CA2103278C

CA2103278C - Multi-layer female component for refastenable fastening device and method of making the same

Info

Publication number: CA2103278C
Application number: CA002103278A
Authority: CA
Inventors: David Joseph Kenneth Goulait
Original assignee: Procter and Gamble Co
Current assignee: Procter and Gamble Co
Priority date: 1991-05-20
Filing date: 1992-05-04
Publication date: 1998-05-05
Anticipated expiration: 2012-05-04
Also published as: DE69223780T2; WO1992020250A1; BR9206023A; SG65560A1; US5470417A; EP0585354B1; JPH06507799A; US6637079B1; MX9202363A; PT100505A; ES2110501T3; PT100505B; ATE161400T1; AU696198B2; US5569233A; IE921604A1; CZ282775B6; AU5048096A; EP0585354A1; DK0585354T3

Abstract

The present invention provides a female component (22) for engaging a complementary hook component in a refastenable fastening device (20). The female component (22) comprises at least two, and preferably three zones or layers. These include a first zone (31) for admitting and engaging at least some of the hooks of the complementary hook component (the "entanglement"
zone), a second zone (32) 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 (34) adjacent to the spacing zone (32) 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 multilayer 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.

Description

O 92/20250 ~ 1 0 3 2 7 ~ P(~r/US92/03720 AND METHOD OF MAKING THE SAME

FIEIn OF THE INVENTION

The present invention relates to a female component for a mechanical refastenable fastening device. More particularly, this invention relates to a low-cost multi-layer female component for such a fastening device, and a method for producing such a component.

EAr~rn~llND OF THE INVENTION

Refastenable fastening devices of the hook and loop-type are currently used widely in a great number of situations. Such refastenable fastening devices have been used in clothing, disposable articles, and various miscellaneous articles such as safety belts and the like. Such devices are used when it is desirable to create a refastenable bond between two or more articles or between several surfaces of the same article. In certain applications, these refastenable fastening devices have replaced conventional buckles, zippers, buttons, snaps, tie fasteners, and sewing.

A popular type of mechanical fastener currently in wide use which ut11izes mechanical entanglement to create a refastenable bond is sold under the trademark "VELCROn. VELCRO fastening devices are described in greater detail in U.S. Patent 2,717,437, U.S. Patent 3,009,235, U.S. Patent 3,266,113, U.S. Patent ~ 3,550,837, U.S. Patent 4,169,303, and U.S. Patent 4,984,339.

VELCRO fasteners utilize two components, a male component and a female component. The male and female components are often referred to as the hook and loop components, respective1y. The wo g2/202~0 PCI'/US92/037~
210~27'8 hook component consists of a fabric which contains a plurality of resilient, upstanding hook-shaped elements. The female component of the fastening device consists of a fabric containlng a plurality of upstanding loops on its surface. When the hook component and the loop component are pressed together in a face-to-face relatlonship to close the fastening device, the hooks entangle the loops form1ng a plurality of mechanical bonds between the individual hooks and loops. When these bonds have been created, the components will not generally disengage under normal conditions. This ls because it is very difficult to separate the components by attempting to disengage all of the hooks at once.
However, when a gradual peeling force is applied to the components, dis~nga~ t can be easily effected. Under a peeling force, since the hooks are comprised of a resilient material, they will readily open to release the loops.

This type of fastening device has been found especially useful on disposable articles such as disposable garments, disposable diapers, disposable packages, cartons and the like.
Such fastening devices provide a secure closing means. However, the use of existing fastening devices of this type on disposable articles has been limited due to the fact that such fastening devices are relatively costly. The major reason that such fastening devices are costly is that they have high manufacturing costs. These high manufacturing costs are associated with both the hook and loop components of these devices.

Conventional hook and loop components are typically formed by making a fabric with a number of woven loops extending outwardly from a backing. The loops may be provided by weaving a base fabric containing supplementary threads to form the loops, or by knitting loops into a fabric. In other hook and loop components, the loops may be formed by pleating or corrugating processes. The hook components of such fastening devices are typically formed by - ; tly cutting the loops. The cut loops serve as the hooks of the hook component.

~o g2~202s0 2 l q 3 2 7 ~ PCl'/US92/03720 ~ i .

These processes generally produce costly hook and loop fastening materials because they are relatively slow. The hook and loop components of such fastening devices are also usually made out of the same relatlvely expensive material. This material is generally relatively expenslve for the hook component because the material used in the hook component needs to be resilient so that the hooks can disengage from the loop component when the device is opened. Conventional loop fastening materials are generally made entirely out of a single material. This material is generally relatively expensive due to the need of such materjal to be strong enough to hold the engaged hooks when subjected to forces applied on the fastening device.

Several attempts have been made to make alternative types of female components for fastening devices. However such attempts have generally suffered from a number of drawbacks.

One such attempt is described in U.S. Patent 3 708 833 issued to Ribich et al. on January 9 1973. The Ribich et al. patent discloses a refastenable fastening device having a female component that comprises reticulated urethane foam secured to a backing layer. The female component disclosed in the Ribich et al. patent suffers from the drawback that foams typically do not have enough openings for the hooks of conventional hook components to penetrate. Reticulated foam also does not have sufficient strength to hold such hooks when forces are applied to the fastening device. Further manufacturing reticulated foam is a relatjvely expensive process.

U.S. Patent 3 905 071 issued to Brumlik on September 16 1975 discloses a "press-through self-gripping device.~ The device described in the Brumlik patent does not appear to be suitable for use in a refastenable fastening device that utilizes a conventional mating hook component with resilient hooks. The fastening device disclosed in the Brumlik patent is intended to be used for fastening one or more sheets of material between a a ~03 278 ~ 4 gripping member and a receiving member. The gripping member disclosed in the Brumlik patent has rigid and stiff needle-shaped elements for gripping elemems. These needle-like elements are particularly unsuitable for use in fastening devices on disposable absorbent articles. The disclosure of the Brumlik patent, thus, appears to be limited to devices that employ gripping elements adapted to penetrate and pass through several sheets of material and lodge inside a receiving member~ .

Therefore, there is a need for a low-cost fastening device for disposable articles.
In particular, there is a need for such low-cost fastening devices to perform in a manner cvlll~dldblc to tbe more expensive commercially-available fastening devices.

It is an object of an aspect of the present invention to provide an improved low-cost female component for a fastening device.

It is an object of an aspect of the present invention to provide a female component for a fastening device that can be used with both commercially-available hook 1~.~,,.,l,.:,,,. ., having resilient individual hooks, as well as less expensive hook l,UlllpOn~ with more brittle hooks than those currently in use.

It is an object of an aspect of the present invention to provide a low-cost female component that makes more efficient use of materials than existing fastening devices and that utilizes reduced amounts of expensive materials.

It is an object of an aspect of the presènt invention to form a low-cost female component for a l.,fd~lclldlJle fastening device by stacking materials on top of one another which have certain desired individual cLdld~t~ for entangling and engaging the hooks of a mating hook component.

It is an object of an aspect of the present invention to provide a low-cost and improved method for producing such a female component.

~ O 92/20250 2 1 0 ~ 2 7 ~ P(~r/US92/03720 =
These and other ob~ects of the present invention will be more readily apparent when considered in reference to the following description and when taken in connect10n w;th the accompanying drawings.

~UMMARY OF THE INVENTION

The present invention provides a multi-layer (or multi-zone) female component for engaging a complementary hook component 1n a refastenable fastening device. The female component of the present invention is capable of engaging a hook component that has individual hook elements having blunt heads. The female component does not require individual loops of the conventlonal type to be present. Typically, the hooks will be engaged by elements that present the female component with a relatively flat outwardly-facing surface.

The female component comprises at least two, and preferably three layers or zones. Each zone has certain of the desired individual characteristics for entangling and holding the hooks of the mating hook component. The zones include a first zone (the ~entanglement~ zone), a second zone (the ~spacing~ zone), and a backing. The entanglement zone may be a woven fabric, a nonwoven web, or some other type of material that has fibers, strands, or the like to entangle the hooks of the hook component. There should be sufficient space between these fibers to admit the hooks of the hook component. The spacing zone may be any suitable material that provides space for the hooks to occupy after they have been admitted by the entanglement zone. The spacing zone may be comprised of the same type of material as the entanglement zone, or a completely different material. For instance, in one alternative embodiment, the spacing zone can comprise loose particles. The spacing zone will preferably be a ~high loft~
(high caliper) material so that it will be able to provide adequate space for the stems and heads of the hooks. The backing is adjacent to the spacing zone. The backing prov1des foundation for the entanglement and spacing zones.

,,,,,, . , ,,,,, ... , . , . _ _ .. ....... ..... .... ... . ... ... ..

WO92/20250 ' PCI/US92/037~
~3~q8 In one preferred embodiment, the entanglement zone comprises a first nonwoven web having a basis weight of between about 7 and about 15 g/yd2 (about 8.5 to about 18 g/meter2) and fibers with a denier of between about 2 and about 6; the spacing zone comprlses a second nonwoven web having a bas1s weight of between about 7 and about 30 g/yd2 (about 8.5 to about 36 g/meter2) and fibers with a denier of between about 6 and about 15; and the entanglement and spacing zones are held in place relative to a f11m backing with the spacing zone in between the entanglement zone and the backing.

This arrangement of layers results in a lower cost female component. Less expensive materials can be used in the spacing zone, in lieu of using the same, relatively expensive raw material for the entire composition of the female component. The female component can also be produced by a lower cost laminating process, rather than the conventional weaving, knittlng, pleating, or corrugating processes.

The preferred embodiment of the female component described above is formed by a method comprising the steps of:

(a) providing a first material having a basis weight of between about 7 and about 15 g/yd2 (about 8.5 to about 18 g/meter2) and being comprised of fibers with a denier of between about 2 and about 6 for a first zone;

(b) providing a second material having a basis weight of between about 7 and about 30 g/yd2 (about 8.5 to about 36 g/meter2) and being comprised of fibers with a denier of between about 6 and about IS for a second zone;

(c) providing a backing material; and (d) securing at least the first material to the backing material so that the second material is positioned between the first material and the backing material.

~ 1 0 3 2 7 8 The present Inventlon also relates to a fastenlng devlce having a hook fastening component and ~ female component The female component comprlses the multl-7ayer fem-le component of the present lnventlon The hook fasten1ng component comprlses a hook fastening component whlch had ~ base and a number of indlvldual hooks extending from the base The mult1-layer female component and the complementary hook f-stenlng component provlde a secure refastenable closlng means that will reslst forces encountered durlng use The present lnventlon also relates to dlsposable artlcles and more particularly to a disposable diaper havlng such an improved fastenlng devlce Other aspects of this invention are as follows:

A multl-zone female component for a refastenable fastening device said multi-zone female component characterized in that it is capable of engaging a complementary hook fastening component whlch has a base with individual hooks having blunt heads extending outward from said base said multi-zone female component comprlsing a flrst zone comprlsing 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 15;

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 2 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 b~cking with said second nonwoven web between said first nonwoven web and said backing ~ ~a Z! 'I Q 3 2 7 8 A multi-layer female COmDOnent for a refastenable fastening device said multi-layer female component characteri~ed in that it is capable of 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 crlmped 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 I cm. and about 13 cm. long with a denier of between about 6 and about said fibers being crimped with a crimping frequency of at least about ~ crimps/cm.i 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 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.

A multi-zone component that is affixed to a substrate that serves as a backing to form a female component for a refastenable fastening device, said female component being capable of engaging a C~ f " lluly hook fastening component which has a base with individual hooks having blunt heads extending outward from said base, said multi-zone component CU~ h~

~3 ,... , ..... ,, . ,. .. , .. , ,,,, ,_, ,, _,,,, ,,, _ ~ 1 0 3 ~ 7 8 7b 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 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;

a spacing zone for providing space for at least portions of said hooks to occupy after said hooks have penetrated by s-id entanglement zone said spacing zone comprising a second material wherein said entanglement zone and said spacing zone are held in place with respect to said substrate with said spacing zone between said entanglement zone and said substrate A method of making a multi-zonc female component for refastenablc fastening device said mcthod 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 gjm2 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 7c 2 ~ 2 8 ~0 ~7 (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 A method of making a multi-~one 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 for admitting and mechanically entangling at least some of the hooks of the complementary hook component _ said 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 materi-l; and (d) securing 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 between said first material ind said backing material 7d ~ 1 0 3 2 7 8 SRIEF ~ESCRIPTION OF THE ORA~INGS

~ hile the specification concludes w1th claims particularly pointing out and distinctly claiming the subJect matter which is regarded as forming the present invent10n it is believed that the invention will be better understood from tht following description in conjunction with the accompanying drawings in which Figure I is a perspective view of the refastenable fastening device of the present invention Figure 2 is ~ part~ally cut-away plan view of the multi layer fem~le component of the present invention shown in use with a tape fastening system of ~ disposable diaper (only a port10n of which is shown) Figure 3 is a side view of thc fastening device shown in Figure 1 Figure 3A is a plan view of an individual hook of the hook component -92/20250 PCI'/US92/037~
~~ 21~3278 F1gure 3E is a side vlew of the hook shown ln Figure 3A.

Flgures 4A and 4B are a s1de view and a partlally cut-away plan vlew of an alternatlve embodlment of the female component of the present lnventlon in whlch the diameter of the fibers are the same denier in the entanglement and spacing zones.

Figure 4C is a slde vlew of the female component shown ln Figures 4A and 4B whlch shows the bonding between the zones of the same in a slightly less schematic form.

Flgure S is a slmpllfied side view of an alternatlve embodlment of the multi-layer female component of the present lnvention ln which the entanglement zone is a woven fabric.

Figures 6 and 7 are slmplified schematlc side views of alternatlve embodiments of the multl-layer female component in which the spacing zone comprises a loose pellet-like materlal.

Flgures 8 and 9 are side views of alternatlve embodlments of the multi-layer female component in which the spacing zone comprises a screen bonded by heattpressure bonds to the adjacent layers.

Figures lO and 11 are side views of alternative embodiments of the muiti-layer female component ln which the spacing zone comprises a screen bonded to the adjacent layers by an adhesive.
.

Figures l2-17 are side views of alternative embodiments of the multi-layer female component that are formed by forming a laminate, and then folding the laminate on top of itself.

Figures l8-23 are side views of alternative embodiments of the multi-layer female component ln which the same type of material is used for both the entanglement zone and the backing.

~0 92/20250 2 1 ~ 3 2 ~ 8 PCI/US92/03720 Figure 24 is a partially cut-away perspectlve view of a disposable dlaper that 1ncludes the fastening device of the present invention.

Figure 25 is a schematic side view of a process for making the multi-layer female component of the present invention.

Figure 26 is a schematic side view of an alternative process for making the multi-layer female component.

Figure 27 shows an optional means for folding a web of material to form the multi-layer female component shown in Figures 12-17.

Figure 28 is a schematic front view of one type of patterned roll that can be used in the processes shown in Figures 25 and 26 ~the dimensions of the pattern being greatly enlarged for purposes of illustration).

DETAr~Fn DESCRIPTION OF THE INVENTION

The Refast~nahle Fasteninq Device 1. Overall Characteristics of the Refastenable FasteninQ
Device A preferred embodiment of the refastenable fastenlng device of the present invention, fastening device 20, is shown in FIG. 1.

The fastening device 20 comprises the multi-layer female component 22 of the present invention and a complementary hook fastening component 24.

The male portion of the device, hook fastening component (or simply "hook component~) 24, comprises a base, such as fabric 26 that has a first surface 27 and a second surface 29. The fabric 26 contains a plurality of upstanding engaging elements or ~hooks~

WO92/20250 . PCI/US92/037~
21~327~ lo 28 extendlng from the first surface 27. The hooks 28 have heads 38. The heads 38 are on top of the shanks or stems 40 that extend from the first surface 27.

The female portion of the device, multi-layer female component (or simply ~female componentn) 22, of the present lnvention recelves and engages the hooks 23 of the hook component 24. The female component 22 shown in FIG. I has a first, outwardly-facing surface 31 and a second, lnwardly-facing surface 33.

The female component 22 comprlses three layers or zones: a first layer or zone, entanglement zone 30; a second layer or zone, spacing zone 32; and, a backing 34. The entanglement zone 30 contains a plurality of structural components or structural elements, such as fibrous elements (or simply "fibers") 36. The fibers 36 entangle the hooks 28 of the hook component 24. The spaclng zone 32 spaces the entanglement zone 30 away from the backing 34. The backing 34 provides a foundatlon for the other zones.

The arrangement of the different zones of the female component 22 ls shown in FIG. 1. The entanglement zone 30 is positioned on top of the spacing zone 32 and the backlng 34. The entanglement zone 30 is the portion of the female component 22 that generally faces outward to form the first surface 31 of the female component 22. That is, the entanglement zone 30 is exposed 50 that it will be available to entangle the hooks 28 of the hook component 24. The spacing zone 32 is positioned between the entanglement zone 30 and the backing 34. The backing 34 is inwardly-oriented so it will be adjacent and generally joined to the portion of the article to which the female component 22 is attached.

The fastening device 20 of the present invention functlons in the following manner. The fastening device 20 is closed when the female component 22 and the hook component 24 are pressed , _ ~ O 92/20250 2 1 0 3 2 7 ~ P(~rtUS92/03720 . I ~t :U ~

face-to-face against each other. When this happens, the hooks 28 are entangled by the structural elements of the female component 22 (or more speclfically, by the fibers 36 of the entanglement zone 30). The spaclng zone 32 provldes space for the hooks, particularly, the heads 38 of the hooks 28 to occupy when the fastening device 20 is closed. The backlng 34 provldes a supportlng foundatlon for the other zones or layers. Wlth the hooks 28 mechanically entangled by or ~hooked~ onto the flbers 36 (shown ln the portlon of the fastenlng devlce 20 to the rlght slde 1n FIG. 1), the connectlon between the male and female components resists the forces that may be exerted on the fastening device 20.

The fasten1ng device 20 is opened by peeling the hook component 24 away from the female component 22 (or by peellng the female component 22 away from the hook component 24). If the hook component 24 has resllient hooks, the peeling action may cause the hooks 28 to be bent so that they are disengaged from mechanlcal entanglement with the fibers 36 of the entanglement zone 30. In other cases ~partlcularly if the hooks 28 are relatlvely 1nflexible), the hooks 28 may disengage by breaking the fibers of the female component 22. In either case, the hooks 28 are d1sengaged, and the hook component 24 is completely detached from the female component 22. The fastening device is then capable of being refastened in the manner described above.

The components of the refastenable fastening device 20 are d1scussed more fully in the following sectlons of thls descriptlon. The mult1-layer female component 22 of the present 1nvention is discussed in Sectlon 2 below. The hook component 24 is discussed ln Sect1On 3. Sectlon 4 gives examples of uses of the refastenable fastening device 20.

2. The Multl-Laver Female COmDOnent The multi-layer female component 22 shown in FIGS. 1-3 is one preferred embodiment of the female component of the refastenable fastenlng device 20 of the present inventlon.

. _ . ... _, _ _ _ WO 92/20250 PCI/US92/037~
2~03278 12 Several alternatlve embodiments are shown ln the figures that follow FIGS. 1-3. It should be understood that the zones of the female component 22 are generally shown in schematic form in most of the figures, for simpliclty. The conflguratlon of the zones and the bonding between the zones of the female component 22 more closely resembles that shown in FIG. 4C in the actual product.

The definitions of several terms are flrst provided to assist the reader in understanding the present lnventlon.

The term "multi-layer~ is intended to include structures that are comprised of ~uL-- ts arranged in multiple zones, as well as those arranged in multiple layers. (Preferably, these multiple zones are generally parallel zones.) The term ~multl-layer~, as used herein, thus, may be sj"ony~ ~ with the term ~mult1-zone~.
The term ~layer" may be synonymous with the term ~zone~.

Therefore, a female component that comprtses a zone of loose material sandwlched between two layers would be considered to be d ~multi-layer" female component. Other a~.~ , ts of zones and layers are also within the scope of the present invention. The ~layers" referred to herein, thus, may actually comprise strips of material, loose or bonded particles or fibers, laminates of material, or other combinatlons of such materials, such as several sheets or webs of the types of material described below. Thus, the term ~multl-layer~ is not llmited to structures having components that are in the form of layers or sheets of material.

The term "generally parallel" is used above to describe the arrangement of the zones of the female component 22. The term ~generally parallel~, as used ln this context, is intended to include not only al, , ts of layers or zones whlch are flat and parallel, but also a,.~r,g ts that were originally generally flat and parallel prior to bonding, and after bondlng are in the form of the a" ~ ~ shown in FIG. 4C.

~0 g2/20250 PCI/US92/03720 ~32783 The ter0 ~loop component~, as used herein, refers to the portion of a hook and loop-type fastening devlce that 1s designed to engage the hooks of a complementary hook component. The multi-layer female component 22 of the present lnvent10n could be thought of as a replacement for a loop component. Generally, however, the multl-layer female component 22 does not requlre that loops of material be specifically formed to engage the hooks of a mating hook component. Typically, the indlvidual structural elements 36 ~e.g., the fibers of the woven or nonwoven material) that form the entanglement ~one 30 will serve to entangle the hooks 28, even though these structural elements are not necessarily "looped~.

The multl-layer female component 22 does not require the formatlon of loops of material that extend outward from a backing.
(Thus, for the purposes of the present invention, the female component 22 may be considered to be ~loop-less~.) The term "loop~, as used herein, refers to a fibrous material that is curved or doubled to form a closed curve into which a hook may be inserted. The term ~loop~, as used herein, also includes materials made by any process in which fibrous materials are manipulated, individually or collectively, to form loops, regardless of whether the fibers are formed into a closed or partially open curve. The term ~loopn, as used herein, however, does not include the fibrous elements disposed within a web or fabric which are not separately manipulated.

The multl-layer female component 22 of the present invention should have certain characteristics.
-The multi-layer female component 22 operates upon the principle that engaging the hooks of a hook component involves several separate functions. These include the functions of entangllng the hooks and providlng space to "store~ the hooks after they have been entangled. The multi-layer female component WO 9~/202S0 PCI'/US92/037 2~ 03278 14 22 comprises zones that each have character1stics speclfically suited for serving at least one of the funct10ns of receiving, entangling, and holding the hooks of the mating hook component.

The ind1vidual fibers of the material that form the layers generally prov1de the female component 22 with an outwardly fac1ng surface 3I that is relatively level, planar, or flat in comparison to the surfaces of conventional loop components which have many loops of material extending outward from a backing. The term ~planar~, as used herein, inc1udes, but is not lim1ted to those surfaces that lie in a single, relatively flat plane as shown in FIGS. 1-3, as well as those surfaces that are gradually curved such as shown in FIG. 4C.

The multi-layer female component Z2 should have suffic1ent open space between the structural elements that comprise both its entanglement zone 30 and 1ts spacing zone 32. The term ~structural elements~, as used herein, refers to the ind1vidual fibers, yarns, strands, loose particles, and the like which may comprise the webs, fabrics, screens, and the like that form these respective zones. Alternatively, or additlonally, these structural elements should be able to spread, or otherwise move to create the open space needed to accommodate the hooks 28 of the mating hook component 24.

The materials that comprise the zones of the female component 22 may be described as ~being capable~ of providing a certa1n amount of open space between their structural elements. This terminology 1s intended to include materials that originally have the specified open space, those that have structural elements that move to prov1de such open space, and those materials prov1de such open space in both of these manners. The movement of the structural elements to prov1de open space is part1cularly apparent 1n the case of the spacing zone 32.

For example, the spacing zone 32 may be compr1sed of loose part1cles that are initially in contact with each other. As a result, there may be some port10ns of the spacing zone 32 that ~ O 92/Z0250 2 ~ ~ 3 2 7 ~ PC~r/US92/03720 have essentially no open space between the partlcles. These loose particles should be able to spread apart, be pushed downward (toward the backing 34 or the substrate), or otherwise move out of the way to make the open space needed to accommodate the hooks 28 of the mating hook component 24. The open space between the structural elements of the female component 22 described hereln, thus, means that the female component has or is capable of providing a multipliclty of openlngs between 1ts structural elements.

The female component 22 should allow the hooks 28 of the mating hook component 24 to readily enter between the openings (the spaces, or interstices) between the fibers or other structural elements that comprise the entanglement and spaclng zones 30 and 32. The hooks 28 should be able to enter wlthout plercing through these fibers or other structural elements. The hooks 28 should be able to enter, and if necessary, spread these flbers or other structural elements apart. Thls should, however, require the application of relatively little, if any force (e.g., in comparison to that needed when uslng a ~press-through~ devlce such as that described ln the Brumlik patent discussed above).

When the female component 22 is provided with such space between its structural elements, it will work with conventional, commercially available hook materials. The female component 22, however, is not limited to use with conventional hook materials having flexible, resllient hooks. It can also be used with hook materials that have less expensive, more brittle hooks. The female component 22 is also particularly well-suited for use with hook components having hooks with generally rounded and/or blunt heads. It does not require specially-made rigid, sharp hooks to be used. It is, however, possible for sharp hooks to be used with the female component 22 Thus, when the female component 22 of the present invention is said to be ~capable~ of engaging a hook component wlth a certain type of hooks, thls means that the type of hook component referred to can be used. The female component 22, however, ls WO 92/20250 PCI'/US92/037~

typ1cally not limited to use with such a hook component; other types of hook components can usually also be used with the female component.

The amount of open space required between the structural elements of the entanglement and spacing zones 30 and 32 depends on the slze of the hooks 28 of the hook component 24. The dimens10ns of var10us parts of a hook 28 of one type are shown in FI65. 3A and 3B. The hook 28 shown 1n FIGS. 3A and B has an overall height h, and a head 38 with a certa1n length, width, and he19ht, designated l, w, and hI, respectively.

The head~ of the hooks, as that term is used herein, refers the port10ns of the hook 28 that project laterally (or radially) outward from the stems 40 1n one or more d1rections. Often, there will not be a line of demarcat10n between where the stem 40 of the hook 28 ends and where the head 38 begins. For the purposes of the present 1nvention, the head 38 of the hooks 28 w111 be considered to begin at the port10n of the stem 40 des19nated 43 1n FIG. 3B. This is the portion of the stem 40 that 1s spaced the same perpendicular d1stance away from the backing 36 as the lowermost point 45 on the head 38 of the hook 28. The lowermost point 45 is the portion of the head 38 spaced the smallest perpendicular distance from the base 26 of the hook component 24.

The length l and width w of the hook s head 38 are most important 1n determ1ning the amount of open space requ1red between the structural elements of the entanglement and spac1ng zones 30 and 32. More specif1cally, the amount of open space required between the structural elements is generally determined by the dimensions known as the projected plan view area (the projected plan view dimensions ) of the heads 38 of the hooks 28. This area is represented by reference letter Ah in FIG. 3A. Th1s 1s the surface of the hooks 28 that will initially come in contact with the female component 22 of the present invention. Thus, the open space provided by between the structural elements of the entanglement and spacing zones 30 and 32 should be either sl19htly larger 1n dimens10ns than the projected plan view dimens10ns of . . . : . . . . . . : _ . . _ . . . _ . . . . _ . . . . . . . . . . . . . . . . . . . . _ . . . . _ . . = . . . . . .

~ 0 92/20250 2 1 ~ ~ 2 7 8 P(~r/US92/03720 the heads 38 of the hooks 28, or the structural elements should readily spread apart to such dlmensions. Therefore, when large hooks 28 are used (that is, hooks havlng a relatively large Ah), there should be more open space than if relatively small hooks 28 are used.

There are several factors that determine the amount of open space between the structural elements of the multi-layer female component.

One factor is the type of structure used in the entanglement and spacing zones 30 and 32. The amount of open space in the entanglement and spacing zones 30 and 32 will differ depending upon whether these zones comprise woven, nonwoven, or some other type of material.

If, for instance, the entanglement and spacing zones 30 and 32 both comprise nonwoven webs, the fibers that comprise such nonwoven webs will spread easier without the appllcation of force to accommodate the hooks 28 than will the yarns of a woven fabric (or the strands of a screen, or the like). That is because in a woven fabric, each point where one yarn crosses over another yarn will tend to be fairly rigid in the presence of forces that attempt to spread the fabric apart. Because of this resistance to spreading, it is generally preferable the dimensions between adjacent yarns in a woven fabric ~i.e., the size of the jnterstices) be at least slightly larger than the projected plan view dimensions of the heads of the hooks. The same is true of the dimensions between the strands of a screen, and the like.

The amount of bonding between the structural elements in each layer or zone will also determine the open space in the entanglement and spacing zones 30 and 32. The same is true of the bonding between the different zones of the female component. The bond sites created by the bonds between the structural elements within each layer or zone tend to reduce the spreading of structural elements needed to accommodate hooks 28. The bond sites also tend to interfere with the penetration of the hooks 28 of the ~ o 92/202S0 P{~r/US92/037 n ~ ~ ~ o va~ (o la mating hook component 24. The same is true for the bonds between the different layers or zones of the female component 22.

The basic elements of the multi-layer female component 22 of the present lnvention are from top to bottom: a first zone, entanglement zone 30; a second zone, spacing zone 32; and a backing 34.

The entanglement zone 30 permits the hooks of a mating hook component to penetrate through its thickness. The entanglement zone 30 entangles the hooks until it is desired to open the fastening device 20. The entanglement zone 30 may be referred to by any suitable name that describes its function, such as the ~penetrable/entanglement layer" or simply as the ~entanglement layer~ 30. The entanglement zone 30 should have certain characteristics.

The entanglement zone 30 should have sufficient open area so a plurality of the hooks of a mating hook component may penetrate its thickness when a hook component is placed in a face-to-face relationship with the female component Z2. It is not necessary, however, that all of the hooks of the hook component penetrate the entanglement zone 30. It is only necessary that a sufficient number of hooks penetrate the entanglement zone 30 for the female component 22 to be operable. The openings in the entanglement zone 30 should be sufficiently large relative to the size of the hooks so that the hooks which penetrate the entanglement zone 30 are able to do so without forcibly piercing the material of the entanglement zone 30. Further, the total number and distribution of such open spaces per unit area of the female component 22 should be adequate to accommodate a sufficient number of hooks 28 of the mating hook component 24.

The entanglement zone 30 should also be able to entangle and hold a sufficient number of the hooks of the mating hook component 24 for the fastening device 20 to be operable. Therefore, the number of fibers or other structural elements that comprise the entanglement zone 30 must be sufficient to entangle and hold the . . _ ~ 0 92/202S0 2 1 0 3 2 7 8 P(~r/US92/03720 , 19 ; ~

hooks 28 unt11 a peeling force ls applled to open the fastenlng device 20. These structural elements must alsD have sufficient strength to hold the hooks when forces that are not lntended to open the fastening device 20 are applled. in addltlon, ln some embodiments, it ls preferred that the structural elements comprislng the entanglement zone 30 have the ablllty to wlthstand repeated dise"ga, t of the hooks without being destroyed or disrupted by the removal of the hooks.

The caliper of the entanglement zone 30 should be sufflclent that an adequate number of the heads 38 of the hooks 28 are able to catch onto the structural elements of the female component 22.
The caliper can be very small if, at a low callper, the entanglement zone 30 contains a sufflcient number of structural elements which are strong enough to hold the hooks 28 of the matiny hook component 24. The caliper of the entanglement zone 30 can range to as large as the total height h of the hooks, or more.
However, embodiments in which the caliper of the entanglement zone ls larger than the height of the hooks are generally less preferred because they do not take advantage of the spaclng zone.
~When the caliper of the entanglement zone 30 is larger than the helght of the hooks, the hooks will not be long enough to reach and utllize the spacing zone). Therefore, preferably, the caliper of the entanglement zone 30 is generally less than the height h of the hooks, so the spacing zone 32 also provides a benefit.

The material used in the entanglement zone 30 should, preferab'y, be relatively soft lf the female component 22 is used ln a fastening system on a disposable absorbent article, so that the female component 22 will be comfortable for the wearer in the event it contacts the wearer s skin.

The entanglement zone 30 may be in any suitable structural form. for instance, in the preferred embodiment shown in FIGS.
1-3 of the drawings, the entanglement zone 30 is a nonwoven layer or web of material. The term nonwoven~, as used hereln, refers to fabrics made of fibers held together by interlocklng or bonding which are not woven, knitted, felted, or the llke. (The term : .. _ . .. _ . _ _ _ , , .

' i;

~lVd~ ( 0 ~fabrlc~, as used herein, may refer to a nonwoven web, a woven material, or other types of fabrics.) Alternatively, as shown in FIG. S, the entanglement zone 30 may be a woven fabrlc. In still - other alternative embodiments, the entanglement zone 30 could comprise netting, perforated film, foams, or any other type of material that is capable of providing open spaces for hooks to penetrate and entangling those hooks unt11 it is desired to open the fastening device 20.

If a nonwoven web 1s used as the entanglement zone 30, the characteristlcs used 1n the nonwoven fabric industry, such as basis weight, length and denier of fibers are used to specify those nonwoven materials which have the qualities set forth above.
The open area between structural elements and the number of the structural elements (at least on a relative basis), can be approximated from the basis weight of the web. (For instance, a nonwoven web of a lesser basis weight will generally have greater open area and fewer structural elements than a web of greater basis weight having the same denier and length flbers.) The strength of the web for use in a female component (at least on a relative basis) can be approximated from the basis weight of the web and the denier and material composition of the fibers.

Suitable nonwoven webs include those having a basis weight of between about 7 and about 35 g/yd2 (about 8.5 to about 42 g/meter2), more preferably, between about 7 and about 30 g/yd2 ~about 8.5 to about 36 g/meter2), and most preferably, between about 7 and about IS g/yd2 (about 8.5 to about 18 g/meter2). The basis weight is measured by die-cutttng a certain size sample and weighing the sample on a standard scale. The weight and area of the sample determines the basis weight of the sample. The density can be calculated from the basis weight of the sample and its caliper.

The lengths of the fibers that comprise such nonwoven webs may depend upon the type of process used to make the nonwoven web.
For instance, if a carded nonwoven web is used, the fibers that comprise such a web can have lengths that can range from about O.S

-~ 0 92/20250 PC~r/US92/03720 2~32~ .

inch to about S inches (from about I cm. to about 13 cm.J.
Preferably, the flbers are between about 2 inches and about 3 inches (between about S cm. and about 8 cm.) long. If, on the other hand, a spunbonded nonwoven web is used, the fibers or filaments of such a web will typically be continuous length.

The d1ameter of the fibers is one factor that determines the strength of the nonwoven web. Generally, the larger the diameter of the fiber is, the stronger the fiber. The maximum diameter that can be used depends in part on the size of the gap 41 defined by the hooks 28. The term ~gap~, as used herein, refers to the openings formed by the heads 38 of the hooks. These are the portions that grab the fibers or other structural elements. The diameter of the fibers 36 must not be so great that the heads 38 of the hooks 28 are unable to fit around and entangle the flbers 36. Typically, for currently available hook components, the fibers 36 should have a denier of between about 2 and about IS, more preferably, between about 2 and about 6. If hook components become available that have hooks 28 which are substantially smaller than those currently available, the denier of the fibers could be between about O.S and about IS, or less. It is possible that fibers having deniers as low as between about O.S and about I.O, or less, could be used. Such fibers may be referred to as ~micro denier~ fibers. (Denier is a unit of fineness of a yarn weighing one gram for each 9,000 meters, thus a IOO denier yarn is finer than a ISO denier yarn.) The fibers of such nonwoven webs can be comprised of any suitable material, including, but not limited to polyesters (such as polyethylene therapthalate (or PET)), polyethylene, and polypropylene, or any combinations of these and other suitable materials known in the nonwoven fabric industry. For example, a suitable nonwoven web could comprise a mixture of fibers of two d1fferent types of materials (e.g., a mixture of polyester and polypropylene fibers). In still other cases, a suitable nonwoven web could be comprised of fibers that are comprised of more than one material (e.g., a polyester fiber coated with polypropylene).
Suitable polypropylene fibers for such a nonwoven web include WO 92/20250 PCT/US9Z/037~
2 ~ Q3~ 78 22 those available from the Hercules, Inc. of Wilmington, Delaware as product numbers T-181, T-182, and T-196.

The nonwoven webs suitable for use in the entanglement zone 30 can be produced by many different processes. For example, the nonwoven web could be either a carded or a sp ':,d-i web. Such nonwoven webs can be made by any suitable commercial carding or spunbonding processes.

Suitable materials for such an entanglement ~one 30 can be obtained in the form of a carded nonwoven web from Yeratech Nonwoven Group of the International Paper Company of Walpole, Massachusetts 02081 by specifying the desired characteristics described herein (such as basis weight, fiber denier and composition). Suitable s, ~ nonwoven webs can be obtained from the Nonwovens Division of the James River Corporation located in Simpsonville, South Carolina. tIt is expressly not admitted, however, that any of the materials described herein are known to have been used in fastening devices.) Another example of a suitable carded nonwoven web can include materials that have been used as topsheets in dlapers and other d1sposable absorbent art1cles (that ls, provided they have the characteristics described herein).

The orientation of the structural elements 36 in the entanglement aone 30 is important. This is part1cularly true when a nonwoven web is used for the entanglement zone 30. The orientatlon of the fibers 36 in such a preferred entanglement zone 30 is preferably primarily in a single direction.

In addition, as shown in FIG. 2, when the female component 22 1s incorporated into a refastenable fastening device 20 on a disposable diaper S0 (a portion of which is shown), the orientat1On of the structural elements 36 in the entanglement zone 30 relative to the edges of the diaper S0 is also important. The ~?10 92/20250 2 1 ~ 3 2 7 8 PCI'/US92/03720 '' 23~

structural elements 36 of the entanglement zone 30 are preferably oriented so that they generally parallel to the longitudinal edges 60 of the diaper 50.

Such an orientatlon of the structural elements 36 ln the entanglement zone 30 provides the the greatest res1stance to the disel,.3 t of the hooks 28 when the fastenlng devlce 20 ls subjected to the forces typically exerted on a diaper fastenlng system. These forces are usually applled in the plane of the lnterface between the fastening components in a dlrectlon parallel to the end edges of the diaper. The orientatlon of structural elements 36 referred to above can be contrasted with the situation in which the structural elements are perpendicular to the longitudinal edges 60 of the diaper 50. In this latter less desirable case, the structural elements 36 would run in the same dlrectlon as (or parallel to the direction of) such forces. In the latter case, the structural elements 36 may not be as able to serve as a ~catch~ for the hooks 28 of the mating hook component.

A woven fabric could be used in the entanglement zone 30.
The woven fabrics used in the entanglement zone 30 should have an open weave. Typically, such fabrics will have a geometric weave.
Suitable woven fabrics may have weaves with square, rectangular, or other shape openings. The spacing between adjacent yarns in the direction of the plane of the fabric should, preferably, be at least slightly larger than the projected plan view dimensions of the heads 38 of the hooks 28 of the mating hook component 24.

In those cases where the heads 38 of the hooks have length and width dlmensions that are not equal (for example, where the hooks 28 have heads 38 wh;ch define a rectangular projected plan vlew area Ah), the openings in the woven fabrics can be made of a correspondlng sllghtly larger size and dimensions than the heads 38 of the hooks 28. In such cases, the openings in the woven fabric should be oriented to register with the heads 38 of the hooks 28 when the hook component 24 is brought into contact with the female component 22. In alternatlve embodiments, the spacing between adjacent yarns could be at least as great as the largest _ _ WO 92/20250 - PCI /US92/037~
2103~78 24 of the plan view d1mensions of the heads 38 of the hooks 28 so it will not matter whlch way the fabr1c 1s orlented when the hook component 24 is brought into contact with the female component 22.

Su1table woven materials can handle hooks 28 of the dimensions specifled ln Section 3 below. Thus, the woven materials used 1n the female component 22 may have openlngs that 1nclude, but are not llmited to, the shape of rectangles that are ln the following sizes: slightly greater than about I mm. by about 0.2 mm; slightly greater than about O.S mm by about 0.2 mm.;
slightly greater than about 0.25 mm. by about O.I mm; or any combinatlon of these length and width dimensions. In addltlon, with different size and shapes of hooks 28, the openings could be larger or smaller, or of different shapes. Examples of a commercially-available woven material suitable for use as the entanglement zone 30 are knits like women s Nylons.

The yarns that comprise these woven fabrics can be made of any suitable natural materials, such as cotton or wool, etc., or synthetic materials such as Nylon, rayon, and polyester, to name few. Similar materials can be used for entanglement zones 30 that are arranged in other structural forms. Thus, the yarns, strands, and the like that comprise the structural elements of screens, netting, and the other types of entanglement zones may also be comprised of the foregoing materials.

In other alternative embodiments, the entanglement zone 30 may comprise a perforated fllm. Suitable perforated films may be in the nature of, and manufactured in accordance with the processes described in the following patents: U.S. Patent 3,929,I35 entitled Absorptive Structure Having Tapered CapillariesN, issued December 30, 1975 to Thompson; U.S. Patent 4,324,246 entitled Disposable Absorbent Article Having a Stain Resistant Topsheet , issued April I3, I982 to Mullane, et al.;
U.S. Patent 4,342,3I4 entitled Resilient Plastic Web Exh1b1tlng Fiber-Like Propert1es , issued August 3, 1982 to Radel, et al.;
and U.S. Patent 4,463,045 entltled h~..u,~lcally Expanded Three-Dimensional Plastlc Web Exhibiting Non-Glossy Vlslble 'l o ~ O 92/20250 2 ~ ~ 3 ~ 7 o P(~r/US92/03720 . ~,, ~ ..

Surface and Cloth-Like Tactlle Impression~, issued July 3I, 1984 to Ahr, et al. The disclosures of all these patents are hereby incorporated by reference herein.

The spacing zone 32 lies under the entanglement zone 30. The spacing zone 32 operates in the following manner. When the fastening device 20 is closed, the hooks 28 of the matlng hook component 24 first pass through the entanglement zone 30 into the spaclng zone 32. The hooks 28 may inlt1ally penetrate the spacing zone 32 to a greater depth than they will eventually be located in when they have engaged the structural elements 36 of the entanglement zone 30. In other words, there is usually an inward, then outward movement of the hooks 28 before they hook onto the structural elements 36 of the entanglement zone 30.

The spacing zone 32 must, therefore, provide space for the hooks 28 of the mating hook component 24 to penetrate before they hook onto the fibers 36 of the entanglement zone 30. The spacing zone 32 must also provide space for the hooks 28 to occupy after the hooks 28 come to rest in the spacing zone 32. The spacing zone 32, like the entanglement zone 30, should be some type of structure that has sufficient space between its structural elements to readily admit the hooks 28 of the mating hook component 24. Alternatively, or additionally, the structural elements of the spacing zone 32 should be arranged into a structure that is flexible enough for the structural elements to move out of the way of the hooks 28 of the matlng hook component 24 when a hook component 24 is placed in a face-to-face relationship with the female component 22.

The spacing zone 32 can be any type of structure having the above open space characteristics that separates the entanglement zone 30 from the backing 34, or if there is no backing 34, from the substrate. The spacing zone 32 can, thus, be a layer or web of material. Alternatively, the spacing zone 32 can be some type of structure which simply separates the entanglement zone 30 from the backing 34 and occupies space. Examples include beads, and other types of loose material. The spacing zone 32, thus, does . ~

WO 92/20250 PCr/US92/037;~
Q l ') '~

not have to be comprised of a material havlng the strength needed to make lt capable of engaging and holdlng the hooks. It ls, however, within the scope of the present inventlon for the spacing zone 32 to be comprised of a materlal capable of engaging and holdlng the hooks 28 of the hook component 24.

The spaclng zone 32 is also, preferably resillent. A
resilient spaclng zone 32 is especially deslrable when the fastenlng devlce is used on disposable absorbent articles. Th1s allows the spacing zone 32 to continue to maintain space between the entanglement zone 30 and the backlng 34, even after the female component 22 has been compressed during manufacturing, packaging, in use, and the like.

The spacing zone 32 is typically thicker (that ls, it has a greater caliper or is more "lofted") than either the entanglement zone 30 or the backing 34. The greater callper is needed because the spacing zone 32 must provide sufficient space to store the heads, and in many cases, at least a portion of the stems 40 of the hooks. The spacing zone 32 may, therefore, be referred to as a ~hlgh loft~ material.

The caliper of the spacing zone 32 required depends on the helght of the hooks 28 of the matlng hook component 24. More particularly, the caliper depends on the dimension designated hl ln FIG. 3B, which represents the height of the heads 38 of the hooks 28. The caliper of the spacing zone 32 should be at least as large as the height hl of the heads 38 of the hooks 28. Thls will assure that there ls room to accommodate the inward and outward movement needed for the hooks 28 to hook onto the structural elements 36 of the entanglement zone 30.

The caljper of the spacing zone 32 can range to as large as the total helght of the hooks h, or more. Thus, there ls no fixed upper limlt on the callper of the spaclng zone 32. In some embodiments, the caliper of the spaclng zone 32 may be set so that the total caliper of the entanglement zone 30 and the spaclng zone 32 ls about the same as the helght h of the hooks 28 to assure a ~'0 92/20250 2 1 0 3 2 7 8 PCI'/US92/03720 good fit between the female component 22 and the hooks 28 of the mating hook component 24. The caliper of the spacing zone 32 should, however, preferably only be slightly larger than the height hl of the heads 38 of the hooks 28 of the matlng hook component 24. If the caliper of the spacing zone 32 is any greater, the additional material used to create such addit10nal caliper will not be used, and will ln effect, be wasted.

The caliper of the spaclng zone 32 may more specifically, by way of example, be sufficient to accommodate hooks of the sizes that are discussed in greater detail in Section 3 below. For instance, if the hooks 28 are between about 0.015 inch and about 0.025 inch (about 0.38 mm. to about 0.64 mm.) in overall height and have heads 38 which are about 0.3 mm. in height, the caliper of the spacing zone 32 should generally range from between slightly greater than about 0.3 mm. to about 0.38 mm, or to about 0.64 mm, respectlvely. (All caliper dimensions can also be measured in combination with the caliper of the entanglement zone 30). In still other embodiments, the caliper of the spacing zone 32 can be more or less depending on the size of the hooks 28 of the mating hook component 24. For example, the caliper of the spacing zone 32 can be as small as about I/2 or I/4 of the calipers set forth above, or less, if proportionately smaller hooks 28 are used.

The spacing zone 32 can be in many different structural forms. The spacing zone 32 can comprise nonwoven webs, woven fabrics, netting, loose filler material such as beads, pellets, packing filler, or bubbled film (this will work if the bubbles are sufficiently small that the hooks can go into the space between the bubbles), perforated film, foams, pieces of sponge, and any other type of material that is capable of providing space for hooks to penetrate at least partially into the thickness of the same and spacing the entanglement zone 30 away from the backing 34.

W O 92/20250 P~r/US92/037 ~

~03278 28 Suitable nonwoven webs for use in the spacing zone 32 may either be identica1 to those used for the entanglement zone 30, or of different properties and characteristics. Such webs may be made by any of the processes specified above for maklng the entanglement zone 30. In addition, melt blown nonwoven webs may also be suitable for use in the spacing zone 32.

Suitable nonwoven webs include those having a basis weight of between about 7 and about 35 g/yd2 (about 8.5 to about 42 g/meter2), more preferably, between about 7 and about 30 g/yd2 (about 8.5 to about 36 g/meter2), and most preferably, between about I0 and about 30 g/yd2 (about I2 to about 36 g/meter2).

The nonwoven webs used in the spacing zone 32 should be comprised of fibers that have a denier of between about 2 and about IS, more preferably, between about 6 and about IS. Most preferably, the denier of the fibers in the spacing zone 32 is about 9. Thus, the structural elements, such as f1bers 42, preferred for use in the spacing zone 32 are preferably thicker than those in the entanglement zone 30. Thicker fibers are more desirable because when the fibers are stacked (as described below), it is possible to create a spacing zone 32 having a relatively large caliper with fewer fibers. Further, using thicker fibers for the spacing zone 32 does not result in any dlscomfort to the wearer, because the finer, softer fibers of the entanglement zone 30 will typically cover the spacing zone 32.

Preferably, if the spacing zone 32 comprises a nonwoven material, the fibers 42 of such a material are randomly-oriented.
A random orientation will cause the fibers 42 in the spacing zone 32 to "criss-cross" and stack upon one another to create loft (or height). This will provide additional space for the hooks 28 of the mating hook component 24 to occupy when the hook component 24 engages the multi-layer female component 22.

The orientation of fibers in the various zones can be analogized to an a,, -~ t of logs. If several logs are laid side-by-side, the height of the group of logs will be only equal to the d1ameter of the logs. However, if the logs are or~ented in ~ O 92120250 2 1 ~ 3 2 ~ ~ P(~r/US92/03720 dlfferent dlrectlons, e.g., lf they are stacked (for lnstance, as in a log cabln), the height of the stack would be equal to the sum of the dlameters of the stacked logs.

The flbers in the spaclng zone 32 may preferably also be crlmped for additlonal loft. The term ~crimped~, as used hereln, means that the flbers are wavy or bent along thelr lengths. The flbers may be crimped (preferably before carding, or the llke1 by any suitable commercial crimping process. The flbers 42 1n such a nonwoven spacing zone 32 preferably have at least about 10 crimps/lnch (about 4 crimps/cm.), and more preferably at least about 14 crimps/inch (an average of about S.S crimps/cm.).

Suitable commercially-available nonwoven materials for such a spacing zone 32 having the above characteristlcs can be obtalned from Veratech Nonwoven Group of the Internatlonal Paper Company of ~alpale, Massachusetts.

Sultable woven fabrlcs for use in the spacing zone 32 may elther be identlcal to those used in the entanglement zone 30, or may be woven fabrlcs with dlfferent properties and characteristics.

Suitable loose materials for use in the spacing zone 32 can be any of those types of loose materials speclfled above. The loose materlals can be partlcles of any shape. The loose materlals can be cubic, polyhedral, spherical, rounded, angular, or irregularly shaped. The partlcles of loose material can be of unlform size or randomly sized. The size of each partlcle of such loose materlal can range from equal to or sllghtly less than the callper of the spacing zone 32 to many times less than the caliper of the spaclng zone 32.

Sultable perforated films for use in the spacing zone 32 may elther be ldentical to those used ln the entanglement zone 30, or may have dlfferent properties and characteristics.

WO 92/20250 ; PClr/US92/û37~
21~3278 30 The backing 34 is positioned beneath both the entanglement zone 30 and the spacing zone 32. The backing 34 prov1des a foundation for these other two zones. The backing 34 serves as a surface to which the other zones can be affixed. The backing 34 1s optional, however. In an alternative embodiment in which there ls no backing, the entanglement zone 30 and the spacing zone 32 can be bonded directly to the substrate ~the surface of the article to whlch the female component is to be attached), and the substrate will serve the function of the backing.

Many types of material are suitable for use as the backing 34. The backing 34 preferably should be some type of material that the hooks 28 of the mating hook component 24 will not penetrate. (Although the backing 34 is not limited to such a material.) The backing 34 could be a film, a nonwoven web, a woven fabric, or any other suitable type of material. The backing 34 is generally a layer of material. The backing 34 can be made of polyester, polyethylene, or polypropylene, or any other suitable material. Suitable materials for use as the backing 34 include any commercially-available low gauge (e.g., from about 0.75 to about 3 mil (about 0.02 mm. to about 0.08 mm.)) polyester, polyethylene, or polypropylene film. Suitable polypropylene f!lm can be obtained as the product designated JR-136 from the Food and Consumer Packaging Group of the James River Corporation of Cincinnati, Ohio.

If the substrate comprises the backsheet of a disposable diaper, the layer that takes the place of the backing may be comprised of any of the above materials, or similar materials.
Typically, however, such a backsheet wjll be comprised of polyethylene.

The individual zones or layers of the female component 22 described above can be held together in any suitable manner. The entanglement zone 30 and spacing zone 3Z are held in place on the backing 34. As long as the layers do not separate, !t is not necessary for all three layers to be secured together, however.

~ ~O 92/20250 2 ~ 0 3 2 7 ~ P(~r/US92/03720 ', , ;~ 31 The spacing zone 32 can, therefore, be sandwiched between the entanglement zone 30 and the backlng 34 without being secured to either, as long as the entanglement zone 30 and the backing 34 are secured in some manner.

The means used to hold the elements together (bonding means 44) must have several characterist1cs. The bondlng means 44 must not create bonded regions, bonded areas 46, that occupy so much space that the bonded areas 46 interfere with the spaces needed for the hooks 28 of the mating hook component 24 to penetrate and occupy within the female component 22. The bonded areas 46 must also be sufficiently strong that the layers or zones of the female component 22 will not separate when the hooks 28 are disengaged.

The bonding means 44 may form bonded areas 46 that are either stronger or weaker than the structural elements that entangle the hooks 28. In preferred embodiments of the present invention, the bonded areas 46 are sufficiently strong relative to the strength of the structural elements that when relatively stiff hooks are used, the structural elements will fail instead of being pulled loose at an individual bonded area, bond site 46. If, on the other hand, the bond sites are the weakest element of the female component 22, each rigid hook 28 may be able to break several bond sites when the fastening device 20 is opened. This could cause entire structural components to be either nearly or completely torn away from the backing 34. If that occurs, the number of secured structural elements available to engage the hooks 28 wlll be significantly reduced. In addition, such loose structural elements will tend to interfere with the open space needed for the hooks 28 of the mating hook component 24 to penetrate.

The possible types of bonding means 44 may include, but are not limited to stitching, ultrasonic bonds, adhesive bonds, and heat/pressure bonds.

In some cases, it may be preferable for ease of ~ c~l if the layers are autogenously secured. The term autogenously , as used herein, means that the materials are secured to each other .

WO 92/202~0 PCI /US92/037~
21 ~278 without the aid of a third material. Thus, the materials can be fused or melted to each other. This will typically occur when ultrasonic or heat/pressure bonds are used.

The type of bonding means 44 used may be limited to some extent by the types of materials in the different layers or zones of the female component 22. This is particularly true if the bonding means 44 are ultrasonic or heat/pressure bonds. When these two types of bonding means 44 are used, at least the materials comprising the entanglement zone 30 and the backing 34 should be compatible as far as the type of material and the melting temperature of the same are concerned. The term ~compatlble~, as used herein, means that the materials are capable of belng fused together.

When materials are described herein as being ~similar~, it is meant that the materials are generally comprised of the same compound, such as polypropylene. Similar materials may, however, comprise two different types of such a material (for instance, two different polypropylene materials).

The material comprising the spacing zone 32, however, does not have to be compatlble with the mater;als comprising the entanglement zone 30 and the backing 34 (or if there is no backing, the substrate). The spacing zone 32 only needs to be held between the other two zones or layers; it need not be bonded to either. In fact, in some preferred embodiments, a material may be selected for the spacing zone 32 that is incompatible with the materials comprising the other two zones. Such a combination of materials may be advantageous because it may allow the structural elements of the spacing zone 32 (such as pellets) to remain unbonded and, thus, free to move between the other two zones.
This will provide more room to accommodate the hooks 28 of the mating hook component 24.

When adhesive bonding means 44 are used, the materials comprising the entanglement zone 30 and the backing 34 do not necessarily have to be compatible. However, for ease of ~VO 92/20250 2 ~ ~ 3 2 ~ 8 PCI/US92/03720 ,, ;.
3~3 . .~

manufacture lt may be preferable that these materlals be capable of being bonded to the spacing zone 32 with the same adheslve.

The pattern that the bonded areas 46 are arranged ln 1s also lmportant. The bonding pattern may be contlnuous, intermlttent, or spot bonded, depending on the type of materlals used ln the dlfferent zones. Some of the bondlng patterns dlsclosed in U.S.
Patent Applicatlon Serlal Number 07/355,065 entitled ~Loop Fastening Material for Fastenlng Devlce and Method of Maklng Same~
flled ln the name of John R. Noel, et al. on May I7, 1989, may be sultable, provided the bonding pattern meets the criteria set forth herein.

A continuous bonding pattern is often preferred when the entanglement zone 30 comprises a nonwoven web because the fibers 36 ln such a structure will be most likely to be secured in place.

An intermittent pattern that provides relatlvely small spaces or breaks between bonded areas 46, however, may also be suitable when nonwovens and certa1n other types of materials are used for the entanglement zone 30. A non-limiting example of an lntermittent bonding pattern is provided in the upper left hand corner of FIG. 4B for purposes of lllustration. The breaks 46' between the bonded areas 46 of such an intermittent pattern should be sufficlently small that there will be relatively few structural elements 36 in the entanglement zone 30 with unbonded loose ends.
It is believed that an intermittent bonding pattern which has breaks 46' between bonded areas 46 that are less than or equal to the dlameter of the smallest diameter structural elements ln the entanglement zone 30 will be suitable. Larger breaks 46' between bonded areas may also be suitable. For instance, in some cases, the breaks 46' between bonded areas 46 could be as large as I I/2 times, or even S times (or possibly even larger) the d1ameter of the smallest diameter structural elements in the entanglement zone 30.

WO 92/202S0 ,, PCI'/US92/037i 210~ ~ o 34 If an intermittent bonding pattern is used, another important factor is the frequency of the breaks 46' in the pattern. The breaks 46' should not occur too frequently. If the breaks 46' occur too frequently, there will be too many fibers 36 with unbonded loose ends. It is preferred that the bonded areas 46 are longer (occupy more area) than the breaks 46' along each intermittent line in the bond pattern.

If the entanglement zone 30 comprises a structure that has more 1nherent integrlty (for instance, if a woven fabric or ~
screen is used for the entanglement zone 30), the entanglement zone 30 may be spot bonded to the other zones.

The pattern of the bonded areas 46 is preferably regular.
Suitable bonding patterns (particularly for nonwovens), include continuous lines. Such lines can be curved, e.g., sinusoidal, or they can be arranged in the form of grids that define different geometrical shapes such as squares, rectangles, hexagons, diamonds, and circles. This will provide the female component 22 with relatively uniform holding characteristlcs.

The bonded areas 46 preferably have certain additional characteristics if the entanglement zone 30 comprises a nonwoven material. In such a case, the bonded areas 46 in the bond pattern must be sufficiently close together that the fibers 36 of the nonwoven material will have relatively few unbonded loose ends.
In order to ensure that this happens, the distance between bonded areas 46 should preferably be less than the average length of fibers 36 in the entanglement zone 30, more preferably, less than or eoual to about one-half the length of the fibers 36 in the entanglement zone 30. (The distance between bonded areas 46 specified refers to the spaces other than the breaks 46' in an intermittent bonding pattern.) A preferred bonding pattern is the diamond-shaped pattern shown in FIG. 4B. The ~diamonds" in the ~diamond-shaped~ pattern are generally square elements. These elements are rotated approximately 45 degrees to give them the appearance of diamonds.

. . _ . . _ . . .

~ 0 92/20250 21~ 3 2 ~ 8 Pc~r/us92/o372o , The dimensions of the pattern should be such that the distance between bonded areas 46, in at least some port1On of the area between bonded areas, is greater than the projected plan view dimensions of the heads 38 of the hooks 28 of the mating hook component 24.

Examples of diamond-shaped bonding patterns which are suitable for use with some of the hook components described herein are as follows. These include, but are not limited to patterns having sides that measure about I/4 inch x I/4 inch (about 0.6 cm.
x 0.6 cm.); about 3/8 inch x 3/8 inch (about I cm. x I cm.); about I/2 inch x I/2 inch (about I.3 cm. x 1.3 cm.); and, about 3/4 inch x 3/4 inch (about 2 cm. x 2 cm.J.

The width of the bonded areas 46 in cross-section, Bw, shown in FIG. 48, can vary. In the examples of the diamond-shaped bonding patterns described above, a suitable bond width (measured at the backing 34) 7s between about 0.03 inch and about 0.05 lnch (about 0.76 mm. and about I.3 mm.).

The cross-sections of the bonds shown in FIGS. 3 and 4A are shown to be tapered in width so that they become narrower from the first surface 3I of the female component 22 to the second surface 33. The tapering of the width of the bonds in cross-section is primarily of interest in relation to the cost and life of the patterned rolls used to form such bonds in the method of making the female component 22. (For instance, it may be less expensive to manufacture rolls having patterned surfaces tapered to form such bonds.) In one particularly preferred . ~.. t of the female component 22 of the present invention, the entanglement zone 30 is a first nonwoven web. The first nonwoven web is a r L- ~ ~
nonwoven web. The first nonwoven web has a basis weight of between about 7 and about I5 grams/square yard (between about 8.5 and about I8 grams/square meter). The first nonwoven web is comprised of continuous filament polypropylene f1bers that have a denier of between about 3 and about 6, most preferably, about 3.
The fibers are preferably primarily oriented in a single ..... . ~

W O 92t20250 , PY~r/US92/037 ~
21~327~

direction. In addlt10n, in this preferred embod1ment, the spactng zone 32 also comprises a nonwoven web, and the fibers in the entanglement zone 30 are finer than those in the spacing zone 32.

In the preferred embodiment described above, the spacing zone 32 1s a second nonwoven web. The second nonwoven web 1s a carded nonwoven web which has a bas1s weight of between about 7 and about 30 grams/square yard (about 8.5 to about 36 grams/square meter).
The second nonwoven web is comprised of polypropylene fibers having a length of between about I.5 inches and about 2.5 1nches (between about 4 cm. and about 6 cm.) and a den1er of between about 6 and I5, most preferably, about 9. The fibers of the spacing zone 32 are preferably crimped with at least about I0 crimps/inch (about 4 crimps/cm.), most preferably with at least about 14 crimps/inch (an average of about 5.5 crimps/cm.). The crimped f;bers are preferably randomly oriented in the spacing zone 32. The spacing zone 32 is preferably also res111ent.

The composite or total basis weight of both the entanglement zone 30 and the spac1ng zone 32 should be between about I5 and about 35 grams/square yard (about 18 to about 42 grams/square meter). (This total basis weight could also include the backing 34 since the backtng will typically have a relatively low basis weight.) In the particularly preferred embodiment described above, the backing 34 is preferably a polypropylene film. The three layers, the entanglement zone 30, the spacing zone 32, and the backing 34 are secured with the preferred diamond-shaped bonding pattern shown in FIG. 4B, and described in greater detail above.

FIGS. 4A to 23 show various alternative embod1ments of the mult1-layer female component 22 of the present invention.

FIG5. 4A and 4B are a side view and a partially cut-away plan view, respect1vely, of a second alternative embod1ment of the multi-layer female component 22 of the present invent10n. In th1s second alternat1ve embodiment, the fibers of the nonwoven web used ~ O 92/202S0 2 1 ~ 3 2 7 ~ Pq~r/US92/03~20 37 ~

for the entanglement zone 30 and the fibers of the nonwoven web used for the spacing layer 32 are of the same thickness. (Rather than fibers with large diameters being used for the spacing zone 32, and finer fibers for the entanglement zone 30 as shown in FIGS. I-3).

FIG. 5 shows a third alternative embodiment of the female component 22 in which the entanglement zone 30 comprises a woven fabric rather than a nonwoven web.

FIG5. 6 and 7 show a fourth alternative embodiment of the female component 22 in which the spacing zone 32 is a loose pellet-like material rather than a nonwoven material as in the case of the previous embodiments. The structural elements of such an embodiment comprise pellets 42. FIG. 6 shows a version of th1s alternatlve embodiment having a nonwoven entanglement zone 30.
FIG. 7 shows a version ln which the entanglement zone 30 is a woven fabric.

FIG5. 8-ll show a fifth alternative embod{ment of the female component 22 in which the spacing zone 32 is a net, screen or geometric screen, scrim, or similar element. The terms net , screen~, geometric screenD, scrim , as used herein, typically refer to structures comprised of ribs, filaments, strands, or the like, in which the junctures between such structural elements 42 are integral with the structural elements. (It is also within the scope of the present invention, however, for the spac1ng zone to comprise structures having junctures which are not integral with the structural elements.) For simplicity, the type of structure shown in FIGS. 8 - 11 will be referred to as a screen .

In these embodiments, the screen 32 spaces the entanglement zone 30 away from the backing 34. The hooks 28 are stored in the spaces between the structural elements 42 of the screen 32.

The screen 32 may have structural elements 42 that are flexible enough to move out of the way of the hooks 28 of the mating hook component 24. In alternative cases, the screen 32 may WO 92/20250 PCI'/US92/037~

~iO327~ 38 be so rlgid that no such movement ls possible. If the structural elements 42 of the screen 32 are not capable of mov1ng, the hooks 28 will simply not be stored in the areas occupled by the structural elements 42.

The screen 32 may have structural elements 42 that are small enough to be entangled by the hooks 28 of the mating hook component 24. In other alternatlves, the structural elements 42 may be larger than the gap 41 defined by the heads 38 of the hooks 28 so that no such entanglement ls possible.

Typically, the structural elements 42 of the screen 32 that run in each directlon will be of approximately the same diameter.
The structural elements 42 of the screen 32 that are oriented in different dlrectlons have, however, been shown in FIGS. 8-II to have dlfferent diameters for clarity of illustratlon. The structural elements 42 which run parallel to the plane of the paper have been shown as belng of a slightly smaller diameter than the structural elements 42 that run ln a dlrectlon lnto the plane of the paper. It is possible that a suitable screen could be formed with structural elements of different diameters.

FIGS. 8-II show four examples of possible combinations of layers of material and bonding between the layers when the spacing zone 32 is a screen. In all of the embodlments shown in FIGS.
8-II, the entanglement zone 30 comprises either a woven fabric or a nonwoven web, and the backing 34 is a film. There are two basic types of bonding means 44 shown schematlcally in FIGS. 8-11, heat/pressure bonding means and adhesive applied to both sides of the screen 32.

FIG. 8 shows a female component 22 that comprises a nonwoven entanglement zone 30 and a film backing 34 bonded to a screen that serves as the spaclng zone 32 by heat/pressure bonds. FIG. 9 shows a female component 22 that comprises a woven entanglement zone 30, a screen spacing zone 32, and a fllm backlng 34 bonded by heat/pressure bonds. FIG. IO shows a female component 22 that comprises a nonwoven entanglement zone 30, a screen spacing zone ~- ~ O 92/20250 2 1 0 3 2 7 ~ P(~r/US92/03720 ; 39 32, and a film backing 34 bonded by an adheslve. FIG. 11 shows -female component 22 that comprises a woven entanglement zone 30, a screen spacing zone 32, and a film backing 34 bonded by an adhesive. Any of the other materials and types of bondlng means 44 described herein may be used to form additlonal embodiments.

FIGS. 12-17 show a sixth alternative embodiment of the female component 22 of the present inYention. In the slxth alternative embodiment, the film backing 34 1s eliminated. The dlfferent zones of the female component are formed by stacking one of the materials generally used in the spacing zone 32 on top of one of the materials generally used as the entanglement zone 30, or vice versa, to form a laminate. This laminate is then folded over on top of itself so that the spacing zone material faces other spacing zone material. The folded laminate may then be bonded to form the female component 22. (In the process of making this embodiment, the fold is oriented in the machine direction.) As shown in the drawings, after folding, the spacing zone 32 material is disposed in two layers, The layers of spacing zone 32 material are sandwiched between layers of the entanglement zone material. One layer of the entanglement zone material is designated 30 as forming the entanglement zone, and the other layer is designated 34 as forming a backing, This folding process may form a spacing zone 32 that has characteristics that make it react as if it has either more structural elements or more loft than a single layer of spacing zone 32 material of equivalent thickness. This is especially the case when the material used in the spacing zone 32 is a woven or nonwoven fabric, a screen, or the like (typically not loose particles), The folding usually causes the structural elements of different portions of the spacing zone material to be slightly misaligned or offset with respect to each other at the interface between the folded port10ns, That is, there is a ~mismatch~ of structural elements so they are not in direct alignment, This WO 92/202~0 ; , PCI'/US92/037~
, .", 21~3278 40 often provldes a female component 22 that exhibits increased resistance to the removal of the hooks 28 of the mating hook component 24.

There are various combinations of thls sixth folded embodiment depending on the material chosen for the respect1ve zones or layers. These include but are not limited to the versions shown in the drawings. The drawings are merely intended to show some examples of possible structures.

FIG. 12 shows a female component 22 in which the material used for the spacing zone 32 is a nonwoven web and the material used for the entanglement zone 30 is another nonwoven web. The laminate before folding comprises a nonwoven material stacked on top of another nonwoven material. After folding the female component 22 comprises a nonwoven entanglement zone 30 and a nonwoven backing 34 with two nonwoven layers of spacing zone 32 material in between.

FIG. I3 shows a female component 22 in which the spacing zone 32 material is a nonwoven web and the entanglement zone 30 material is a woven fabrlc. The laminate before folding comprises a nonwoven material stacked on top of a woven material. After folding the female component 22 comprises a woven entanglement zone 30 and a woven backing 34 with two layers of nonwoven spacing zone 32 material in between.

FIG. 14 shows a female component 22 in which a loose material is used for the spacing zone 32 and the entanglement zone 30 material is a nonwoven web. The laminate before folding comprises layer of loose material on top of a nonwoven material. After folding the female component 22 comprises a nonwoven entanglement zone 30 and a nonwoven backing 34 with a loose material in between.

FIG. 15 shows a female component 22 in which a loose material 1s used for the spacing zone 32 and the entanglement zone 30 material is a woven fabric. The laminate before folding comprises ~ O 92/20250 2 ~ ~ 3 ~ 7 ~ P(~r/US92/03720 layer of loose material on top of a woven material. After folding, the female component 22 comprises a woven entanglement zone 30 and a woven backing 34 with a loose material in between.

FIG. 16 shows a female component 22 in which material used for the spacing zone 32 is a screen and the material used for the entanglement zone 30 is a nonwoven web. The laminate before folding comprises a screen placed on top of a nonwoven material.
After folding, the female component 22 comprises a nonwoven entanglement zone 30 and a nonwoven backing 34 with two thicknesses of the screen in between.

FIG. 17 shows a female component 22 in which the material used for the spacing zone 32 is a screen and the material used for the entanglement zone 30 is a woven fabric. The laminate before folding comprises a screen placed on top of a woven fabric. After folding, the female component 22 comprises a woven entanglement zone 30 and a woven backing 34 with two thicknesses of the screen in between.

There are still other versions of the sixth folded embodiment.

For instance, an embodiment could be constructed in which only one of the materials that forms the female component is folded. A non-limiting example of this type of structure would occur if loose particles are used for the spacing zone 32 and a nonwoven web is used for the entanglement zone. In such a case, the loose particles could be distributed across only half of the width of the nonwoven web. The other half of the nonwoven web could be folded on top of the loose particles. This would form a female component in which only one of the materials is folded.

In another version of such an embodiment, the material that forms the top layer of the laminate could be folded instead. For instance, a nonwoven web could be placed on top of a woven material. The nonwoven web could have twice the width of the . _ _ : . .. .. . _ .. _ _ . .. . . . _ . _ _ _ .

21~32~8 42 woven materlal. The nonwoven web could then be folded over on top of ltse1f and secured to the woven materlal to form a female component.

Numerous other varlatlons are posslble. For lnstance, the folded layer could be an intermedlate layer. Thus, the slxth embodlment could be any embodlment ln whlch at least one of the layers ls folded. All such verslons are capable of belng understood from the above descrlptlon and the examples shown ln the drawlngs.

FIGS. I8-23 show a seventh alternatlve embodlment of the present inventlon. In the seventh alternatlve embodlment, a layer of the same material used in the entanglement zone 30 ls used ln place of the fllm backlng. There are varlous comblnatlons of the seventh embodlment depending on the material chosen for the respective zones or layers. These include, but are not llmlted to the verslons shown ln the drawlngs. As before, the drawlngs are merely lntended to provlde some examples.

FIG. 18 shows a verslon of the seventh embodlment ln whlch the female component 22 comprises a lofted nonwoven materlal between two layers of less lofted nonwoven materlal. FIG. I9 shows a version of the seventh embodiment ln whlch the female component 22 comprises a lofted nonwoven materlal as an lntermedlate layer between two layers of woven materlal. FIG. 20 shows a verslon of the seventh embodlment ln which the female component 22 comprlses a loose materlal as an lntermedlate layer between two layers of nonwoven materlal. FIG. 21 shows a verslon of the seventh embodlment in whlch the female component 22 comprlses a loose material as an lntermedlate layer between two layers of woven material. FIG. 22 shows a verslon of the seventh embodlment ln whlch the female component 2Z comprises a screen as an lntermedlate layer between two layers of nonwoven material.
FIG. 23 shows a version of the seventh embodlment ln which the female component 22 comprises a screen as an lntermedlate layer between two layers of woven material.

~O 92/202!;0 2 I ~ 3 2 7 ~ PCI/US92/03720 It should be understood that the embodiments of the multi-layer female component 22 of the present inventlon described above are for purposes of illustration only. It is apparent that there are many possible combinations of the different zones or layers described herein. These combinations are capable of being understood from the description provided above and the examples set forth in the drawlngs. The multi-layer female component 22, however, is not limited to the speclfic embodiments shown in the drawings.

The present invention provides a low-cost female component for a refastenable fastening device. The female component 22 makes more efficient use of raw materials than existlng fastening dev kes by utilizing reduced amounts of expensive materials and by providing a female component in which the different functlons served by conventional loop components are served by separate layers. Each layer or zone has certain of the desired individual characteristics for entangling and holding the hooks of the matlng hook component.

The first zone, entanglement zone 30, admits and engages at least some of the hooks of the complementary hook component. The second zone, spacing zone 32 provides space for the hooks to occupy after they have been admitted by the entanglement zone.
The backing 34 provides a foundation for the entanglement and spacing zones 30 and 32. Because the spacing zone 32 is not required to serve the function of entangling the hooks, less expensive materials can be used in the spacing zone 32. This is a departure from existing loop components in which the same, relatlvely expensive raw material is used for the entire composition of the loop component.

Thus, the fastening device 20 is especially useful on such disposable articles as packaging, disposable absorbent art1cles, disposable wraps, and the like. The female component 22 is more suited for disposable articles since the fastening device on a disposable article is opened and closed far fewer times than on reuseable articles. The female component 22 generally only needs .. . .... : . _ . _ . , _ _ WO 92/20250 PCI'/US92/0372~
2~ ~3278 ~ 44 to be strong enough to provide a limited number of secure closures ~for example, a maximum of about 10-20 closures).

It should be noted, however, that the female component 22 can be made much stronger for use on durable articles or for any other contemplated use. This can be done by, for example, lncreaslng the dlameter or denler of the structural elements of the entanglement zone 30, more strongly securlng the structural elements to the backing 34 or increaslng the density of the structural elements relatlve to the number of hooks 28. However, these changes also increase the cost of the female component 22.

The female component 22 can also be used in conjunctlon with lower cost hook components having more brittle hooks. In such cases, instead of the hooks bending to release from mechanical entanglement with the structural elements, the structural elements of the female component 22 may advantageously break or serve as a ~fallure mechanism~ to allow the dlsP~g;~ t of the hooks upon opening the fastenlng devlce.

3. The Mttlnq Hook Com~onent The mating hook component 24 is shown in numerous places ln the drawings.

The term "hook component", as used herein, ls used to designate the portion of the fastening device 20 having engaging elements, such as hooks 28. The term "hook' is nonlimiting in the sense that the engaging elements may be in any shape known in the art as long as they are adapted to engage a complementary loop fastening material or the female component 22 of the present invention.

The hook component 24 comprises a base 26 having a first surface 27 and a second surface 29 and a plurallty of engaging elements 28 extending from the first surface 27 of the base 26.

~ W O 92/202S0 2 1 0 3 2 7 8 P(~r/US92/03720 ~ 45 Each of the engaging elements 28 are shown to preferably comprjse a stem 40 supported at one end on the base 26 and an enlarged head 38 positioned at the end of the stem 40 opposite of the base 26.

The hook components 24 used with the multi-layer female component 22 of the present invention can be conventional commerclally available hook materials. The hook component 24 however is not limited to conventional materials with flexible res11ient hooks. Suitable hook components can have less expensive more brittle hooks.

The hook components 24 used with the multi-layer female component 22 can have hooks 28 with blunt heads 38. The portion of the heads 38 of the hooks 28 that are blunt is that portion designated as the apex 39 of the hook 28 in FIG. 3B. The apex 39 will first come in contact with the female component 22 of the present invention when the female component 22 and the complementary hook component 24 are placed in face-to-face relationship with each other. This portion is referred to as the apex of the hook 28 because it is portion of the hook 28 that is greatest perpendicular distance from the base 26 of the hook component 24. The term blunt~ as used herein means that the apex 39 is dull in that it forms an edge or point that is not sharp. The apex 39 of a hook 28 having a blunt head can be generally rounded flat or any other shape that does not provide a sharp point.

The female component 22 of the present invention thus does not require specially-made rigid sharp hooks to be used. It is however possible for hooks of all configurations including such sharp hooks to be used with the female component 22.

A suitable hook component 24 may comprise a number of shaped engaging elements projecting from a woven backiny such as the commercially available material designated "Scotchmate~ brand No.
FJ3402 available from Minnesota Mining and Manufacturing Company St. Paul Minnesota. The engaging elements may have any shape known in the art such as hooks ~T s~ mushrooms or any other shape. A particularly preferred hook component is described in WO 92/202~0 PCr/US92/037~

U.S. Patent 4,846,815 entltled "Dlsposable Dlaper Havlng An Improved Fastening Device" which issued to C. L. Scripps on July 1I, 1989. Another part;cularly preferred hook component ls described in European Patent Application Publlcatlon Number 0 381 087 A1 entitled "Refastenable Mechanical Fastenlng System and Process of Manufacture Therefor'. publlshed August 8, l990 by Dennls A. Thomas. The disclosure of these patent publlcatlons, and all other patents, patent applicat10ns, and publlcatlons referred to ln this application are hereby lncorporated by reference herein.

(It should be understood that the various portlons of the hook components may be described in these references with sllghtly different terminology than is used herein. However, the drawings and elements contained herein can be compared to those of the references to readily locate the corresponding port10ns of the hook components described in those publications.) The hook component 24 may be manufactured from a wide range of materials. Such suitable materials include, but are not limited to nylon, polyester, polypropylene or any combination of these or other materials.

The size of the heads 38 of the hooks 28, as noted above, determines the open space required between the structural elements of the entanglement and spacing zones 30 and 32. Some non-limiting examples of sizes of hooks 28 that are useful with the female component 22 of the present lnvention are provlded below.

One suitable hook component 24 has T-shaped hooks 28 with the following dimensions. The length of the head l, ls about I mm.;
the width w, is about 0.2 mm.; and the height h1, 1s about 0.3 mm.
If this type of hook component is used, the openings between the structural elements of the entanglement and spaclng zones 30 and 32, should be (or should readily spread without belng plerced to~

~F'~ 92~202~0 PCI'/US92103720 2~327~ 47 dimensions of slightly greater than about 0.2 mm by about 1 mm.
The ca1iper of the spacing zone 32 should be greater than about ~ 0.3 mm.

Another suitable hook component 24 hooks 28 in the shape of an upside down letter "J". (The hooks 28 of such a hook component 24 could also be said to resemble candy canes.) In other variations, such a hook could resemble an upside down upper case letter RL". Such hooks could have the following dimensions. The length of the head 1, is about O.S mm.; the width w, ls about 0.2 mm.; and the height hI, is about 0.3 mm. Thus, if this type of hook component is used, the openings between the structural elements of the entanglement and spacing zones 30 and 32, should be (or should readily spread without being pierced to) dimensions of slightly greater than about 0.2 mm. by about O.S mm. The caliper of the spacing zone 32 should be greater than about 0.3 mm.

Stlll other hook components 24 could have hooks as small as I/2 to I/4, or smaller than the hooks described above.

4. ExamDles of Uses of the Refacten~hle Fastening Device The fastening device 20 of the present invention is especially useful as a fastening device for disposable articles, particularly disposable absorbent articles.

The term "disposable absorbent articlen, as used herein, refers to articles which absorb and contain body exudates. More particularly, the term refers to articles 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 ~disposabler means that such articles are intended to be discarded after a single use (i.e., they are not intended to be laundered or otherwise reused). Examples of disposable absorbent articles include diapers, incontinent garments, sanltary napklns, bibs, bandages, and the like.

WO 92/20250 PCI'/US92/0371~
2 ~ 8 The fastening device 20 ls shown in FIG. 24 pos1t1Oned on a preferred embodiment of a disposable absorbent art1cle, disposable dlaper S0. The term diaper , as used herein, refers to a garment generally worn by infants and incontinent persons that ls drawn up between the legs and fastened about the waist of the wearer.

The disposable diaper S0 has an inside surface (or body surface) 52, intended to be worn adjacent to the body of the wearer. The d1aper S0 has an outside surface (or garment surfaceJ
54 lntended to be placed adjacent the uearer s clothing when the d1aper S0 1s worn. The diaper S0 has two waist reg1Ons, which are designated as first waist region 56 and second waist region 58.
The diaper S0 has two spaced apart longltudinal edges 6D and two spaced apart transverse or end edges 62.

The disposable diaper S0 comprises a body portion SI and a mechanical fastening system, such as tape tab fastening system, or s1mply fastening system 72. The body port1On SI of the diaper S0 comprises a liquid pervious topsheet 64, an absorbent core 66, a liquid impervious backsheet 68, and elastic members 70. The topsheet 64, the absorbent core 66, the backsheet 68, and the elastic members 70 may be assembled in a variety of well known configurations.

Several examples of the kinds of diapers to which the present invention is read11y adapted are shown in U.S. Patent Re. 26,151 entitled Disposable Diaper which reissued to Robert C. Duncan, et al., on January 31, 1967; U.S. Patent 3,860,003 ent1tled "Contractible Side Port1Ons For Disposable Diapers~ which issued to K. B. Buell on January !4, 1975i U.S. Patent 4,695,278 entitled "Absorbent Art1cle Having Dual Cuffs , issued to Michael 1. Lawson on September 22, 1987; U.S. Patent 4,834,735 entltled ~High Density Absorbent Members Hav;ng Lower Dens1ty And Lower Bas1s ~e1ght Acquisition 7ones wh;ch issued to Miguel Alemany, et al.
on May 30, 1989; and U.S. Patent 4,909,803 ent1tled ~Disposable Absorbent Article Having Elasticized Flaps Provided With Leakage Res1stant Port1Ons which issued to Mohammed I. A212, et al. on March 20, 1990. It should be understood, however, that the ~092~20250 PCI/US92/03720 21~3278 fastening device 20 of the present invention is not limited to use with any speclfic diaper structure or configuratlon.

The fastening system 72 of the diaper 50 preferably comprises the fastening devlce 20 of the present invention, among other elements. The fastening system 72 may be ln the form of any of the well known configurations and constructlons currently ln use.
Preferably, the fastening system 72 is a tab fastening system, preferably a tape tab fastening system.

The tape tab fastening system can comprise any of the well known tape tab configurations and constructions currently in use.
A preferred tape fastening system uses the Y-tape tab described in detail in U.S. Patent 3,848,594 entitled ~Tape Fastening System For Disposable Diaper" which issued to K. B. Buell on November 19, 1974. Alternatively preferred tape fastening systems are described in detail in European Patent Application 0 233 704-A, entitled "Disposable Diaper Having Wide Tapered Fastening Tapes~
published August 26, 1987 by H. R. Burkhart and Kenneth B. Buell;
previously referenced U.S. Patent 4,846,815 1ssued to C. L.
Scripps; and U.S. Patent 4,963,140 entitled ~Mechanical Fastening Systems With Disposal Means for Disposable Absorbent Articles' which issued to Anthony J. Robertson, et al. on October 16, 1990.

In stlll other preferred embodiments, the female component 22 of the fastening system 72 could comprise an element, such as a patch located on one of the surfaces of the body port10n of a diaper (or other suitable placesj to form an ~inner fastening member~ as described in U.S. Patent 4,699,622 entitled "Disposable Diaper Having An Improved Side Closure" which issued to J. W.
Toussant, et al. on October 13, 1987.

The tape fastening system 72 shown in Figure 24 is a non-limitin3 example of the type of fastening system which can use the fastening device 20 of the present invention. The tape fastening system 72 comprises a tape tab 74 having a first fastening element 72a located thereon, and a second fastening , .. : . _ _ . _ .: . ~ . . . . . . . _ _ _ _ _ _ W O 92t20250 P~r/US92/037 ~

element (or ~landing member ~ 72b. The second fastenlng element 72b 1s mechanically engageable with the first fastening element 72a.

Preferably the first fastening element 72a compr1ses a hook component 24. The hook component 24 provides hooks 28 that extend from the tape tab 74. In a preferred embodiment of the disposable diaper 50 the second fastening element 72b comprises the multi-layer female component 22 of the present invention. In other embodiments the positions of the components of the fastening device 20 of the present invention could be reversed so that the first fastening element 72a comprises the multi-layer femile component 22 and the second fastening element 72b comprises the hook component 24.

As shown in FIG. 24 the multi-layer female component 22 is preferably located on the second waist region 58 of the diaper S0.
In a preferred embodiment of the disposable diaper 50 a plurality of the structural elements 36 of the entanglement zone 30 are aligned in a single directton. The female component 22 is oriented so that the structural elements 36 of the entanglement zone 30 extend essentially parallel to the longitudinal edges 60 of the diaper S0. This orientation aligns the structural elements generally perpendicular to the direction of shear forces applied to the fastening device 20 during use. In this configuration the structural elements 36 provide the maximum peel and shear force resistance. The female component 22 may however be oriented on the second waist region 58 in any manner with the structural elements 36 extending in any direction.

In use the diaper 50 is applied to the wearer by positioning the first waist region 56 under the ~earer s back and drawing the remainder of the diaper 50 between the legs of the wearer so the second waist region 58 is positioned across the front of the wearer. The tape tabs 74 are then positioned adjacent to the female component 22 positioned on the outside surface 54 of the ~ O 92/20250 2 1 0 3 2 7 ~ PC~r/US92/03720 , 51 second waist region 58 so the hooks 28 whlch are disposed on the tape tab 74 will engage the female component 22 to form a side closure.

Method of Makina the Female Com wnent The method or process of making the female component 22 of the present lnvention is shown in schematic form in FIG. 25.

The apparatus for making the multi-layer female component 20 of the present invention is designated 100. The apparatus 100 includes a first supply means 102, a second supply means 104, and a thlrd supply means 106, for feeding into the system the materials that will comprise the zones or layers of the multi-layer female component 22.
.

The apparatus 100 may also include an element that provides an embossed surface, embossed roll 110 (which may be patterned), and an anvil member, such as anvil roll 112. The embossed roll 110 and anvil roll 112 define a nip 114 between them. The nip 114 ls where the laminae of the webs or other materials fed into the system are bonded together. The bonded web 124, may then travel to a take-up roll 116, where it is wound for subsequent use. The apparatus 100 may further include an optional folding means, such as folding bars 108, shown in enlarged scale in FIG. 27. The individual parts of the apparatus 100 are described more fully below.

In the apparatus 100 shown in FIG. 25, the preferred method of making the multi-layer female component 22 involves feeding the materials for the different zones or layers into the system and and bonding the same. The materials may be bonded by various different methods, including, but not limited to by stitching, adhesives, ultrasonics, and by heattpressure processes.

The preferred method of bonding the materials together is by passing the composite of the materials between two heated rolls, one of which has a pattern on its surface, and impressing the bond .. ..... ..... . . _ . _ _ _ . . . . . . .

W O 92/20250 PC~r/U592/037 ~

2~327~ 52 pattern into the materials. One method of heat/pressure bondlng that could be used is described in U.S. Patent 4,854,986 lssued to Ball, et al. on August 8, 1989 (provlded the patterned cylinder descr1bed therein forms bonded areas that meet the criter1a set forth in this description).

The first supply means 102 feeds a first material I18 used for the entanglement zone 30 into the system. The f1rst material II8 can be any of those materlals specified as being suitable for use 1n the entanglement zone 30 ln Section 2 of this descr1pt10n.
Thus, the f1rst supply means 102 could be any conventional means used to introduce a material into a laminat1ng process. The f1rst supply means 102 could be, but is not limited to an unwind roll; a web or fabric producing machine, such as a conventlonal carding machine, spunbonding machine, loom, or knitting machine; or a hopper for feed1ng a layer of loose fibers into the system.

In the preferred embod1ment of the process of the present invention, the first supply means 102 comprises either a supply of , cnird fibers or a conventlonal machine for producing the same. Preferably, the first supply means 102 feeds a layer of loose (i.e., unbonded) continuous length fibers into the system.
These fibers are, preferably, uniformly deposited onto a su1table surface. These fibers could be deposited onto a surface such as the material described below that will comprise the spacing zone 32.

In other alternative embodiments, rather than being 1n the form of a layer of loose fibers, the first material II8 could be in the form of a web of entangled fibers or a web of bonded fibers, a woven fabric, or the like.

Regardless of the form in which the first mater1al is fed into the apparatus, (whether it be in the form of a web, or in the form of loose, unbonded fibers, etc.), the structural elements of the first material II8 are preferably oriented primarily in the machine direction when the first material 118 is introduced into the system. This will provide the female component 22 with ~/0 92/20250 2 1 0 3 2 7 8 PCI/US92/03720 .
,. - i structural elements having the desired single direction or1entation that is preferred for holdlng the hooks of the mating hook component.

The term machine direction (MD) refers to that direction which is parallel to the flow of the materials 118, 120, and 122, through the apparatus 100. The ~cross-machine direction~ (CD) is perpendicular to the machine direction. These directions are lndicated by arrows in FIG. 25 and in several of the figures which follow.

The second supply means 104 feeds a second material 120, used for the spacing zone 32 into the system. The second material 120 can be any of those materials specified as being suitable for use in the spacing zone 32 in Section 2 of this description. Thus, the second supply means 104 could be any of the means used to introduce a material into a laminating process that were described above as being suitable for the first supply means 104.

In the preferred embodiment of the process of the present invention, the second supply means 104 comprises either a supply of carded fibers or a conventional carding machine. The second supply means 104, preferably feeds a layer of loose (i.e., unbonded), fibers into the system. The fibers are preferably randomly-oriented, crimped, and between about 2 and about 3 inches (between about 5 cm. to about 8 cm.) long. These fibers are preferably, uniformly deposlted onto a suitable surface such as the third material described below that will comprise the backing 34.

In other alternative embodiments, rather than being in the form of layer of loose fibers, the second material 120 could be in the form of web of bonded fibers, a woven fabric, a screen, loose particles, or the like.

Preferably, the material 120 used in the spacing zone 32 will have sufficient thickness or loft built into its structure to accommodate the hooks of the mating hook component. If not, it is WO 92/20250 PCI'/US92/037~
2~27~ 54 contemplated that the materlal 120 used to form the spacing zone 32 could be lofted during the process of making the female component. If that is the case a means for 10ftlng the second materlal could be included in the apparatus. Such a means could 1nclude a conventlonal pleatlng or corrugatlng process (represented by block 128 ln FIG. 25). However a process that requires such an extra step ls generally less preferred.
..
~ ith respect to the formatlon of the spaclng zone 32 varlous alternatives embodiments of the process are possible.

FIG. 26 shows an alternative embodiment of an apparatus that may be used lf the material to be used as the spacing zone 32 ls not a fibrous structure. (For example the embodiment shown in FIG. 26 could be used if the materlal to be used ln the spaclng zone 32 ls particulate.) In the embodiment shown in FIG. 26 the second supply means 104 is replaced by a hopper 126. The hopper 126 ls disposed over the thlrd material 122. The thlrd materlal 122 serves as a surface upon whlch the loose material for the spaclng zone 32 may be dispersed.

The third supply means 106 feeds a third material 122 into the system. The third material 122 is used for the backing 34.
The third material 122 can be any of those materials specified as belng suitable for use as the backing 34 in Sectlon 2 of thls description. The backing 34 as noted above may be optional. If the backlng 34 is eliminated the functlon ordinarily served by the backing 34 may be performed by the substrate to which the female component 22 is attached. The third materlal 122 could therefore be a substrate such as a material used for the backsheet of a d1sposable diaper.

The optional folding bars 108 may be used to produce the folded embodiments of the female component 22 such as thcse shown in FIGS. 12-17. As discussed above. in such an b~ i ~ the film backlng 34 is eliminated. As shown ln FIG. 27 one of the mater~als generally used in the spaclng zone 32 such as 120 can be placed on top of one of the materials generally used as the entanglement zone 30 such as 118 to form a laminate 130. The j~po 92/20250 2 I 0 3 2 7 ~ PCI/US92/03720 . i , laminate 130 can then be folded over on top of itself to form the female component 22.

The overa11 process of making such a folded female component 22 can general1y be represented schemat1ca11y by FIG. 25.
However, the materia1s fed lnto the system by the supply means are switched. Second material 120 is fed lnto the system by flrst supply means 102. First material 118 is fed lnto the system by second supply means 104. This will produce a laminate of the second materlal 120 on top of the first material 118. The thlrd supply means 106 is eliminated. The optional folding bars 108 used in such a process are located before the nip 114.
Preferably, the folding bars 108 are located at the place designated by reference letter A in FIGS. 25 and 26.

In other alternative embodiments, only one of the mater1als that forms the female component could be folded. Alternatively, more than one, but less than all of such materlals (that ls, at least one layer) cou1d be folded. The folded materlal(s) could be the top layer, the bottom layer, or an intermediate layer or layers.

In still other alternative embodiments of the apparatus 100 shown in FIG. 25, additiona1 optional supply means of similar configuration to those shown could be provided 1f it is des1rable to construct a mu1ti-layer female component with more than three layers.

The element that provides the embossed surface can be in any suitable configuration. For example, it can be in the form of an emboss1ng plate or in the form of a cylinder. Preferably, 1t is a patterned cylinder, such as patterned cylinder 110. The patterned cylinder I10 1s used to bond the layers of the multi-layer female component 22. The pattern forms the bonded areas 46 of the female component 22. The pattern should be 1n relief so that only a relatlvely small portion of the first and second materials will be compressed during the process. The remainder (partlcularly the remainder of the second mater1al 120 wh1ch will form the spacing W0 92/20250 ~; . PCI'/US92/037 2~ ~327~
zone 32J should not be compressed so that the overall lofted character of the second material 120 will be maintained The pattern must form a bond with the characterlstlcs described above. Thus, the space between the bonded areas 46 must be sufficient so that the hooks 28 of the mating hook component 24 can easily penetrate the entanglement and spacing zones 30 and 32.
The space between the bonded areas 46 should not be too large, however. If, for instance, the space between bonded areas 46 ls too large in relation to the length of the fibers used ln a nonwoven entanglement zone 30, there will be an inordinate number of fibers with unbonded loose ends.

The surface of the patterned roll 110 is shown in greater detail in FIG. 28. The surface defines lands 132 and recesses 134. The lands 132 and recesses 134 of the roll 110 have several characteristics. These include roll depth or depth of the recesses, dimensions of the pattern, etc. These characteristics will vary depending on the materials used for the layers or zones of the female component 22 and on the type of bond pattern desired.

The patterned roll 110 shown in FIG. 28 is used to form the preferred diamond-shaped bond pattern shown in FIGS. 1-3.

The depth of the recesses 134 (or the height of the lands 132J should generally be greater than the sum of the calipers of the first and second materials. Typically, the depth of the recesses is about 1 1/2 times the sum of the calipers of these two materials.

The patterned roll 110 has lands 132 that are essentially square shapes that have been rotated approximately 45 degrees with respect to the cross machine directlon. These squares can have any suitable dimensions. For instance, these squares can be 1/4 inch x 1/4 inch (about 0.6 cm. x 0.6 cm.); about 3/8 inch x 3/8 inch (about 1 cm. x 1 cm.); about 1/2 inch x 1/2 inch (about 1.3 cm. x 1.3 cm.J; and, about 3/4 inch x 3/4 inch (about 2 cm. x 2 ~ 0 92/202~0 2 1 0 3 2 7 8 PC~r/US92/03720 ' ! . ' ' cm.) to form the bonds described ln Sectlon 2 above. The wldth of such lands 132 can, for example, be between about 0.03 1nch and about O.OS lnch (about 0.76 mm. and about I.3 mm.).

The embossed roll lI0 may be, and preferably 1s, heated. The temperature to which the rolls, such as embossed roll 110, are heated depends on the materials used to form the layers of the female component 22. In the preferred embodlment shown, the flrst, second, and thlrd mater1als are compr1sed of polypropylene.
When polypropylene is used, the embossed roll 110 1s preferably heated to a temperature of between about ISS' C and about 168- C.

The anvil member is preferably a cyllnder w1th a smooth, surface, such as anv11 roll 112. Preferably, the anv11 roll 112 1s also heated. Preferably, the anvil roll 112 is heated to a temperature of between about 104- C and about I10- C when polypropylene mater;als are used for the layers. The anv11 roll 112 rotates in the oppos1te d1rect10n as the embossed roll 110 (in other words, the two rolls are counter-rotat1ng).

The first, second, and third materials are bonded together when they pass through the nlp 114. The materlals for the three layers are bonded together by the applicat10n of heat and pressure from the rolls I10 and II2 at the n1p II4. In one preferred embod1ment of the process of the present invention, the rolls rotate so that the bonded web I24 is formed at a rate of about lO0 feet/m1nute (about 30.5 meters/minute). The rolls exert a pressure of between about 300 and about 400 pounds per linear inch (between about S0 and about 70 kg./linear cm.) as measured across the nip in the cross-machlne directlon.

In alternatlve embodiments of the process of mak1ng the female component of the present invent10n, adhesiYes can be used to bond the layers together instead of heat or heat and pressure.
In an adheslve bonding process, adhes1ve can be applied by any suitable commercial adheslve supply means I08. Preferably, the adhes1ve supply means appl1es adhes1ve ln a pattern s1mllar to that formed by the lands I32 of the patterned roll 110. In such , . _ , . . _ W O 92/20250 P~r/US9Z/037 ~
~Q327~ ss adheslve bonding processes, the patterned roll II0 could be replaced with a second smooth roll. However, in most cases lt ls preferable that the patterned roll II0 stlll be used so that portions of the first and second materials 118 and 120 are not compressed and the lofted character of the second materlal 120 ls malntained. Such adheslve bonding processes, could be conducted without the applicatlon of pressure. Preferably, however, in such cases pressure is also applied with the rolls.

In stlll other alternative embodiments, the rolls 110 and 112 could be replaced by a commercially avallable ultrasonlc welding device.

The rewind roll 116 collects the bonded web I24 of female component material. The roll of female component mater1al can be taken from the rewind roll 116 and can be cut into appropr1ate sizes for use in a refastenable fastening device with a sultable hook component. For example, the cut pleces of the female component material can be bonded onto a disposable dlaper. In other alternatlve embodlments of the process of the present lnvention, the rewind roll 116 could be eliminated, and the bonded web 124 could be fed directly into the appropriàte place of a dlaper manufacturing line. The bonded web 124 could be cut and affixed directly to the appropriate places on a web of diaper material.

The multl-layer female component 22 can, thus, be made relatlvely inexpensively in comparison to conventlonal loop materials. This process eliminates the need to loft or manipulate material to form individual loops. This process also results in a lower cost female component because the female component can be produced by a lower cost and relatively straight-forward bonding or lamlnating process, rather than the conventional weaving, knitting, pleating, or corrugat1ng processes.

Wh11e particular embodiments of the present invention have been lllustrated and described, it would be obvious to those skilled in the art that various other changes and modlfications .

~ W 0 92/202~0 2 ~ 0 3 ~ 7 8 PC~r/US92/03720 can be made without departing from the spirlt and scope of the invent1cn. It is to be understood that all of the limits and ranges spectfled in the foregoing descrlpt10n of the fastentng devtce 1nclude all narrower rangeS and 11m1ts that are wtthtn the spec1f1ed ltmits and ranges. Thus for example tf a range ts spec1f1ed as betng between about 6 and about 42 g/m2 all narrower range5, such as between about 10 and about 40 g/m2 and between about 20 and about 30 g/m2 etc. may be claimed even though these ranges are not separately listed. It 1s therefore 1ntended to cover tn the appended Cla1ms all such changes and mod1f1cat10ns that are w1th1n the scope of th1s tnvent1On.

What ts Claimed ts:

Claims

1. A multi-zone female component for a refastenable fastening device, said multi-zone female component characterized in that it is capable of 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 15;

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 2 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 between said first nonwoven web and said backing.

2. A multi-layer female component for a refastenable fastening device, said multi-layer female component characterized in that it is capable of 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 crimpedwith 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 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.

3. A multi-zone component that is affixed to a substrate that serves as a backing to form a 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 fromsaid base, said multi-zone 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 being capable of providing a multiplicity of openings for said hooks sothat 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 for providing space for at least portions of said hooks to occupyafter said hooks have penetrated by said entanglement zone, said spacing zone comprising a second material, wherein said entanglement zone and said spacing zone are held in place with respect to said substrate with said spacing zone between said entanglement zone and said substrate.

4. The multi-zone female component of Claim 3 wherein:

said entanglement zone comprises a first material selected from the group consisting of: a nonwoven web comprised of plurality of fibers, said nonwoven web being capable of providing interstices between said fibers; 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 interstices therein;

said spacing zone comprises a second material selected from the group consisting of: (a) at least one nonwoven web; (b) at least one layer of woven material; (c) at least one thickness of a screen; and, (d) a plurality of loose particles; and said substrate comprises a material selected from the group consisting of: a film, a nonwoven web of material, and a woven fabric.

5. The female component of Claims 1, 2 or 3 wherein said respective second zone, second layer, or second material is resilient.

6. A fastening device comprising a hook fastening material comprising a base and a plurality of engaging elements extending from said base, and the female component of Claims 1, 2, or 3.

7. 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 the female component of Claims 1, 2, or 3 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.

8. The disposable absorbent article of Claim 7 wherein the fibers comprising said first nonwoven web are generally parallel to said longitudinal edges of said disposable absorbent article.

9. 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.

10. 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 for admitting and mechanically entangling at least some of the hooks of the complementary hook component, said 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) securing 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 between said first material and said backing material.