Zero scrap method for manufacturing side panels for absorbent articles

• US 5,580,411 A
• Filed: 02/10/1995
• Issued: 12/03/1996
• Est. Priority Date: 02/10/1995
• Status: Expired due to Term

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Moran, Richard T., Bergman, Carl L., Nease, Michael G.
• Primary Examiner(s): Simmons, David A.
• Assistant Examiner(s): GRAY, LINDA LAMEY
• Application Number:
  US08/386,832
• Time in Patent Office: 662 Days
• Field of Search: 156/260, 156/259, 156/266, 156/265, 156/264, 156/256, 156/263, 156/66, 156/182, 156/512, 156/177, 156/160, 156/163, 604/385.1, 604/385.2, 604/384
• US Class Current: 156/260
• CPC Class Codes: A61F 13/15699 Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs
• CPC Class Codes: A61F 13/15804 Plant, e.g. involving several steps
• CPC Class Codes: A61F 13/49009 with elastic means
• CPC Class Codes: A61F 13/49015 the elastic means being elastic panels
• CPC Class Codes: Y10T 156/1069 Bonding face to face of laminae cut from single sheet
• CPC Class Codes: Y10T 156/1075 of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 156/1077 Applying plural cut laminae to single face of additional lamina

Abstract

A zero scrap method for manufacturing side panels for use with absorbent articles including the following steps. First, a web of material having predetermined portions is provided in a machine direction. The predetermined portions are then activated to provide stretch in the side panels. The web is then cut continuously severing the web into a first panel and a second panel, each of the panels having alternating, nested inwardly extending elements defined by the cut and terminating at a distal edge. The inwardly extending elements are offset with respect to each other in the machine direction. The first and second panels are separated and positioned such that the inwardly extending elements of the first panel and the inwardly extending elements of the second panel are aligned in the machine direction. The distal edge of at least a portion of the first panel is then joined with at least a portion of the distal edge of the second panel. Finally, the composite of the first and second panels is severed in the cross machine direction to create an extensible side panel that can be joined to an absorbent article.

Claims

1. A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

a) providing a web of material in a machine direction, said web having predetermined portions;

b) activating said predetermined portions of said web of material to impart elasticity thereto;

c) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;

d) separating said first panel from said second panel;

e) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction; and

f) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;

wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut from said first and second panels, said front side panels being positioned in a front waist region of said diaper web and said rear side panels being positioned in a rear waist region of said diaper web before being joined to said diaper web.

2. A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

a) providing a web of material in a machine direction, said web having predetermined portions;

b) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal

side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;

c) separating said first panel from said second panel;

d) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction; and

e) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;

wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut from said first and second panels, said front side panels being positioned in a front waist region of said diaper web and said rear side panels being positioned in a rear waist region of said diaper web before being joined to said diaper web.

3. A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

a) providing a web of material in a machine direction, said web having predetermined portions;

b) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;

c) separating said first panel from said second panel;

d) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction; and

e) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;

wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut and separated from each other after said side panels are joined to said diaper web.

4. A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edge, the method comprising the steps of:

a) providing a web of material in a machine direction said web having predetermined portions;

b) activating said predetermined portions of said web of material to impart elasticity thereto;

c) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;

d) separating said first panel from said second panel;

e) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction; and

f) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article.

wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut and separated from each other after said side panels are joined to said diaper web.

5. A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

a) providing a web of material in a machine direction, said web having predetermined portions;

b) activating said predetermined portions of said web of material to impart elasticity thereto;

c) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;

d) separating said first panel from said second panel;

e) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;

f) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;

g) rotating said first and said second panels such that said inwardly extending elements are outboard of said longitudinal side edges;

h) aligning said longitudinal side edges of said first and said second panels with said opposed longitudinal edges of said diaper web; and

i) joining said side panels along said longitudinal edges of said diaper web;

wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut from said first and second panels, said front side panels being positioned in a front waist region of said diaper web and said rear side panels being positioned in a rear waist region of said diaper web before being joined to said diaper web.

6. A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

a) providing a web of material in a machine direction, said web having predetermined portions;

b) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;

c) separating said first panel from said second panel;

d) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;

e) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;

f) rotating said first and said second panels such that said inwardly extending elements are outboard of said longitudinal side edges;

g) aligning said longitudinal side edges of said first and said second panels with said opposed longitudinal edges of said diaper web; and

h) joining said side panels along said longitudinal edges of said diaper web;

wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut from said first and second panels, said front side panels being positioned in a front waist region of said diaper web and said rear side panels being positioned in a rear waist region of said diaper web before being joined to said diaper web.

7. A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

a) providing a web of material in a machine direction, said web having predetermined portions;

b) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;

c) separating said first panel from said second panel;

d) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;

e) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;

f) rotating said first and said second panels such that said inwardly extending elements are outboard of said longitudinal side edges;

g) aligning said longitudinal side edges of said first and said second panels with said opposed longitudinal edges of said diaper web; and

h) joining said side panels along said longitudinal edges of said diaper web;

wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut and separated from each other after said side panels are joined to said diaper web.

8. A zero scrap method for manufacturing side panels to be joined to a diaper web having opposed longitudinal edges, the method comprising the steps of:

a) providing a web of material in a machine direction, said web having predetermined portions;

b) activating said predetermined portions of said web of material to impart elasticity thereto

c) making a continuous cut in said web, said cut severing said web into a first panel and a second panel, each of said panels having longitudinal side edges and alternating, nested inwardly extending elements defined by said cut and terminating at a distal edge, said inwardly extending elements being offset in said machine direction;

d) separating said first panel from said second panel;

e) aligning said inwardly extending elements of said first panel and said second panel such that said distal edges of said inwardly extending elements are aligned in the machine direction;

f) severing said first and said second panels at predetermined locations to create side panels to be joined to said absorbent article;

g) rotating said first and said second panels such that said inwardly extending elements are outboard of said longitudinal side edges;

h) aligning said longitudinal side edges of said first and said second panels with said opposed longitudinal edges of said diaper web; and

i) joining said side panels along said longitudinal edges of said diaper web;

wherein each of said inwardly extending elements of said first and second panels comprises a front side panel and a rear side panel, said front side panel and said rear side panel being cut and separated from each other after said side panels are joined to said diaper web.