Method of making multi-layer female component for refastenable fastening device

• US 6,849,142 B1
• Filed: 10/19/1993
• Issued: 02/01/2005
• Est. Priority Date: 05/20/1991
• Status: Expired due to Fees

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Goulait, David Joseph Kenneth
• Primary Examiner(s): Johnstone, Adrienne C.
• Application Number:
  US08/139,363
• Time in Patent Office: 4,123 Days
• Field of Search: 244/42, 244/50, 428 99-100, 428/137, 428/286, 428/294, 52D/IG.13, 156/66, 156 622- 628, 156/167, 156176-182, 156/209, 156/219, 156221-222, 156/276, 156/308.2, 156/73.1, 604/386, 604/391, 604/389
• US Class Current: 156/62.4
• 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 female component for engaging a complementary hook component in a refastenable fastening device 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. 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. 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 method of making a multi-zone female component for a refastenable fastening device, said method comprising the steps of:

(a) providing a first material having a basis weight of between about 8.5 and about 18 g/m² and being comprised of a plurality of fibers with a denier of between about 2 and about 15 for a first zone;

(b) providing a second material having a basis weight of between about 8.5 and about 36 g/m² and being comprised of a plurality of fibers with a denier of between about 2 and about 15 for a second zone;

(c) providing a backing material; and

(d) securing at least said first material to said backing material so that said second material is positioned between said first material and said backing material.

2. The method of claim 1 wherein said first material comprises loose fibers.

3. The method of claim 1 wherein the step (a) of providing a first material comprises depositing a layer of loose fibers onto said second material.

4. The method of claim 1 wherein said first material comprises a web of bonded fibers.

5. The method of claim 1 wherein the step (a) of providing a first material comprises unwinding a web of bonded fibers from a roll.

6. The method of claim 1 wherein the step (a) of providing a first material comprises supplying a web of spunbonded fibers from a spunbonding machine.

7. The method of claim 1 wherein the fibers of said first material are primarily oriented in a single direction.

8. The method of claim 1 wherein said second material comprises loose fibers.

9. The method of claim 1 wherein the step (b) of providing a second material comprises depositing a layer of loose fibers onto said backing material.

10. The method of claim 1 wherein said second material comprises a web of bonded fibers.

11. The method of claim 1 wherein the step (b) of providing a second material comprises unwinding a web of bonded fibers from a roll.

12. The method of claim 1 wherein the step (b) of providing a second material comprises supplying a web of carded fibers from a carding machine.

13. The method of claim 1 wherein the fibers of said second material are randomly oriented.

14. The method of claim 1 wherein the fibers of said second material are crimped.

15. The method of claim 1 wherein said backing material comprises a material selected from the group consisting of:

a film, a nonwoven web of material, and a woven fabric.

16. The method of claim 1 wherein said first material is adhesively bonded to said second material and said second material is adhesively bonded to said backing material.

17. The method of claim 1 wherein said first material is bonded to said backing material by a heat process or a heat and pressure process.

18. The method of claim 1 wherein said first material is bonded to said backing by an ultrasonic process.

19. A method of making a multi-zone female component for a refastenable fastening device, said female component being capable of engaging a complementary hook fastening component which has a base with individual hooks having blunt heads extending outward from said base, said method comprising the steps of:

(a) providing a first material comprised of at least one structural element, said first material being capable of 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;

(b) providing a second material comprised of at least one structural element, said second material being capable of providing a multiplicity of openings for said hooks so that a plurality of the hooks of the hook component may at least partially readily penetrate the thickness of said second material without forcibly piercing said second material;

(c) providing a backing material; and

(d) bonding at least said first material to said backing material so that said second material is held in place with respect to said backing material with said second material in between said first material and said backing material.

20. The method of claim 19 wherein said first material is selected from the group consisting of:

a woven material comprised of a plurality of yarns that define interstices therebetween;

a screen comprised of a plurality of structural elements that define interstices therebetween;

a perforated film having perforations that define interstices in said perforated film; and

a foam having a plurality of interstices therein.

21. The method of claim 20 wherein the complementary hook fastening component has hooks which have an overall height, and the heads of said hooks have a length, a width, a height, the length and width defining the projected plan view dimensions of the heads of said hooks, and said interstices are larger than the projected plan view dimensions of the heads of said hooks.

22. The method of claim 21 wherein said interstices have dimensions that are greater than about 0.5 mm. by about 0.2 mm.

23. The method of claim 19 or 20 wherein said second material is selected from the group consisting of:

(i) at least one nonwoven web;

(ii) at least one layer of woven material;

(iii) at least one thickness of a screen; and

, (iv) a plurality of loose particles.

24. The method of claim 23 wherein the complementary hook fastening component has hooks which have an overall height, and the heads of said hooks have a length, a width, a height, the length and width defining the projected plan view dimensions of the heads of said hooks, and said second material comprises at least one layer of woven material having interstices that are larger than the projected plan view dimensions of the heads of said hooks.

25. The method of claim 23 wherein the complementary hook fastening component has hooks which have an overall height, and the heads of said hooks have a length, a width, a height, the length and width defining the projected plan view dimensions of the heads of said hooks, and said second material comprises at least one thickness of a screen having interstices that are larger than the projected plan view dimensions of the heads of said hooks.

26. The method of claim 23 wherein said second material comprises loose particles having a largest dimension of less than or equal to the overall height of the hooks of the mating hook component.

27. The multi-zone female component of claim 23 wherein said backing material comprises a material selected from the group consisting of:

a film, a nonwoven web of material, and a woven fabric.

28. A method of making a multi-zone female component for a refastenable fastening device, said female component being capable of engaging a complementary hook fastening component which has a base with individual hooks having blunt heads extending outward from said base, said method comprising the steps of:

(a) providing a first material comprised of at least one structural element, said first material being capable of 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;

(b) providing a second material comprised of at least one structural element, said second material being capable of providing a multiplicity of openings for said hooks so that a plurality of the hooks of the hook component may at least partially readily penetrate the thickness of said second material without forcibly piercing said second material, wherein said second material is selected from the group consisting of;

(i) at least one nonwoven web;

(ii) at least one layer of woven material;

(iii) at least one thickness of a screen; and

, (iv) a plurality of loose particles;

(c) providing a backing material; and

(d) bonding at least said first material to said backing material by a heat process, a heat and pressure process, and/or by an ultrasonic process so that said second material is held in place with respect to said backing material with said second material in between said first material and said backing material.