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Publication numberUS3578155 A
Publication typeGrant
Publication dateMay 11, 1971
Filing dateFeb 24, 1969
Priority dateFeb 24, 1969
Also published asDE2001893A1
Publication numberUS 3578155 A, US 3578155A, US-A-3578155, US3578155 A, US3578155A
InventorsRudolph E Small, John J Bradley
Original AssigneePaper Converting Machine Co
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Disposable product
US 3578155 A
Images(2)
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Description  (OCR text may contain errors)

United States Patent lnventors Rudolph E. Small;

John .1. Bradley, Green Bay, Wis. Appl. No. 801,407 Filed Feb. 24, 1969 Patented May 11, 1971 Assignee Paper Converting Machine Company Green Bay, Wis.

DISPOSABLE PRODUCT 4 Claims, 7 Drawing Figs.

US. Cl 206/58 128/287 Int. (I 865d 85/67 Field of Search 206/56 (A4), 56 (A3), 58, (Adhesive Digest); l56/(lnquired); 161/(lnquired); 128/284, 287

References Cited UNITED STATES PATENTS 7/1959 DeVaud 128/284( UX) 2/1960 Lumpkin 206/(Adh. Digest) 8/1962 Burnett 206/58 7/1965 Chauviere 128/287 12/1965 Ekberg et a1... 128/287 1 1/1966 Wanderer 206/ 56(A3) 4/1967 Cooper 128/287 Primary Examiner-William T. Dixson, Jr. Anomey-Dawson, Tilton, Fallon & Lungmus ABSTRACT: A disposable product such as a diaper characterized by having a generally trapezoidal configuration and made up of outer sheets confining a generally rectangular fluff pad, tl e product sheets being united to confine the pad and perforated along generally straight lines to define detachable products.

" Patentd May 19711 ,5 15 I 2 Sheets-Shut 1 I g/3m A jfiad es DISPOSABLE PRODUCT BACKGROUND AND SUMMARY OF INVENTION Through the use of webs united together in a unique fashion and of specified construction, a complete unit is readily produced by an in-line machine to provide a product available for ready and secure installation. The provision of such constitutes an important object of the invention. Other objects and advantages of the invention may be seen as this specification proceeds.

DETAILED DESCRIPTION The invention is described in conjunction with the accompanying drawing, in which:

FIG. 1 is a perspective view of the inventive diaper and shown in operational condition, i.e., as it would be installed on an infant; I

FIG 2 is a perspective view essentially similar to FIG. 1 but in a slightly different operational condition as would be the case when it is installed on a smaller infant;

' FIG. 3 is a perspective view of a commercial product, complete with packaging, utilizing teachings of the invention;

FIG. 4 is a perspective view partially disassembled of the diaper seen in FIG. 1;

FIG. 5 is a schematic representation of apparatus employed in the manufacture of the inventive disposable product;

FIG. 6 is a schematic view of alternative equipment; and

FIG. 7 is a top plan view of the product before folding.

In the illustration given and with particular reference to FIGS. 1, 2 and 4, the numeral 10 designates generally a disposable diaper. The diaper is made up of a first or outer sheet or web 11 and a second or inner sheet or web 12. Interposed centrally of the sheets 11 and 12 is a pad of fluff material designated 13. In the illustration given in FIG.'4 the outer sheet 11 is a laminate of paper and a polyethylene film. This renders the product impervious to moisture penetration but it will be appreciated that in certain instances this moisture barrier may be dispensed with. In some cases, the mother may prefer to use some kind of extra pants and thus would not need the moisture barrier. Alternatively, the barrier may be provided by a single impregnated paper sheet. As illustrated, however, the sheets 11 and 12 are advantageously constructed of paper such as the tissue employed in toilet paper.

The individual diaper I0 is integrated into a single unit by means of a plurality of areas of union 14 as can be appreciated best from a consideration of FIG. 4. These serve to confinethe pad 13 against movement longitudinally, i.e., parallel to top and bottom edges 15 and 16. Further, longitudinally aligned areas of union are provided along the top as at 17 and the bottom as at 18. These, like the areas 14, may be glue (via a liquid adhesive, for example) or heat seals where a thermoplastic material is employed as part of the web 11.

Comparing FIGS. 1 and 2 reveals another facet of the invention and that is the adjustability in size of the diaper made available through the provision of adhesive patches 19 and 20.

These patches may be covered with a release strip and when exposed permit the comers of the diaper to be positioned in contacting, adhering relation with the top" portion of the inner sheet 12 as seen at 10a in FIG. 1 or in mutual overlapping relation as seen at 19' and 20' in FIG. 2.

The zigzag folded product 21 is seen in final usable form in FIG. 3. There the numeral 22 generally designates a carton in which a dozen diaper units are provided for use by the person dressing the baby. It will be seen that a given diaper unit 10a is in the process of being removed from the carton 22 and is adapted to be detached from the remaining web along the angled line of perforation 23. In this fashion, the diapers can be dispensed sequentially yet confined in an easy to store rectangular container. Because the adjacent diapers are oriented oppositely, it is possible to store them compactly along transverse fold lines, designated in dot-dash lines as at 24 in FIG. 7.

The procedure and equipment for producing the inventive diaper 10 can be appreciated principally from a consideration of FIG. 5. There, the numeral 25 designates generally a fluffforming drum apparatus wherein shredded cellulosic material is introduced axially as at 26 and by virtue of suction is caused to build up on the inner circumference of. the rotating drum, this being depicted schematically. Crossbars as at 27 are provided which separate the fluff pads into discrete segments. The fluff is laid down on a carrier sheet 28 (see also FIG. 4) which is unwound from a reel as at 29. A wire screen 30 is continuously moved to accompany the rotation of the drum 30 and confine the carrier sheet thereagainst.

The pads issuing from the apparatus 25 are supported on the carrier sheet 28 which is transversely severed by a cutoff mechanism generally designated 31. Following cutoff, the individual pads are conducted by a speedup conveyor generally designated 32 for engagement with a web 33. The web 33 ultimately becomes the outer sheet 11, and, in the illustration given, is a laminate of polyethylene and tissue delivered from a reel 34. .lust prior to the engagement of the web 33 with the pads 13, a liquid adhesive is applied from the adhesive fountain and applying unit generally designated 35. This ultimately provides the areas of union previously identified as at 14 relative to FIG. 4. v

A top web 36 is applied to the fluff pads 13, this ultimately becoming the top sheet 12 previously identified in FIG. 4. The web 36 is unwound from a reel 37 positioned at the extreme left-hand portion of FIG. 5. The diaper blanks are subjected to a calendering operation via the calender generally designated 38 after which the edges are folded by the folding apparatus 39. This develops the fold 40 seen in FIG. 4 after which adhesive (as at 17 in FIG. 4) is applied by the device designated 41 in FIG. 5.

Moving further to the right in FIG. 5, it is seen that the webs 33 and 36 are transversely perforated by means of a perforating apparatus generally designated 42. This develops the trapezoidal configuration seen most clearly in FIGS. 3 and 7. In otherv words, the lines of perforation are arranged at an angle to both the transverse and longitudinal directions with alternate lines being parallel, i.e., running from the rear corner of one pad to the opposite front corner of the successive pad, asfrom 43 to44in FIG.7.

Next in the path of the web in the in-line machine, the diaper blanks are subjected to another adhesive applying unit generally designated 45. Here the pressure sensitive adhesive which results in the areas 19 and 20 is applied after which a release tape is applied by the mechanism generally designated 46. This can be peeled off to expose the areas 19 and 20 to develop diaper configurations such as those seen in FIGS. 1 and 2.

The now completed, interconnected, detachable diapers are conducted to a packaging station which makes use of a vacuum delivery orbital packer generally designated 47. The packer 47 in FIG. 5 is arranged for vertical delivery and permits a manual count and separation into the units ultimately to be packaged.

In FIG. 6 the orbital packer is generally designated by the numeral 147 and is arranged for horizontal delivery on the conveyor 148. It will be seen that the conveyor 148 is positioned lower than the conveyor 48 of the apparatus seen in FIG. 5 and the vacuum applying unit 149 is effective over a greater segment of the periphery of the packer 147 than is the vacuum system 49 associated with the packer 47 of FIG. 5. Just prior to encountering the packer 47 or 147, as the case may be, the interconnected, detachable diaper unit has the configuration seen in FIG. 7.

We claim:

1. A disposable product comprising first and second elongated sheets, one of said sheets being substantially liquid impermeable, a plurality of elongated generally rectangular fluff pads having opposing right and left short sides disposed in spaced relation along the length of said sheets with the longitudinal dimension of each fluff pad extending transversely to the length of said sheets, said sheets being joined along the side edges thereof and between adjacent pads, a first set of spaced-apart generally parallel lines of perforation, each perforation line of said first set extending between opposite side edges of said joined sheets from adjacent the left short side of a pad to adjacent the right short side of the next pad, each perforation line of said first set being separated by a pair of intervening fluff pads, a second set of spaced-apart generally parallel lines of perforation, a perforation line of said second set extending between opposite side edges of said joined sheets between the fluff pads of each of said intervening pairs from adjacent the right short side of a pad to adjacent the left short side of the next pad whereby said sheets may be separated along adjacent lines of perforation to provide a generally trapezoidal-shaped diaper unit.

2. The product of claim 1 in which said first sheet is wider than said second sheet whereby said first sheet is foldable on itself along the longitudinal edges thereof, the folded portions of said first sheet being adhesively united to said second sheet.

3. A process for forming a disposable diaper comprising advancing spaced-apart generally rectangular fluff pads sequen tially along a predetermined path, applying first and second webs to a plurality of said pads to sandwich the same, one of said sheets having adhesive areas thereon for engagement with the other of said sheets, and perforating said sheets along lines at an angle to said path with the lines extending from one rear comer of a given pad to the opposite front corner of the succeeding pad whereby generally trapezoidal-shaped diaper units are provided.

4. The process of claim 3 including the steps of applying a pressure-sensitive adhesive to spaced-apart areas on the outside of one of said sheets and thereafter applying a release tape over each of said pressure sensitive adhesive areas.

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US2894511 *Jan 19, 1955Jul 14, 1959L Ancienne Maison Devaud SaSwathing means for infants
US2925675 *Oct 15, 1958Feb 23, 1960Frank K LumpkinTransparent covered certificate holder
US3049228 *Jan 8, 1960Aug 14, 1962Gerber ProdDisposable baby pants
US3192927 *Jun 29, 1962Jul 6, 1965Papeterie De L Eure SaAbsorbent strip for diapers and band for cutting the same
US3221738 *Apr 1, 1963Dec 7, 1965Green Tord DavidMethod for manufacturing diapers and the like, and a diaper manufactured in accordance with this method
US3285405 *Oct 26, 1964Nov 15, 1966Illinois Tool WorksPackage for storing and dispensing articles
US3315676 *Sep 16, 1963Apr 25, 1967Cooper AbrahamDisposable diaper
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US3731689 *Feb 1, 1971May 8, 1973Kendall & CoDisposable diaper having an integral container and means for application
US3880165 *May 20, 1974Apr 29, 1975Prizzia RoseDisposable diaper with T-shirt holding means
US3984272 *Jul 25, 1974Oct 5, 1976Riegel Textile CorporationMethod and apparatus for successively forming disposable diapers
US4085753 *Apr 14, 1975Apr 25, 1978The Procter & Gamble CompanyDisposable diaper with integral disposal bag
US4417935 *Oct 13, 1981Nov 29, 1983Paper Converting Machine CompanyPolyethylene, adhesive and elastic lamination
US4547243 *Oct 9, 1984Oct 15, 1985Whitestone ProductsMethod and apparatus for continuously attaching elastic strands to disposable absorbent products
US5387173 *Dec 22, 1992Feb 7, 1995Ranpak Corp.Fan-folded stock material for use with a cushioning conversion machine
US5882767 *Dec 29, 1994Mar 16, 1999Ranpak Corp.Packaging
US6068125 *May 26, 1998May 30, 2000Illinois Tool Works Inc.Method and apparatus for storing and dispensing container carriers
US7318820Mar 12, 2004Jan 15, 2008The Procter & Gamble CompanySimple disposable absorbent article having breathable side barriers
US7320684Sep 21, 2005Jan 22, 2008The Procter & Gamble CompanyDisposable absorbent article having deployable belt strips
US7377914Jun 30, 2005May 27, 2008The Procter & Gamble CompanyDisposable absorbent article having backsheet strips
US7517572 *Apr 27, 2005Apr 14, 2009Kimberly-Clark Worldwide, Inc.Composite web
US7618404Jun 23, 2005Nov 17, 2009The Procter & Gamble CompanyDisposable absorbent article having doubled side flaps and backsheet strips
US7695463Jun 22, 2005Apr 13, 2010The Procter & Gamble CompanyDisposable absorbent article having dual layer barrier cuff strips
US7736351Feb 2, 2004Jun 15, 2010The Procter & Gamble CompanySimple disposable absorbent article
US7737324Nov 23, 2005Jun 15, 2010The Procter & Gamble CompanyDisposable absorbent article having deployable chassis ears
US7763004May 18, 2005Jul 27, 2010The Procter & Gamble CompanyDisposable absorbent article having layered containment pockets
US7857801Mar 23, 2007Dec 28, 2010The Procter & Gamble CompanyDiaper having deployable chassis ears and stretch waistband
US7931636Aug 4, 2005Apr 26, 2011The Procter & Gamble CompanySimple disposable absorbent article
US8187239May 31, 2005May 29, 2012The Procter & Gamble CompanySide notched folded diaper
US8257335Jan 31, 2007Sep 4, 2012The Procter & Gamble CompanyDiaper having hip stretch panels
US8585672Feb 28, 2007Nov 19, 2013The Procter & Gamble CompanyDisposable absorbent article having deployable belt ears
US8684988Jun 29, 2004Apr 1, 2014The Procter & Gamble CompanyDisposable absorbent article having barrier cuff strips
US8684990Sep 12, 2005Apr 1, 2014The Procter & Gamble CompanySimple disposable pant-like garment having breathable side barriers
US8696855Jul 10, 2009Apr 15, 2014Kimberly-Clark Worldwide, Inc.Simplified absorbent article construction and method of making
US8734417Apr 19, 2011May 27, 2014The Procter & Gamble CompanySimple disposable absorbent article
US20090321552 *Jun 26, 2008Dec 31, 2009Frank Stephen HadaMoldable paper product
WO1994014548A1 *Dec 8, 1993Jul 7, 1994Ranpak CorpFan-folded stock material for use with a cushioning conversion machine
Classifications
U.S. Classification156/70, 156/202, 604/390, 206/820, 206/390
International ClassificationA61F15/00, A61F13/15
Cooperative ClassificationA61F13/15634, A61F15/001, Y10S206/82
European ClassificationA61F13/15M3C, A61F15/00B