Process and apparatus for making individually packaged disposable absorbent articles

Abstract

The present invention relates to a process for manufacturing disposable absorbent articles, typically sanitary napkins or pantiliners, which are individually packaged in a bag or pouch. The articles are directly attached to the wrapper material forming the bag or pouch by means of their panty fastening adhesive. The articles are cut from a continuous layered structure, and the cut is made directly through the layer of panty fastening adhesive applied onto the outer surface of the continuous layered structure. The present invention also relates to an apparatus for performing the process.

1 . A process for manufacturing individually packaged disposable absorbent articles comprising the steps of: 
 providing a continuous web-like layered structure comprising at least a liquid pervious outer structure, a liquid impervious outer structure, and an absorbent material intermediate said liquid pervious outer structure and said liquid impervious outer structure,    applying a layer of pressure sensitive adhesive for garment attachment onto at least part of said liquid impervious outer structure,    cutting individual disposable absorbent articles along a perimeter from said continuous web-like layered structure, said cutting occurring at least partially directly through said layer of pressure sensitive adhesive, said perimeter of each of said individual disposable absorbent articles having longitudinal perimeter segments substantially parallel to a longitudinal axis of said individual disposable absorbent articles; wherein said cutting step is carried out with a cutting implement comprising at least one knife which is internally cooled;    releasably attaching each of said individual disposable absorbent articles to a respective wrapper element by means of said layer of pressure sensitive adhesive;    folding said wrapper element around each of said individual disposable absorbent articles;    sealing said wrapper element around at least part of said perimeter of each of said individual disposable absorbent articles in order to form said individually packaged disposable absorbent articles.    
     
     
         2 . A process according to  claim 1 , wherein said wrapper element has longitudinal side portions extending outward from said longitudinal perimeter segments of said individual disposable absorbent article.  
     
     
         3 . A process according to  claim 2 , wherein each of said individual disposable absorbent articles and said respective wrapper elements are folded as a unit about at least two fold-axes substantially perpendicular to said longitudinal axis of said individual disposable absorbent articles, and said longitudinal side portions are frangibly sealed together to form said individually packaged disposable absorbent articles.  
     
     
         4 . A process according to  claim 1 , wherein said wrapper elements are provided from a continuous band of wrapper material.  
     
     
         5 . A process according to  claim 1 , wherein said layer of pressure sensitive adhesive is applied as a continuous stripe.  
     
     
         6 . A process according to  claim 1 , wherein said layer of pressure sensitive adhesive is applied with a basis weight from 10 g/m 2  and 40 g/m 2 .  
     
     
         7 . A process according to  claim 1 , wherein said cutting implement is comprised in a cutting unit comprising a knife roll and a counter roll, said knife roll being internally cooled and comprising said at least one knife.  
     
     
         8 . A process according to  claim 1 , wherein said at least one knife is cooled at a temperature between 0° C. and 6° C.  
     
     
         9 . A process according to  claim 7 , wherein said counter roll is internally cooled.  
     
     
         10 . A process according to  claim 9 , wherein said counter roll is cooled at a temperature between 5° C. and 20° C.  
     
     
         11 . A process according to  claim 9 , wherein the temperature of said counter roll is lower than the temperature of said at least one knife, with a difference ΔT between 2° C. and 20° C.  
     
     
         12 . A process according to  claim 7 , wherein the area of said knife roll comprised within the perimeter defined by the at least one knife is recessed with respect to the outer surface of said knife roll.  
     
     
         13 . An apparatus for manufacturing individually packaged disposable absorbent articles according to the process of  claim 1 , said apparatus comprising at least: 
 a supply unit of said continuous web-like layered structure;    an adhesive application unit;    a supply unit of said wrapper material;    a cutting unit comprising a knife roll and a counter roll;    a coupling unit for releasably attaching said individual disposable absorbent articles to said wrapper material;    a folding/cutting/sealing unit for forming said individually packaged disposable absorbent article;    wherein said knife roll comprises at least one knife which is internally cooled.