Multi-layer female component for refastenable fastening device and method of making the same

• US 5,407,439 A
• Filed: 06/01/1994
• Issued: 04/18/1995
• Est. Priority Date: 05/20/1991
• Status: Expired due to Term

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Goulait, David J. K.
• Primary Examiner(s): Green, Randall L.
• Assistant Examiner(s): ZUTTARELLI, ANTHONY
• Application Number:
  US08/252,985
• Time in Patent Office: 321 Days
• Field of Search: 604/358, 604/385.1, 604/386, 604/389, 604/391, 602/45, 602/57-58, 24/450, 428/99, 428/100, 428/286, 428/294
• US Class Current: 604/391
• CPC Class Codes: A44B 18/0011 Female or loop elements A44B18/0007 takes precedence
• CPC Class Codes: A44B 18/0061 Male or hook elements A44B18/0053 takes precedence
• CPC Class Codes: A61F 13/627 characterised by the loop
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29L 2031/729 Hook and loop-type fasteners
• CPC Class Codes: G01R 19/16542 for batteries charge condition monitoring in G01R31/36
• CPC Class Codes: G01R 19/225 by means of thermocouples or other heat sensitive elements
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 10/488 Cells or batteries combined with indicating means for external visualization of the condition, e.g. by change of colour or of light density
• CPC Class Codes: H01M 6/505 Cells combined with indicating means for external visualization of the condition, e.g. by change of colour or of light intensity
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 156/1008 Longitudinal bending
• CPC Class Codes: Y10T 156/101 Prior to or during assembly with additional lamina
• CPC Class Codes: Y10T 156/1011 Overedge bending or overedge folding
• CPC Class Codes: Y10T 156/1023 Surface deformation only [e.g., embossing]
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly
• CPC Class Codes: Y10T 156/1044 of parallel stacked sheets only
• CPC Class Codes: Y10T 156/1046 Bending of one lamina only
• CPC Class Codes: Y10T 24/27 including readily dissociable fastener having numerous, protruding, unitary filaments randomly interlocking with, and simultaneously moving towards, mating structure [e.g., hook-loop type fastener]
• CPC Class Codes: Y10T 24/2708 : Combined with diverse fastener
• CPC Class Codes: Y10T 24/2758 : Thermal or adhesive
• CPC Class Codes: Y10T 24/2775 : having opposed structure formed from distinct filaments of diverse shape to those mating therewith
• CPC Class Codes: Y10T 24/2792 : having mounting surface and filaments constructed from common piece of material
• CPC Class Codes: Y10T 428/24008 : including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/24017 : Hook or barb
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet

Abstract

The present invention provides a female component for engaging a complementary hook component in a refastenable fastening device. The female component of the present invention is capable of engaging a hook component that has flexible, resilient individual hook elements. The female component comprises at least two, and preferably three zones or layers. Each zone has certain of the desired individual characteristics for entangling and holding the hooks of the mating hook component. These include a first zone for admitting and engaging at least some of the hooks of the complementary hook component (the "entanglement" zone), a second zone for providing space for the hooks to occupy after they have been admitted by the entanglement zone (referred to as the "spacing" zone), and a backing adjacent to the spacing zone for providing a foundation for the entanglement and spacing zones. The present invention also provides a fastening device having a hook fastening component and a female component that comprises the multi-layer female component of the present invention. The present invention also relates to disposable articles and more particularly to a disposable diaper having such an improved fastening device.

Claims

1. A multi-zone female component for a refastenable fastening device, said multi-zone female component for engaging a complementary hook fastening component which has a base with individual hooks having blunt heads extending outward from said base, said multi-zone female component comprising:

a first zone comprising a first nonwoven web having a basis weight of between about 8.5 and about 18 g/meter² comprised of fibers with a denier of between about 2 and about 6;

a second zone comprising a second nonwoven web having a basis weight of between about 8.5 and about 36 g/meter² comprised of fibers with a denier of between about 6 and about 15; and

a backing adjacent said second nonwoven web, wherein said first nonwoven web and said second nonwoven web are held in place with respect to said backing with said second nonwoven web in between said first nonwoven web and said backing.

2. The multi-zone female component of claim 1 wherein the first and second nonwoven webs have a composite basis weight of between about 18 and about 42 g/meter².

3. The multi-zone female component of claim 1 wherein the fibers in said first nonwoven web are continuous, and the fibers in said second nonwoven web are between about 1 cm and about 13 cm long.

4. The multi-zone female component of claim 1 wherein the fibers in said first nonwoven web are primarily oriented in a single direction, and the fibers in said second nonwoven web are randomly oriented.

5. The multi-zone female component of claim 1 wherein said fibers in said second nonwoven web are crimped with a crimping frequency of at least about 4 crimps/cm.

6. The multi-zone female component of claim 1 wherein said first nonwoven web is spunbonded and said second nonwoven web is carded.

7. The multi-zone female component of claim 1 wherein said second nonwoven web is resilient.

8. The multi-zone female component of claim 1 wherein said backing comprises a film.

9. The multi-zone female component of claim 1 wherein at least said backing and the fibers comprising said first nonwoven web are comprised of similar materials.

10. The multi-zone female component of claim 9 wherein said backing and the fibers comprising said first nonwoven web are comprised of polyester.

11. The multi-zone female component of claim 9 wherein said backing and the fibers comprising said first nonwoven web are comprised of polyethylene.

12. The multi-zone female component of claim 9 wherein said backing and the fibers comprising said first nonwoven web are comprised of polypropylene.

13. The multi-zone female component of claim 1 wherein said first nonwoven web is secured to said backing by continuous bonds.

14. The multi-zone female component of claim 13 wherein said continuous bonds are disposed in a pattern.

15. The multi-zone female component of claim 1 wherein said first nonwoven web is secured to said backing by intermittent bonds that form bonded areas with breaks between said bonded areas, and said breaks are less than or equal to about 11/2 times of a smallest diameter of the fibers in said first nonwoven web.

16. The multi-zone female component of claim 1 wherein said first nonwoven web and said second nonwoven web are bonded together adhesively, and said second nonwoven web and said backing are bonded together adhesively.

17. The multi-zone female component of claim 1 wherein at least said first nonwoven web and said backing are bonded together autogenously.

18. The multi-zone female component of claim 1 wherein at least said first nonwoven web and said backing are bonded together by ultrasonic bonds.

33. A disposable absorbent article comprising:

a body portion having an inside surface, an outside surface, longitudinal edges, end edges, a first waist region, and a second waist region, said body portion comprising a liquid pervious topsheet, a liquid impervious backsheet joined to said topsheet, and an absorbent core between said topsheet and said backsheet; and

a mechanical fastening system positioned on said body portion comprising

a tab attached to the first waist region of said body portion adjacent each longitudinal edge, each of said tabs comprising a hook fastening component disposed on at least a portion of said tab, and

a female component disposed on said outside surface of said body portion in said second waist region, said female component being mechanically engageable with said hook fastening component, said female component comprising the female component of claims 1 or 20.

34. The disposable absorbent article of claim 33 wherein the fibers comprising said first nonwoven web are generally parallel to said longitudinal edges of said disposable absorbent article.

35. A disposable absorbent article comprising:

a body portion having an inside surface, an outside surface, longitudinal edges, end edges, a first waist region and a second waist region that can be placed in an overlapping configuration, said body portion comprising a liquid pervious topsheet, a liquid impervious backsheet joined to said topsheet, and an absorbent core between said topsheet and said backsheet; and

a mechanical fastening system comprising

a female component disposed on one of said surfaces of said body portion to form an inner fastening member, slid female component comprising the female component of claims 1 or 20;

a hook fastening component positioned on the other surface of said disposable absorbent article, said hook fastening component being mechanically engageable with said female component when said first and second waist regions are in an overlapping configuration.

19. A multi-layer female component for a refastenable fastening device, said multi-layer female component for engaging a complementary hook fastening component which has a base with individual hooks having blunt heads extending outward from said base, said multi-layer female component comprising:

a first layer comprising a first nonwoven web of continuous fibers that are primarily oriented in a single direction, said first nonwoven web having a basis weight of between about 8.5 and about 18 g/meter² and being comprised of fibers with a denier of between about 2 and about 6;

a second layer comprising a second nonwoven web of randomly-oriented crimped fibers, said second nonwoven web having a basis weight of between about 8.5 and about 36 g/meter² and being comprised of fibers between about 1 cm and about 13 cm long with a denier of between about 6 and about 15, said fibers being crimped with a crimping frequency of at least about 4 crimps/cm;

a film backing adjacent said second nonwoven web, wherein said first nonwoven web and said second nonwoven web are held in place with respect to said backing with said second nonwoven web in between said first nonwoven web and said backing; and

said first and second nonwoven webs have a composite basis weight of between about 18 and about 42 g/meter².

20. The multi-layer female component of claim 19 wherein said first nonwoven web is spunbonded.

21. The multi-layer female component of claim 20 wherein said second nonwoven web is carded.

22. The multi-layer female component of claim 21 wherein said second nonwoven web is resilient.

23. The multi-layer female component of claim 22 wherein at least said backing and the fibers comprising said first nonwoven web are comprised of similar materials.

24. The multi-layer female component of claim 23 wherein said backing and the fibers comprising said first nonwoven web are comprised of polyester.

25. The multi-layer female component of claim 23 wherein said backing and the fibers comprising said first nonwoven web are comprised of polypropylene.

26. The multi-layer female component of claim 23 wherein at least said first layer is secured to said backing by continuous bonds.

27. The multi-layer female component of claim 26 wherein said continuous bonds are disposed in a pattern.

28. The multi-layer female component of claim 26 wherein said bonds are autogenous.

29. A multi-zone female component for a refastenable fastening device that is capable of engaging a complementary hook fastening component which has a base with individual hooks extending outward from said base, and said hooks comprise a stem comprising two ends, said stem being supported at one end on said base and having a blunt head supported on the opposite end of said stem, said multi-zone female component comprising:

an entanglement zone for admitting and mechanically entangling at least some of the hooks of the complementary hook component, said entanglement zone comprising a first material comprised of at least one structural element, said first material having a thickness and providing a multiplicity of openings for said hooks so that a plurality of the hooks of the hook component may readily penetrate the thickness of said first material without forcibly piercing said first material, said first material comprising a nonwoven web having a basis weight of between about 8.5 and about 18 g/meter² comprised of fibers with a denier of between about 2 and about 15;

a spacing zone adjacent said entanglement zone for providing space for at least portions of said hooks to occupy after said hooks have penetrated said entanglement zone; and

a backing adjacent said spacing zone for providing a foundation for said entanglement zone and said spacing zone, wherein said entanglement zone and said spacing zone are held in place with respect to said backing with said spacing zone in between said entanglement zone and said backing.

30. A multi-zone female component for a refastenable fastening device that is capable of engaging a complementary hook fastening component which has a base with individual hooks extending outward from said base, and said hooks comprise a stem comprising two ends, said stem being supported at one end on said base and having a blunt head supported on the opposite end of said stem, said multi-zone female component comprising:

an entanglement zone for admitting and mechanically entangling at least some of the hooks of the complementary hook component, said entanglement zone comprising a first material comprised of at least one structural element, said first material having a thickness and providing a multiplicity of openings for said hooks so that a plurality of the hooks of the hook component may readily penetrate the thickness of said first material without forcibly piercing said first material;

a spacing zone adjacent said entanglement zone for providing space for at least portions of said hooks to occupy after said hooks have penetrated said entanglement zone, said spacing zone comprising a second material comprising at least one nonwoven web comprised of fibers with a denier of between about 2 and about 15, said second material having an overall basis weight of between about 8.5 to about 36 g/meter² ; and

a backing adjacent said spacing zone for providing a foundation for said entanglement zone and said spacing zone, wherein said entanglement zone and said spacing zone are held in place with respect to said backing with said spacing zone in between said entanglement zone and said backing.

31. A multi-zone component that is affixed to a substrate to form a female component for a refastenable fastening device, said female component for engaging a complementary hook fastening component which has a base with individual hooks having blunt heads extending outward from said base, said multi-zone component comprising:

a first zone comprising a first nonwoven web having a basis weight of between about 8.5 and about 18 g/meter² comprised of fibers with a denier of between about 2 and about 6,

a second zone comprising a second nonwoven web having a basis weight of between about 8.5 and about 36 g/meter² comprised of fibers with a denier of between about 6 and about 15,

said first nonwoven web being secured to said substrate so that said second nonwoven web is between said first nonwoven web and said substrate.

32. A fastening device comprising a hook fastening material comprising a base and a plurality of engaging elements extending from said base, and a multi-zone component, said multi-zone component comprising the multi-zone component of claim 31.