Process for manufacturing disposable fluid-handling article
First Claim
1. A method for manufacturing a disposable fluid-handling article, the disposable fluid-handling article comprising at least two primary components made continuously from bulk starting materials, the method comprising the steps of:
- a) feeding a first polymeric bulk starting material into at least one first polymeric extrusion apparatus disposed adjacent to a first collecting surface moving at a first velocity in relation to the first polymeric extrusion apparatus;
b) extruding a first molten stream of a first polymeric material from the first polymeric extrusion apparatus;
c) continuously forming a first primary component of the disposable fluid-handling article from the first molten stream;
d) feeding a second polymeric bulk starting material into at least one second polymeric extrusion apparatus disposed adjacent to a second collecting surface moving at a second velocity in relation to the second polymeric extrusion apparatus;
e) extruding a second molten stream of a second polymeric material from the second polymeric extrusion apparatus;
f) continuously forming a second primary component of the disposable fluid-handling article from the second molten stream;
g) joining the first and second primary components into a composite web, wherein the first primary component overlaps at least partially with the second primary component; and
h) severing the composite web in a direction generally perpendicular to a machine direction so as to form the disposable fluid-handling article.
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Accused Products
Abstract
A method and an apparatus for manufacturing disposable fluid-handling articles including absorbent articles (e.g., baby diapers, adult incontinence articles, feminine hygiene articles, baby swim diapers, dining bibs, wound dressing) and benefit-component-delivering articles (e.g., wash cloth, body wipes, body wraps, pet grooming articles, cleaning and polishing articles) are disclosed. The present invention can combine the web-forming technology with the web-converting technology into a continuous process for making a disposable fluid-handling article, wherein two or more of the components of the fluid-handling article are formed on the converting line from extruded polymeric materials. Thus, the new method and apparatus can reduce or eliminate the need for continuous webs of fabrics, films, foams, elastics, etc. that have been transported from web producers in a packaged form, e.g., wound rolls and festooned boxes.
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Citations
34 Claims
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1. A method for manufacturing a disposable fluid-handling article, the disposable fluid-handling article comprising at least two primary components made continuously from bulk starting materials, the method comprising the steps of:
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a) feeding a first polymeric bulk starting material into at least one first polymeric extrusion apparatus disposed adjacent to a first collecting surface moving at a first velocity in relation to the first polymeric extrusion apparatus;
b) extruding a first molten stream of a first polymeric material from the first polymeric extrusion apparatus;
c) continuously forming a first primary component of the disposable fluid-handling article from the first molten stream;
d) feeding a second polymeric bulk starting material into at least one second polymeric extrusion apparatus disposed adjacent to a second collecting surface moving at a second velocity in relation to the second polymeric extrusion apparatus;
e) extruding a second molten stream of a second polymeric material from the second polymeric extrusion apparatus;
f) continuously forming a second primary component of the disposable fluid-handling article from the second molten stream;
g) joining the first and second primary components into a composite web, wherein the first primary component overlaps at least partially with the second primary component; and
h) severing the composite web in a direction generally perpendicular to a machine direction so as to form the disposable fluid-handling article. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A production line for producing a disposable fluid-handling article, the disposable fluid-handling article comprising at least two primary components made continuously from bulk starting materials, the production line comprising:
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(i) a first primary component station for providing a first primary component, wherein the first primary component station includes at least one first extrusion module for forming the first primary component from one or more first polymeric bulk starting material by extrusion and formation of the first primary component continuously on the production line; and
(ii) a second primary component station adjacent to the first primary component station for providing a second primary component, wherein the second primary component station includes at least one second extrusion module for forming the second primary component from one or more second polymeric bulk starting material by extrusion and formation of the second primary component continuously on the production line. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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Specification