures having a circumferential edge, a portion of said circumferential edge being defined by a remnant of said melt-stabilized locations and further comprising a patterned plurality of spaced apart discrete bonds, wherein said spaced apart discrete bonds are separated from said melt stabilized locations, and further wherein said fibers are joined by said spaced apart discrete bonds to form a coherent web structure, said spaced apart discrete bonds being substantially unruptured by said application of said tensioning force.
21. The nonwoven web of claim 20, wherein said nonwoven web forms a topsheet on a disposable absorbent article.
22. The nonwoven web of claim 21, wherein said nonwoven web forms a topsheet on a disposable diaper.
23. The nonwoven web of claim 21, wherein said nonwoven web forms a topsheet on a feminine hygiene garment.
24. The nonwoven web of claim 20 wherein said nonwoven web is a web selected from the group consisting of a bonded carded web of fibers, a web of spunbonded fibers, a web of meltblown fibers, and a multilayer material including at least one of said webs.
25. The nonwoven web of claim 24 wherein said meltblown web includes meltblown microfibers.
26. The nonwoven web of claim 24 wherein said fibers comprise a polymer selected from the group consisting of polyolefins, polyesters, and polyamides.
27. The nonwoven web of claim 26 wherein said polyolefin is selected from the group consisting of one or more of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
28. The nonwoven web of claim 27 wherein said nonwoven web is a composite material comprising a mixture of said fibers and one or more other materials selected from the group consisting of wood pulp, staple fibers, particulates and superabsorbent materials.
29. The nonwoven web of claim 20 wherein said nonwoven web comprises an elastic nonwoven web.
30. The nonwoven web of claim 20 wherein said nonwoven web comprises a nonelastic nonwoven web.
31. The nonwoven web of claim 20 wherein said nonwoven web comprises an extensible nonwoven web.
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US08/536,228 US5628097A (en) | 1995-09-29 | 1995-09-29 | Method for selectively aperturing a nonwoven web |
US08/536,228 | 1995-09-29 | ||
PCT/US1996/014643 WO1997011662A1 (en) | 1995-09-29 | 1996-09-12 | A method for selectively aperturing a nonwoven web |
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CA2233236C true CA2233236C (en) | 2003-11-04 |
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CA002233236A Expired - Fee Related CA2233236C (en) | 1995-09-29 | 1996-09-12 | A method for selectively aperturing a nonwoven web |
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EP (1) | EP0852483B1 (en) |
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-
1995
- 1995-09-29 US US08/536,228 patent/US5628097A/en not_active Expired - Lifetime
-
1996
- 1996-09-12 DE DE69620773T patent/DE69620773T2/en not_active Expired - Lifetime
- 1996-09-12 BR BR9610999A patent/BR9610999A/en not_active IP Right Cessation
- 1996-09-12 JP JP51347297A patent/JP3249530B2/en not_active Expired - Lifetime
- 1996-09-12 CA CA002233236A patent/CA2233236C/en not_active Expired - Fee Related
- 1996-09-12 KR KR1019980702355A patent/KR100266493B1/en not_active IP Right Cessation
- 1996-09-12 WO PCT/US1996/014643 patent/WO1997011662A1/en active Search and Examination
- 1996-09-12 CN CN96198375A patent/CN1202100A/en active Pending
- 1996-09-12 ES ES96931539T patent/ES2171718T3/en not_active Expired - Lifetime
- 1996-09-12 EP EP96931539A patent/EP0852483B1/en not_active Expired - Lifetime
- 1996-09-12 AU AU70190/96A patent/AU7019096A/en not_active Abandoned
- 1996-09-27 ZA ZA968181A patent/ZA968181B/en unknown
- 1996-12-26 TW TW085116054A patent/TW350001B/en active
-
1997
- 1997-03-03 US US08/810,205 patent/US5916661A/en not_active Expired - Lifetime
-
1999
- 1999-01-15 HK HK99100223A patent/HK1015248A1/en not_active IP Right Cessation
Also Published As
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CN1202100A (en) | 1998-12-16 |
JP3249530B2 (en) | 2002-01-21 |
US5628097A (en) | 1997-05-13 |
EP0852483B1 (en) | 2002-04-17 |
DE69620773T2 (en) | 2002-11-28 |
DE69620773D1 (en) | 2002-05-23 |
CA2233236A1 (en) | 1997-04-03 |
AU7019096A (en) | 1997-04-17 |
KR100266493B1 (en) | 2000-09-15 |
BR9610999A (en) | 1999-07-13 |
EP0852483A1 (en) | 1998-07-15 |
ZA968181B (en) | 1997-05-02 |
TW350001B (en) | 1999-01-11 |
WO1997011662A1 (en) | 1997-04-03 |
KR19990063883A (en) | 1999-07-26 |
MX9802481A (en) | 1998-10-31 |
ES2171718T3 (en) | 2002-09-16 |
JPH11504993A (en) | 1999-05-11 |
HK1015248A1 (en) | 1999-10-15 |
US5916661A (en) | 1999-06-29 |
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