Method of manufacturing a disposable absorbent article having a reinforced fastening tape landing zone

Abstract

A disposable absorbent brief is provided with a reinforced fastening tape landing zone which permits repeated removal and reattachment of the fastening tape for adjustment of fit. The backing sheet of the brief is a relatively thin and inexpensive sheet material which has at least one relatively thin and inexpensive, adhesively-secured strip of landing zone reinforcement sheet material. The reinforcement strip provides the strength required to allow tape removal and reattachment without causing tearing of the reinforcement strip or backing sheet or separation of the reinforcement sheet from the backing sheet. The adhesive layer is applied to the reinforcement sheet stock by slot coating as a continuous and uninterrupted layer on the reinforcement strip in a cost-effective and efficient process.

We claim:  
     
         1 . A method of manufacturing a disposable absorbent article with a reinforced tape fastening landing zone, comprising the steps of: 
 coating a continuous elongate strip of landing zone reinforcement material with adhesive so that the adhesive forms an elongate, continuous and uninterrupted layer on said material;    cutting said adhesive-coated continuous elongate strip of landing zone reinforcement material to produce a plurality of individual-sized landing zone reinforcement strips; and    applying individual-sized landing zone reinforcement strips onto outer surfaces of backing sheets of the disposable absorbent articles, and securing said reinforcement strips to said backing sheets by said adhesive.    
     
     
         2 . A method according to  claim 1 , wherein the cutting step is carried out by means of a rotary die.  
     
     
         3 . A method according to  claim 1 , wherein the adhesive is a pressure sensitive adhesive.  
     
     
         4 . A method according to  claim 1 , wherein the coating step is carried out by transferring the adhesive from a chill roll onto the elongate strip of landing zone reinforcement material.  
     
     
         5 . A method according to  claim 1 , wherein said adhesive is slot-coated onto one side face of said elongate strip such that said entire face is coated with said elongate, continuous and uninterrupted layer of adhesive except for a pair of opposite elongate edge margins of said face of said elongate strip.  
     
     
         6 . A method according to  claim 1 , wherein said adhesive is transferred through an elongate, narrow slot onto a chill roll and from the chill roll onto the elongate strip of landing zone reinforcement material, and in which the adhesive is at a temperature within a range of about 150° F. to 350° F. when transferred onto the chill roll.  
     
     
         7 . A method according to  claim 1 , wherein said elongate strip is a strip of polypropylene having a thickness in a range of about 0.2-0.9 mil.  
     
     
         8 . A method according to  claim 7 , wherein said backing sheet of the disposable absorbent article is made of polyethylene having a thickness in a range of about 0.3-0.9 mil.  
     
     
         9 . A method according to  claim 8 , wherein a pair of individual-sized landing zone reinforcement strips are adhesively secured to each disposable absorbent article at different locations on said backing sheet.