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Patent 2243390 Summary

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(12) Patent Application: (11) CA 2243390
(54) English Title: FEMALE COMPONENT FOR REFASTENABLE FASTENING DEVICE HAVING REGIONS OF DIFFERENTIAL EXTENSIBILITY
(54) French Title: COMPOSANT FEMELLE POUR DISPOSITIF D'ATTACHE UTILISABLE PLUSIEURS FOIS ET COMPORTANT DES ZONES D'EXTENSIBILITES DIFFERENTES
Status: Dead
Bibliographic Data
(51) International Patent Classification (IPC):
  • A44B 18/00 (2006.01)
  • A61F 13/62 (2006.01)
(72) Inventors :
  • ALLEN, PATRICK JAY (United States of America)
  • WEIRICH, DAVID MICHAEL (United States of America)
(73) Owners :
  • THE PROCTER & GAMBLE COMPANY (Not Available)
(71) Applicants :
  • THE PROCTER & GAMBLE COMPANY (Not Available)
(74) Agent: SIM & MCBURNEY
(74) Associate agent:
(45) Issued:
(86) PCT Filing Date: 1997-01-16
(87) Open to Public Inspection: 1997-07-24
Examination requested: 1998-07-17
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/US1997/000635
(87) International Publication Number: WO1997/025893
(85) National Entry: 1998-07-17

(30) Application Priority Data:
Application No. Country/Territory Date
08/588,481 United States of America 1996-01-18

Abstracts

English Abstract




A female component for a refastenable fastening device having an elastomeric
adhesive backing (34) and a multiplicity of fibrous elements (30) extending
from the backing. The female fastening component is formed by a method
comprising the steps of: providing a first lamina comprising an elastomeric,
pressure-sensitive adhesive film having a first adhesive surface (31) and a
second adhesive surface (33) opposed to said first adhesive surface, a relaxed
orientation, an elongated orientation and preferably at least two regions of
differential elongations; stretching said first lamina from said relaxed
orientation to said elongated orientation; contacting a second lamina
comprising a nonwoven web (30) with said first surface of said first lamina in
said elongated orientation, thereby directly joining said second lamina and
said first lamina to form a laminate; and relaxing said first lamina such that
said second lamina is shirred to form catching regions capable of entangling
the hooks (28) of a complementary male fastening component (20).


French Abstract

Cette invention concerne un composant femelle pour un dispositif d'attache utilisable plusieurs fois, lequel composant possède un support adhésif élastomère (34) ainsi que plusieurs éléments fibreux (30) qui dépassent de ce support. Le procédé de fabrication de ce composant de fixation femelle comprend les étapes consistant à obtenir une première feuille se composant d'un film autocollant, lequel film possède une première surface adhésive (31), une seconde surface adhésive (33) opposée à la première, une orientation détendue, une orientation allongée, et de préférence, au moins deux zones d'élongation différentielle; à étirer la première feuille de manière à ce qu'elle passe de l'orientation détendue à l'orientation allongée; à mettre la première surface de la première feuille se trouvant en orientation allongée, en contact avec une seconde feuille se composant d'un voile non tissé (30), et joindre ainsi les première et seconde feuilles de manière à obtenir un stratifié; et enfin, à détendre la première feuille de manière à ce que la seconde se fronce et forme des zones d'attache capables de s'entremêler aux crochets (28) d'un composant d'attache mâle complémentaire (20).

Claims

Note: Claims are shown in the official language in which they were submitted.





28


1. A female component of a refastenable fastening device capable of engaging a
complementary hook fastening component, said female component
characterized in that said female component comprises:

an elastomeric adhesive backing having an elongated orientation, a relaxed
orientation, a path of response along which said material contracts from said
elongated orientation to said relaxed orientation and at least two regions of
differential elongation; and

a nonwoven web in contact with, and thereby secured to said elastomeric
adhesive backing, said nonwoven web being secured to said elastomeric
adhesive backing while said backing is in said elongated orientation, said
nonwoven web comprising a multiplicity of fibrous elements comprising
filaments that are joined together with inter-fiber bonds at spaced, fixed
regions along the length of each of said filaments to define between each pair
of fixed regions an unsecured catching region, wherein said fibrous elements
comprise those filaments that are shirred when said backing contracts to said
relaxed orientation.

2. A female component for a refastenable fastening device capable of engaging a
complementary hook fastening component, said female component
characterized in that said female component comprises:

an elastomeric adhesive backing having a first surface, a second surface, an
elongated orientation, a relaxed orientation, and a path of response along
which said material contracts from said elongated orientation to said relaxed
orientation;

a nonwoven web in contact with, and thereby secured to, said first surface of
said elastomeric adhesive backing, said nonwoven web being secured to said
elastomeric adhesive backing while said backing is in said elongated
orientation, said nonwoven web comprising a multiplicity of fibrous elements
comprising filaments that are joined together with inter-fiber bonds at spaced,
fixed regions along the length of each of said filaments to define between each
pair of fixed regions an unsecured catching region, wherein said fibrous

29
elements comprise those filaments that are shirred when said backing
contracts to said relaxed orientation; and

a second lamina in contact with, and thereby joined to, said second surface of
said elastomeric adhesive backing.

3. The female component of Claim 2 wherein said second lamina is joined with
said elastomeric adhesive backing while said backing is in said elongated
orientation, or said second lamina is joined with said elastomeric adhesive
backing after said backing has been partially relaxed.

4. The female component of Claims 2 or 3 wherein said elastomeric adhesive
backing comprises regions of differential elongation.

5. The female component of Claim 2, 3, or 4 wherein said second lamina
comprises a second nonwoven web comprising a multiplicity of fibrous
elements preferably positioned on said backing essentially perpendicular to
said path of response of said elastomeric adhesive backing, said fibrous
elements comprising filaments that are joined together with inter-fiber bonds
at spaced, fixed regions along the length of each of said filaments to define
between each pair of fixed regions an unsecured catching region, wherein said
fibrous elements comprise those filaments that are shirred when said backing
contracts to said relaxed orientation, said inter-fiber bonds preferably being
arranged in a diamond-shaped pattern.

6. The female fastening component of any of the preceding Claims wherein said
filaments are positioned on said backing essentially perpendicular or
essentially parallel to said path of response of said elastomeric adhesive
backing, or randomly positioned on said elastomeric adhesive backing.

7. The female fastening component of any of the preceding Claims wherein said
nonwoven web comprises carded polypropylene filaments.

8. The female fastening component of any of the preceding Claims wherein said
inter-fiber bonds are arranged in a diamond-shaped pattern.



9. A disposable absorbent article comprising a liquid pervious topsheet, a liquid
impervious backsheet joined with said topsheet, an absorbent core positioned
between said topsheet and said backsheet, and a fastening system for
fastening said disposable absorbent article about a wearer, wherein said
fastening system comprises the female fastening component of any of the
preceding Claims.

10. The disposable absorbent article of Claim 9 further comprising a waistband,
wherein said waistband comprises the female fastening component of any of
the preceding Claims.

Description

Note: Descriptions are shown in the official language in which they were submitted.


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FEMALE COMPONENT FOR REFASTENABLE FASTENING D~VICE
HAVING REGIONS OF DIFFERENTIAL EXTENSlBILITY




FIELD OF THE INVENTION
The present invention relates to a female component for refastenable hook
and loop type fastening devices and. more particularly~ to a low-cost female
component for a hook and loop type fastening device having regions of differential
l~ elongation.

BACKGROUND O~ THE INVENTION
Refastenable fastening devices of the hook and loop type are currently used
widely in a great number of situations. Such ref~ct~n~hle f~ctening devices havebeen particularly useful in clothing. disposable absorbent articles. and the like. Such
devices are used when it is desirable to create a ref~cfen~ble bond between two or
more articles or between several surfaces of the same article. ln certain applications.
these ref~Pn~ble f~ct~ning devices have replaced conventional buckles. zippers.
buttons. snaps, tie fasteners. and sewing.
~5 A popular type of mech:~nic~l fastener currently in wide use which utilizes
mechanical çnt~nglennent to create a ref~cten~hle bond is sold under the trademark
"VELCRO". 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 f~ctent~rs 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, respectively. The male component contains a plurality
of resilient, upct~n~1ing hook shaped elements. The female component of the
f~tening device generally consists of a fabric cont~ining a plurality of upstanding
3~ loops on its surface. When the male component and the loop component are pressed
together in a face to face relationship to close the f~ct~nin~ device, the hooksentangle the loops forming a plurality of mechanical bonds between the individual

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hooks and loops. When these bonds have been created. the components will not
~enerall- ~liceng~ge under normal cond;tions., This is because it is very difficult to
~e~ldLe the components by attempting to disengage all the hooks at once. However.
when a _radual peeling force is applied to the components. disen~pt~m~nt can be
easily effected. Under a peeling force. since the hooks are comprised of a resilient
material. thev will readily open to release the loops.
This type of f~ct~ning device has been found especially useful on disposable
artic}es such as disposable garments. disposable diapers disposable packages.
cartons. and the like. Such f~ctening devices provide a secure closing means.
o However. the use of existing f~ct~ning devices of this type on disposable articles has
been limited due to the fact that such fastening devices are relatively costly. A
major reason that such f~ct~ning devices are costly is that they have high
m~mlfa~tllring costs. These high manufacturing costs are associated with both the
hook and loop colllpo~ of these devices.
Conventional hook and loop components are typically formed by making a
fabric with a number of woven loops ext~n~ling outwardly from a b~ckinp, The
loops may be provided by weaving a base fabric contzlinin~ supplem~nt~ry threadsto form the loops. or by knittinp the loops into a fabric. In other hook and loop
culllpon~ . the loops may be formed by pleating or corrugating processes. The
male components of such f~ctenin~ devices are typically formed by subsequently
cutting the loops. The cut loops serve as the hooks of the male component.
These processes generally produce costly hook and loop f~ctening materials
because they are relatively slow. The hook and loop components of such f~ct.oning
devices are also usually made out of the same relatively expensive material. This
m~te~i~l is relatively e~ ,ive because the material used in the male component
needs to be resilient so that the hooks can flicpn~ge from the loop component when
the device is open.
Several aLlt;l~ have been made to make ~It~rn~tive types of female
c~ pone.lts for f~ctening devices. However, such attempts have generally suffered
from a number of drawbacks.
U.S. Patent 3.694,867 issued to Stumpf on October 3, 1972. discloses a
"separable clasp" having a female component that comprises a "high loft" nonwoven
fabric and a b~cking layer of consolidated flexible adhesive. However. the loop
component disclosed in the Stumpf patent is ~ ed by performing the steps of:
3~ (1) activating an open pattern adhesive in which the fibers are imberl~i~oA, (2
consolidating the adhesive into a s-lhst~nti~llv continuous backing layer. and (3)

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simnltzln~ously looping portions of the fibers such that the fibers form individual
loops that extend outwardly from the bz~ckinsg The female component disclosed inthis patent suffers from the drawback that it is made bv processes that involvesmechanicallv manipulating fibers in the forrn of loops. Thus. the female
components described therein do not appear to be significantly less expensive tomstnufz~tnre than conventional loop components.
U.S. Patent 4,761.318 issued to Ott. et al. on August ~. 1988, discloses a loop
fastener that can collLt~ )o.dlleously be both formed and also zlttz~h~d to a substrate
without the need for any additional steps such as sewing or nti~i7in~ pressure
o sensitive adhesives to affix it to the substrate. However, the Ott loop fastener
comprises a fibrous structure having a multiplicity of loops that is adhered to a layer
of thermoplastic resin. Thus. the process disclosed in this patent suffers from the
drawback that heat must be applied to bond the fibrous structure to the backing.U.S. Patent 3.70~.~33 issued to Ribich. et al. on January 9. 1973. discloses a
n~ refastenable fzlcf~ening device having a female component that comprises reticulated
urethane foam secured to a bztl~king layer. The female conl~one-lt disclosed in the
Ribich. et al. patent suffers from the drawback that foarns typically do not have
enough openin~s for the hooks of conventional male components to ,v .~ dLe. In
addition. reticulated foam generally does not have sufficient strength to hold such
20 hooks when forces are applied to the fz~ct~-ning device. Further. mzlmlfzlt~tllring
reticulated foam is a relatively expensive process.
U.S. Patent 5,032.~22 issued to Noel, et al. on July 16. 1991. discloses a loop
fztcterlinE material having a bz~cking of orientable material and a multiplicitv of
fibrous elements ext~on~lin~ from the backing. The fibers are secured to the backing
25 while the bz~ckin~ is in a tlim~n~ionally unstable state. The backing is then caused to
be ~ ,r~ ed to its ~lim~ncionally stable state thereby shearing the fibrous
e}~m~ntc to form the cz~tcllit~ regions of the loop mzlf~rizl Although the Noel
patent discloses an acceptable low cost loop fz~st~ning mzlt~riztl, the search has
continued for more economical loop fzlct~nin~ materials and methods for producing
30 such materials.
Thus, it is an object of the present invention to provide an improved
fzlct~ning device for disposable articles.
It is another ob~ect of the present invention to provide an improved female
coll,ponent of a refastenable hook and loop type ~'I'~ g device.
It is a further object of the present invention to provide a female component
for a hook and loop type fzlctening device which may be formed by positioning a

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pluralitv of fil~mcntc on an elastomeric adhesive backing without manipulating the
fibers into the form of loops to form a low cost loop f~ctening material.
It is another object of the present invention to provide a female component
for a fastening device that can be used with both commerciallv available male
components having resilient individual hooks, as well as less expensive male
components with more brittle hooks than those currently in use.
These and other objects of the present invention w ill be more readily
ellt when considered in reference to the following description and when taken
in connection with the accompanying drawings.

SUMMARY OF THE INVENTION
The present invention provides an elastomeric loop f~ctening material having
regions of differential elongation. The loop f~ct~ning material preferably has an
elastomeric adhesive backing and a multiplicity of fibrous elements extenr1ing from
the b~clcin~ The fibrous elements are fomned by fi~m~ntc positioned on the
backing when the backing is in an elongated u~ Lion. The fil~m~ntc are
preferably positioned on the b~rl~ing ecce~ti~liy parallel to each other and ess~ nti~lly
parallel or perp~n~icnl~r to the path of response of the backing material. The
fil:~me~tc are ~ r~.dbly i.~ ently secured to each other at spaced. fixed regions
so that the fixed regions define therebetween r~tching regions. Thus, the fibrous
elements are fomned by shirring of the fil~rn~nts at the r~tchinn regions when the
backing material is retumed to its relaxed o. i~l.~lion.
The present invention also relates to a ~ctenin~ device having a hook
f~5t~ning material and a loop f~ct~ning material. The loop f~ct~ninsg material
comprises the improved loop f~ct~ning material of the present invention. The hook
f~ctening material comrrices any of the well known hook f~cteninf~ materials as are
known in the art and which have a base and a number of en~inE~ elements
e~ct~n-ling from the bace. The loop f~cttonin~ material and the complim~nt~ry hook
fastening material provide a secure closing means that will resist shear stress and
peel forces encountered during use.
The present invention also relates to disposable articles and more particularly
to a disposable diaper having such an improved fastening device.

==
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BRlEF DESCRIPTION OF THE D~AWINGS
Figure I is a perspective view of the filaments and the backing used to fomm
the present invention prior to the fil~mensc being positioned or laid down on the
backing.
Figure ~ is a perspective view of the female component of the present
invention when the backing is in its elongated orientation.
Figure 3 is a perspective view of the female component of the present
invention when the b~cking is in its relaxed orientation.
Figure 4 is a perspective view of a f~ctcning device according to the present
o invention.
Figure ~ is a greatly enlarged side view of the fibrous elements of the female
component of the present invention.
Figure 6 is a greatly eniarged side view of an altemative tri-1~min~te
embodiment of the present invention.
Figure 7 is a y~jyeclive view of a disposable diaper that includes the
fz3ctf~ning device of the present invention.
Figure 8 is a y~-~ye~Live view of a disposable diaper that includes the
f~ctening device of the present invention.
Figure 9 is a schPm~tic side view of a process for making the female
component of the present invention.
Figure 10 is a sch~tn~tic top view of a part of the process for making the
female com~ollcnt of the present invention.
Figure 11 is a sch.-m~tic top view of an alternative embodiment of the
process for making the female component of the present invention.
Figure 17 is a s~h~m~tic top view of an altemative embodiment of the
process for making the female component of the present invention.
Figure 13 is an isometric view of a part of the process for making the female
component of the present invention.
Figure 14 is a sch~m~tic side view sf one embodiment of the process for
making a tri-l~min~t~ embodiment of the present invention.
Figure 15 is a sch~m~tic side view of an altemati-e embodiment of the
process for making a tri-1~min~tc embodiment of the present invention.

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DETAILED DESCRIPTTON OF THE INVENTION

Over~ll Characteristics of the Refastenable Fastenin~ Device
A preferred embodiment of the ref~cten~hle f~ctening device of the present
inveMion. f~ctening device 20~ is shown in FIG. 4. The f~stPning device 20
comprises a nonwoven female component '2 and a complementarv hook f~cterlin
component 24.
The female portion of the device. more specifically. the nonwoven female
component ~or simply "fema}e component") 22 receives and engages the hooks 28 ofo the male component. The female component '~ shown in FIGS. 3 and 4 comprisesat least one nonwoven web 30 secured to a backing 34. As shown in FIG. 1. the
nonwoven web 30 has an outwardly-facing surface 21 and an inwardly-facing
surface 23 opposed to the outwardly-facing surface 21. The nonwoven web 30
comprises a pluraiity of fii~m~ntc (or fibers) 36 that entangle the hooks 28 of the
male component 24. The b~rking has a first surface 31 and a second surface 33
opposed to the first surface 31. and preferablv comprises an elastomeric adhesive.
The male portion of the device. more specifically, the hook fastening
component (or simply "hook component") 24. co,~ ises a base 26 having a first
surface ''7 and a second surface 29. The base 26 comprises a plurality of ~-pstzln-lin~
en~ging elements, or "hooks" 28, extenrling from the first surface 27 The term
"hook" is nonlimitin~ in the sense that the erlg~gin~ elements may be in any shape
known in the art so long as they are adapted to engage a compliment~ry loop
f~cteninsg co",ponent or the female component 22 of the present invention. The
hooks 28 generally have heads 38 ~or en~ing means) which are disposed on top of
2~ the shanks. or stems 40. that extend from the first surface 27 of the male component
24.
The f~ctenin~ device 20 of the present invention functions in the following
manner. The f~ctrning device 20 is closed when the female co,l,l,onent 22 and the
male co",~onent 24 are pressed face-to-face against each other. When this happens.
the hooks 28 are ~nt~ngled by the fibers 36 of the nonwoven web 30. The nonwovenweb 30 provides space for the hooks, particularly. the heads 38 of the hooks to
occupy when the fQctening device 20 is closed. The backing 34 provides a
,ul~OlLirlg foundation for the nonwoven web 30. With the hooks 28 mech~nir~lly
entangled by. or "hooked", onto the fibers 36 (shown in the portion of the f~ctenin~
3' device 20 to the ri~ht side in FIG. 4). the connection between the components resists
the forces that may be exerted on the f~creninD device 20.

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The f~cteninsg device ~0 is opened by peeling the male component 24 away
from the female component 22 (or by peeling the female component 72 away from
the male component 24) If the male component 24 has resilient hooks. the peelin~action mav cause the hooks to be bent so that they are (licer~g~ged from
eManglement with the fibers 36 of the nonwoven web 30 In other cases
(particularlv if the hooks 28 are relatively inflexible). the hooks 28 may be separated
by breaking the fibers 36 of the female component 2'. In either case. the hooks 28
are disengaged and the male component 24 is completely detached from the female
component 22 The f~ctenin~ device 20 is then capable of being refastened in the
o manner described above

The Female Fastenin~ Component
The term "nonwoven female COnlpOri.n~", as used herein refers to a female
component for a ref~cten~ble f~ctening device that co-,lp~.ses a nonwoven web
joined to a backing. (The nonwoven female component may also be referred to as aloop f~ctening material or simply, a loop fastener ) The terrn "nonwoven web" refers
to fabrics made of fibers held together by interlocking or inter-fiber bonding which
are not woven. knitted. felted, or the like. However, the nonwoven web referred to
herein may comprise fibers ehat are initially c~hst~nr~ y unbonded which are
subse~uently bonded to each other.
FIG. 1 shows the backing 34 and the nonwoven web 30 used to form the
female coll,~onent 2 prior to their association The backing 34~ preferably an
elastomeric adhesive. is shown in an elongated orientation (stretched in a direction
parallel to the line clecign~t~d A-A) As used herein. the term "elastomeric" refers to
~s materials that extend in at least one direction when a force is applied and return to
ap~lvkil~lately their original ~imencions after the force is released The nonwoven
web 30, as shown in FIG. l, p,cf~ldbly com~rices a muitiplicity of fil~ments 36 that
are joined with each other by inter-fiber bonds 32 prior to being associated with the
backing 34 As used herein, the term "joined" enco., I.~cc~c configurations whereby
an element is directly secured to another cl..,l.llL and configurations whereby an
element is indirectly secured to another element by ~ffixing an element to
int~rme~ te member(s) which in turn are affixed to another element. The terrn
"inter-fiber bonds" refers to bonds that join one or more fil~mPntc to one or more
other fil~mentc
FIG. 2 shows a ~.ef~.. cd embodiment of the female component 22 where the
backing 34 is in its elongated orientation after the nonwoven web 30 has been

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positioned on and joined to the first surface 31 of the backing 34. Preferably. the
fil~m~ntc 36 of the nonwoven web 3() are aligned essentially parallel to each other
and essentially perpendicular to the path of response of the backing 34. E~owever.
other configurations are contemplated wherein the fil~mPntc 36 are essentially
parallel to the path of response of the backing 34. or are randomly or otherwiseoriented with regard to each other and the path of response of the b~rking 34. (The
terrn "~cc~nfi~lly parallel". is used herein to mean the fil~mentc~ any individual
fil~mPnrls). or portions of any fil~mPnt(s) need not extend absolutely parallel to each
other or the path of response so long as the majority of the fil~m~ntc 36 extendo generally perpendicularly to each other or the path of response. ~ccenti~lly
perpendicular" is used herein to indicate that the fil~mPntc~ any individual
filament(s). or portions of any fil~mPnt(s) need not extend absolutely perpendicular
to each other or the path of response so long as the majority of the filaments 36
extend generally perpendicularly to each other or the path of response. As used
herein. the term "path of response" refers to the direction in which an elastomeric
material in an elongated orientation will respond when the forces acting to elongate
the el~ctomPric material are removed. Further, the fil~m~ntc 36 of the nonwoven
web 30 are pl~r~ .~bly in an untensioned state when they are joined to the elongated
backing 34.) The embodiment described above wherein the fil~mrntc 36 are
~o ecc~nti~lly parallel to each other and ecsPnti~lly perpendicular to the path of
onse of the backing 34 helps to ensure that the fil~mPntc 36 will become
"shirred" when the backing 34 contracts to its relaxed orientation ~shown in F~Ci.3).
The term "shirred" as used herein. refers to the gathering of the fil~m~ntc 36 of the
nonwoven web 30 caused by the contraction of the backing 34 from its elongated
orientation to its relaxed orientation such that portions of the fil~m.ontc 36 that are
not secured to the backing 34 or other fil~m~ntc 36 bend away from the first surface
31 of the backing 34. The shirred fil~m~ntc 36 form ul~se~ d r~tc~hing regions 37
(loops) capable of ent~ngling the hooks 28 of a compl~ ,y male f~ct~-ning
conl~ollcnt 24.
FIG. 3 shows a ~,ere.l~d embodiment of the present invention after the
nonwoven web 30 and the b~c~ing 34 have been joined and after the forces acting to
elongate the backing 34 have been removed such that the b~rking 34 has contracted
to its relaxed orientation. The shirred fil~mAntc 36 form a multiplicity of fibrous
elements 35 extPn-ling outwardly from the first surface 31 of the backing 34. Each
3~ of the fibrous elPrnPntc 35 conl~,ises a pair of fixed regions 42 (ioined to the
backing 34) and an unsecured c~tching region 37 disposed between the pair of fixed

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re_ions 4~. The c:l~ching regions 37 are capable of securel,v ~ng~ginsg the hooks of a
complementary hook f~ct/~ning component to provide a f~ctening device ~0. as is
shown in FIG. 4.
FIG. 6 shows an alternative embodiment of the female component '~? of the
present invention comprising a second lamina 80 joined to the second surface 33 of
the elastomeric adhesive backing 34 to forrn a tri-l~min~f~ 85, Joining a secondlamina 80 to the elastomeric adhesive backing 34 provides the female fact~ning
component with additional adv~nS~gec For inct~n~e~ the tri-l~min~te material 85
may be incorporated into a disposable absorbent artiele. sueh as a diaper as an
o elastomeric w~icth~ntl capable of eng~ging the hooks of a complem~nt~ry male
f~ctening component. Further. the tri-l~min~te 85 provides an elastomeric femalef~ct~ninsg component ~ capable of ~ng~ging the hooks 28 of a complem~nf~tY male
f~ct~ning component 24 on two opposing surfaces.
In an espeeially ~fc~ d ~If~tn~five embodiment of the present invention.
the second lamina 80 comprises a nonwoven web such as the nonwoven web 30
described above with respeet to the female f~ctening eomponent _, However. a
suitable lamina may be m~nnf~etl~red from a wide range of materials. including
plastic films: woven webs of natural fibers (e.g, wood or cotton), synthetic fibers
(e.g. polyester or polypropylene). or a eombination of natural and synthetie fibers:
~o foams: or natural or s,vnthetic rubber.
The second lamina 80 may be joined to the elastomeric adhesive b~ekin~ 34
in the manner deseribed with respeet to the nonwoven web 30 or any other method
as is known in the art. Further. the seeond lamina 80 may be joined to the backing
34 contemporaneouslv with the nonwoven web 3Q when the backin~ 34 is in an
2~ elongated orientation or at any other time after the adhesive backing 34 is forrned.
Embo-ii..,G.~Ic are also eontemplated wherein the tri-l~min~te 85 eomprises the
baeking described below ineluding regions of differential elongation. In a ",G~..~,d
embodiment, however, the lamina 80 is joined to the backing 34 after the nonwoven
web 30 has been joined to the baeking 34 and after the b~e~insg 34 has been at least
partially relaxed. (An elastomerie material in an elongated orientation is "partially
relaxed" when the forees stretching the elastomerie material are redueed~ allowing
the m~tPri~l to eontraet but not eompletely relax. Thus. an elastomerie material in a
- partially relaxed eondition is still eapable of eontraeting further to its relaxed
orientation after the forees are eompletely removed.) Joining the second lamina 80
3' after the baeking 34 has been at least partially relaxed ensures that the fibrous
elements 35 of the nonwoven web 30 will remain shirred when the female f~ct~?ning

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component 2' is stretched. This is because the second lamina 80 will become fully
extended to its elastic limit before the nonwoven we~ 30. thus m~int~ininsg at least
some shirring in the fil~rn~nt.c 36 of the nonwoven web 30. Thus. an elastomericnonwo~en female component ~ is provided that will m~intz~in its ability to entangle
the hooks 28 of a complementary male fastening component 24 even after the female
component '" has been stretched to a point where the second lamina 80 is fully
extended. (If the second lamina 80 is joined to the backing 34 when the b~nking 34
is in its fully relaxed orientation, the female component '2 will lose its elastomeric
qualities. Thus. such an embodiment is not preferred where the female col.lpo~ to must be capable of stretching.)
F~GS. 11 and 12 show the backing 34 of the present invention comprising
two or more regions which are subjected to differing amounts of elongation in the
cross-machine direction. ~In FIG. I l. the b~cking 34 has regions 34a and 34b. in
FIG. ~2. the backing 34 has regions 34a, 34b and 34c.) The differential elongation
can provide the female component 22 with a number of unique characteristics. ~Asused herein, the terrns "differential elongation" or "differential stretch" refer to
regions of a material that have been subjected to unequal arnounts of elongation.)
One unique characteristic that may be provided by differentially stretching the
backing 34 is a female co~llpon~.lt 22 having regions that elongate to different~o extents when a given stretching force is applied. For exarnple. region 34a of the
backing 34, as shown in FIG. 11. could provide less nosict~n~e- and thus elongate
more than region 34b for any given force applied to elongate the female component
22 in the cross-m~ hinP direction. Likewise. as shown in FIG. 12. region 34b would
generally elongate more than either region 34a or 34b of backing 34 for any given
force applied to the female coll-po~ L 2~. Thus. an elastomeric female component22 could be configured such that portions elongate more than other portions which
could. in turn~ provide different ~ng~ging characteristics with regard to mating male
colllyollents 24.
Another uniclue characteristic proyided by differentially stretchin~ the
backing 34 is a female co~npol.~.lt 22 having regions conl~ ,ing ~t~hing regions 37
of different loft. (As used herein. the terrn "loft" refers to the height or ~lict~nce that
a portion of a fi~mcnt 36 is away from the b~rking 34.) When a nonwoven 30 is
joined with the backing while the backing 34 is in an elongated configuration.
certain fil~rnentc of the nonwoven will become shirred when the elongation force is
3~ removed. ~f the pattern which joins portions of the fil~m~nt.c 36 is uniform
throughout the dif~erentially stretched regions of the barking~ those portions of the

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female component comprising the most elongated portions of the backing 34 shouldcomprise shirred filaments 36 with the greatest loft. (Nonuniforrn patterns of joining
the fil~mçntc 36 to the b~cking may be used to exaggerate or reduce the difference in
the loft att:~ineci by the different regions of the female component.) Thus. forexample. the fil~m~nt~ 36 joined to the region 34a would generally have more loft
than the fil~mentc 36 joined to the region 34b of the backing shown in FIG. 11 if a
similar pattern were used to join the nonwoven to the entire backing 34. This could
provide an elastomeric female colllyohenl 22 with different çng~ginE characteristics
with regard to mating male components 24.
o Yet another unique characteristic made possible by dirr~l~e.,lially stretching
the backing 34 is an elastomeric female component 2'' that is capable of m~ir~t~ )g
its ability to engage a mating male component 24 when elongation forces are
applied. As noted above. when a nonwoven web 30 is joined with a backing 34
having regions of differential stretch, the loft of the fil~m~nt~ 36 may vary
throughout the female con-~onent 22. Thus. where the fil~mPntc 36 have less loft,
that portion of the female conlpollel.L 22 will generally reach its elastic limit prior to
the regions of greater loft when a force is applied to elongate the female component
2~ in the cross-m~rhin~ direction. (As used herein. the term "elastic limit" refers to
the point at which a material has been elongated to the point at which the material
can no longer be aLI~L~ ed without rupture, tearing or sl~hst~nti~l deforrnation of the
fil~m~-nt~ 36 and/or the b~c~ing 34.) In some in~t~n~es. an elastomeric female
component or portions of an ela~ ,.;c female component that have been elongated
will lose the ability to effectively engage a mating male colllpolltllt 24 because the
c~t~hing regions 37 comprising shirred fii~ment~ 36 have been elongated so as toremove the loft associated with the shirring of the filaments 36. Therefore. it is
advantageous to be able to configure an elastomeric female colllponenl 72 such that
certain decign5lt~ri low loft regions stretch to their elastic limit before other higher
loft regions. thus preventing the higher loft regions from losing the ability to engage
a mating male component 24. (The above-mentioned examples should not be
considered to limit the scope of the invention in any way. It is understood that a
- female c~,.. pc .. e.. ~ could be configured such that the low loft regions stretch to their
elastic limit with the same of less force than some or all of the higher loft regions do.
- Thus. it is not i.llpO-~-t which region(s~ reach their elastic limit with the least force,
but rather that at least one region has sufficient lofted filz~mentc 36 so as to provide a
3~ suitable entanglement zone for the specified need considering the forces that the
whole or portions of the female component will be subjected to.

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12


1 The Nonwoven Web
The fibrous elements 35 of the present invention are preferably formed from
filzlmentc36 positioned on and secured to the backing 34. As used herein. the term
"filament" defines a member having a high ratio of length to diameter or width.
(FIG 5 shows a portion of the female f~ctening component ~ greatly enlarged to
show the filaments 36 in detail ) Thus. a filament may be a fiber. a thread. a strand.
a yarn or anv other member or combination of these members. including fii~mentc
that are pr~ h~0d together in nonwoven webs. as are known in the art. Suitable
o materials for such fii~mentc 36 include natural fibers such as cotton or wool:
synthetic fibers of nylon. polvamides. polyesters. or polyolefins: spun varns;
polyethylene fibers; polypropylene fibers; nylon fibers. non-woven webs: or any
other material or combination of materials known in the art and suitable for use
herein.
The fil~m~ntc 36 may be m~nllf~rtllred using a number of m~nllf~rJllring
techniques inclu~iing those such that the fil~m~ntc are spun. blown. or the like.
Preferably, each fil~mrnt 36 comprises a polypropylene fibers of between about ~and about 15 denier. The individual fil~m~ontc 36 are preferably comprised in a
nonwoven web 30 having a basis weight of between about 10 g/yd2 and about 40
20 g/yd2 (about 12 g/m2 to about 48g/m2), more preferably between about 15 g/yd2and about 25 g/yd2 (about 18g/m2 and about 30glm2). The nonwoven web 30 may
comprise fil~m~ntc 36 having similar or different deniers and lengths Further. the
nonwoven web 30 may comprise a mixture of fil~mrntc 36 comprisin~ different
m~trri~lc Some nonwoven webs cO,llplisillg suitable fii~mentc include the carded25 polypropylene nonwoven web m~nllf~ctllred by the Veratec Nonwoven Group of the
Tnt/~m~tional Paper Company, of Walpole, lvl~cc~r~ cetts under the trade name P-11.
the spunbonded polypropylene nonwoven web P-9, and the carded polypropylene
nonwoven web P-8. Other suitable nonwoven webs co~ ";!~;r.~ suitable filz~mrntc
include COROVON spunbonded polypropylene m~nnf~rt~lred by Corovin GmbH of
30 Germany. and CELES~RA rn~nllf~rt---ed by the Jarnes River Corporation
The lengths of the fil~m~ntc 36 in the nonwoven web 30 depend upon the
type of process used to make the nonwoven web 30 For inct~nre if a carded
nonwoven web is used the fil~m.ontc 36 that comprise such a web can have lengthsthat range from about 0.5 inches to about 5 inches (from about 1 cm. to about 1335 cm.~. In ~ lcd carded nonwoven webs, the fil~n~rntc are between about 1 inch
and about 3 inches (between about 2 5 cm. and about 8 cm ) long Alternatively. if a

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spunbonded nonwoven web is used. the filaments36 of such a web will typically becontinuous len~th. (As used herein. the term "continuous" refers to relativelv long
filaments that run the entire length of the nonwoven web.~
A ~.er~..ed fi}ament 36 has a length to make at least one complete fibrous
element 35. Thus, for example. the fil~m~nt 36 may only have a pair of fixed
regions 42 positioned adjacent its ends so that the fibrous element 3~iS forrned of a
whole fil~m~r-t 36. More preferably~ the fil~ment 36 has a number of fixed regions
42 positioned along its length to foml a plurality of fibrous elements 35 along each
filament 36. If the fi~m~ntc 36 are short. or staple, complete fibrous elements 35
o having two fixed regions 42 and c~tching regions 37 may not be forrned. The
resulting incomplete fibrous elements 35 may not be able to securelv engage the
hooks ~8 of a complementary hook f~ct~ning material 2~. Thus. the ability of thenonwoven female component 22 to provide a secure closure may be ~limini~h~o~
The amount of inter-fiber bonding between the fil~m~ntc 36 of the nonwoven
13 web 30iS also an illlyO~ factor relevant to the ability of the female co~ on~,llt 2'7
of the present invention to entangle the complementary hook f~ct~nin~ component
24. An excessive number of bond sites created between the fil~m.ont~ 36 in the
nonwoven web 30 will tend to i"l~.~.e with the entry of hooks 28 into the
nonwoven web 30, thus reducing the shear strength of the f~reninE~ device. (In
general. the strength of the f~ctening device will be increased as more hooks are able
to enter and engage the nonwoven web.) Altematively, too few inter-fiber bonds 32
may increase the number of fil~n~Pnr~ 36 having loose ~unbonded~ ends, thus
reclu~ ing the female component's 22 ability to entangle the hooks 28 of the
complementary hook f~ct~ning component 24.
23 In a preferred embodiment of the present invention. the total plan view area
of the inter-fiber bonds 32 is between about 1 percent and about 35 percent of the
total area of the nonwoven web 30. More particularly, the total plan view area of the
inter-fiber bonds is between about 5 percent and about 25 percent of the total area of
the nonwoven web. The y~lcellLage of inter-fiber bonding is preferably measured by
5;~ in~ a ~el~.e;,e~ e sample of the nonwoven web under a microscope. The
sarnple is viewed from directly above the outwardly-facing surface 21 of the
nonwoven web 30. The plan view area of each inter-fiber bond 32 is measured. Thesum of the areas of the bonds is divided by the area of the sample. The result is the
p~:~ce~ ge area occupied by the inter-fiber bonds.
33 The pattern of the inter-fiber bonds within the nonwoven web is anotheri"~o~ t factor relating to the strength and overall efficacv of the female

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component. The inter-fiber bonds 32 mav be continuous lines or interrnittent areas
of bonding. Preferably. the inter-fiber bonds 32 are sufficiently close to~ether that
the fil~ment~ 36 of the nonwoven web 30 have relatively few unbonded loose ends.Thus. the t1ict~nre between inter-fiber bonds 37 is preferablv less than the avera~e
length of the fil~mentc 36 in the nonwoven web 30~ more preferably, less than about
one-half the average length of the fil~mf~ns~ 36 in the nonwoven web 30.
In a ~,ef~".d embodiment of the present invention~ the inter-fiber bonds 32
are arranged in a regular pattern. As used hereim the tenn "regular" refers to bond
panerns that are generally similar throughout the area of the nonwoven web 30 when
o viewed from directly above the outwardly-facing surface 71 of the nonwoven web30. Suitable inter-fiber bonding patterns include a series of straight or curved lines.
or arrangements of inter-fiber bonds 32 that form grids defining different
geome~rical shapes such as squares~ rectangles~ hexagons~ diamonds. and circles.Such regular pa~ ~ will provide the female comyollent 22 with relatively uniform holding characteristics.
One bonding pattern that has been found to work ~cpe~i~lly well in the
female component 22 of the present invention is the int~....iLIr..l diarnond-shaped
pattern shown in FIGS. I and 2. The "diarnonds" in the diamond-shaped pattern
comprise a number of interrnittent inter-fiber bonds 37 regularly arranged in lines
20 that define the edges of generally s~uare shaped regions. (A preferred arrangement
of the inter-fiber bonds 32 of the nonwoven web 30 before the fil~mtont~ 36 become
shirred is shown on the left side of FIG. 2. A preferred arrangement of the inter-
fiber bonds 32 of the nonwoven web 30 after the fil~merltc 36 have become shirred
is shown on the left side of FIG. 4.). The pattern is rotated approximately 45
2~ degrees to give the appearance of diamonds. Preferably, the ~1imencions of the
pattern should be such that the ~icf~nre between the inter-fiber bonds 32. in at least
some portion of the area between the sides of the di~llol1d-shaped areas. is greater
than the pro~ected plan view ~iim~nci~nC of the hooks 28 of the comple .-~ . y male
component 24. (Plan view ~im~n.cion~ of complc.. l~.y male components are
3~ c~ e~ in greater detail below.) Nonlimiting examples of diamond-shaped
bonding p~ c suitable for use in female component 22 of the present invention
include p~ rn~ having sides that measure between about 1/2 inch x 1/2 inch (about
1.3 cm. x 1.3 cm.) and about 1/8 in x 1/8 in. ~about 0.3 cm. x 0.3 cm.). more
preferably between about 1/4 inch x 1/4 inch (about 0.6 cm. x 0.6 cm.) and about 3/8
3~ inch x 3/8 inch ~about I cm. x 1 cm.). and most preferably about 1/4 inch x 1/4 inch
(about 0.6 cm. x 0.6 cm.). A suitable nonwoven web 30 comprising inter-fiber

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. 15
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bonds 32 arranged in a diamond-shaped pattern is available from the Veratec
Nonwoven Group of the International Paper Company. of Walpole. ~Cs~rhncetts
under the trade narne P- 11.
The inter-fiber bonds 32 may be produced by any method that is known in
s the art In a ~ Ç~...d embodiment. the inter-fiber bonds 32 are produced by passing
a nonwoven web 30 through a pair of rollers that have been heated close to the
melting point of the fil~mentc 36 comprised in the nonwoven web 30. One of the
rollers preferably has a smooth surface; the compl~oml-nt~ry roller has a pattern of
pins ,-yten iinsg from its surface in the diaTnond-shaped pattern described above.
10 When the nonwoven web 30 passes between the rollers, the heat and pressure of the
rollers causes distinct regions of the fil~mentc 36 to melt producin_ inter-fiber bonds
32 in the preferred diarnond-shaped pattem.
The nonwoven web 30 is p,~lably positioned on and joined with the
b~ inE 34 while the backing 34 is in an elongated orientation and while the
fil~ml~ntc 36 are in an untensioned condition. While the fil~mentc 36 could
conceivably be positioned on the backing 34 in a tensioned or unstable state. such is
not ~.~Ç~ d to provide m~ximllm shirring of the fil~mentc 36. Further. while thebacking 34 could be in a relaxed orientation when the fil~mentc 36 are positioned on
the b~cl~in~ 34. this is not ~ d because in causing the backing 34 to becomeelor gs~te~l enough fil~mentc 36 may be dislocated, dis~langed. skewed or bonded to
the b~kin~ 34 such that the fibrous elements 35 would not be as effective in
en~ging the hook r~ ..;"~ component
The configuration in which the fil~m~ntc 36 are positioned or laid down on
the b~ing 34 ~etermines the size and the ability of the loop f~ctenin~ component22 to provide an effective f~ctPning device While the fil~mentc 36 may be
randomly positioned on the b~rkinp 34 such that the fil~mPntc 36 overlap or extend
in many di~e.e..l directions, it has been found that the fil~montc 36 should
ef~.dbly be positioned generally parallel with each other to provide fibrous
elements 35 configured in a uniform direction. In addition. while the fil~mPntc 36
may be positioned lengthwise on the backing 34 in any direction. in order to take
advantage of the m~Ximllm shirring effect of the backing 34 to form fibrous
cl~ "~ 35 of lll~hllulll height, the fil~mentc 36 are preferably positioned on the
- backing 34 in a direction eccenti~lly perpendicular to the path of response of the
backing 34. (It has been found. however. that fil~m.ontc 36 positioned eccenti~lly
3~ parallel to the path of response also provide suitable çnt~ngiin~ ability ) The

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fil~mcrltc 36 may be positioned or laid down on the backing 34 by any method or
means that is known in the art.

. The Backin~
The backing 34 of the present invention is that part of the female f~ctening
component 2~ to which the nonwoven web 30 is secured. The b~c~ing 34 is
preferably comprised of an elastomeric, pressure sensitive adhesive. so that it may
be readily joined to the nonwoven web 30 to form the nonwoven female component
22. As used herein. the term "elastomeric" refers to materials that extend in at least
o one direction when a force is applied and return to approximately their original
~l;mçn~ions after the force is removed. Thus. elastomeric materials have an
elongated orientation (when force is applied) and a relaxed orientation (when force
removed). The term "adhesive" refers to materials which are capable of bonding to
another material by sticlcing~ or adhering, to the surface of the other material. A
"pressure sensitive adhesive" is an adhesive that is ~ ollaive to pressure, i.e., is
capable of adhering under the infl~enre of pressure alone.
The elastomeric adhesive c(J~ vl;aillg the b~rl~in~ 34 of the present invention
may take on a number of different configurations. For example. the backing 34 may
comprise a thin film having a uniform or varying thickness. slits. holes.
20 deformations or the like; a l~nnin~te of two or more films; a web of elastomeric
adhesive; a single or multiple strands of elastomeric adhesive; discrete regions of
elastomeric adhesive formed in random or regular p~tt~n~7 or any combination of
the above. In one p.~:r~,.ed embodiment. the b~rkin~ 34 comprises an elastomericadhesive that has been extruded in the form of a thin film of about 0.03 mm. to about
2s 1.0 mm. (about 0.001 in. to about 0.04 in.). In a particularly preferred embo~lim~nt
the elastomeric film has a thickness of b~ about 0.025 mm. to about 0.38 mm
(about 0.001 in. to about 0.015 in.).
The elastomeric adhesive selected for the b~ in~ 34 may comprise any of a
number of di~ elastomeric adhesives as are known in the art. The elastomeric
30 adhesive preferably has an elastic modulus between about I and about 30 PSI and
more preferably between about S and about 15 PSI. (The elastic modulus
c~ nl~tion is preferably ~i~t~rrnin~?d on the strain interval of about 50% to about
150% elongation of any convenient gage length using the original cross sectionalarea of the sample prior to straining the sarnple to ~et~mirtf~ the elastic modulus.3
35 Further. the elastomeric adhesive should be capable of elongation from about 500 to
about 1000 percent in at least one direction without rupture. More preferably. the

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elastomeric adhesi-e should be capable of between about 500 percent and about
1000 percent èlongation without rupture. nol exhibit excessi~,e neckinP or thinning
when elon~ated. or exhibit excessive hysteresis or ~lel~min~tion upon elongation.
Other characteristics that help define suitable elastomeric adhesives relate to
the process in which the present invention is made. As described below. the
elastomeric adhesive preferably forms a film that is stretched prior to the application
of the nonwoven to the elastomeric adhesive backing. One pl~r~ d method of
inducing the stretch is to adhere a portion of the el~ctom~ric adhesive film to
tentering belts that diver~e to stretch the film. The overlap between the film and the
tentering belts forms a "lap joint". (The term "diverge" is used herein to mean move
apart. The term "lap joint" refers to the area where two overlapping materials are
joined to~ether.) Preferably. the tensile strength of the film should be less than the
lap shear bond stren_th between the film and the tentering belts. (As used herein.
the terrn "tensile strength" refers to the pulling stress re~uired to break a given
specimen. The term "lap shear bond stren~th" refers to the force needed to disrupt a
lap joint. wherein the force applied is eCcPnti~lly parallel to the surface which
adjoins the elastomeric adhesive film and the tentering belts.) Thus. as the tentering
belts diver~e and stretch the film. the bond between the film and the tentering belts
remains in tact.
. A p~esa~t: sensitive elastomeric adhesive marketed by the Findley Adhesive
Corporation of Wauwatosa, Wisconsin under the trade name 198-338. has been
found to be particularly well suited for this purpose. However. other suitable
elastomeric materials include H2206 and HS2206~ each of which is available from
the Findley Adhesive Corporation.
2s
3. The Complc.~ Male Colll~..n~llL
The term "male colll~onc.lL", as used herein, is used to deci~n~t~o the portion
of the f~ctening device 20 having eng~ing c~ c.lL~ such as hooks 28. The male
component_ 24 used with the nonwoven female culll~onellt 22 of the present
invention can be con~.c.lLional, commercially available hook materials. The malet conlpol.ellt 24, however, is not limited to conventional m~teris~lc with flexible,
resilient hooks 2~. Suitable male components can have less e~pe"aive~ relatively- inflexible. more brittle hooks. Further, the en~in~ elements may have any shape
known in the art such as hooks. "T's", mushrooms. or any other shape. One suitable
3~ male component 24 may comprise a number of shaped eng~in~ elementc projecting
from a woven backing such as the collllllc,.;ially available material tlpciEn~ted

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- 18


"SCOTCHMATE" brand No. FJ3402 available from Minnesota Mining and
~l~nllf~mring Company. St. Paul. Minnesota. A preferred ma}e component is
described in U.S. Patent 4.846.815 entitled "Disposab}e Diaper Having An Improved
Fastening Device" which issued to C. L. Scripps on July 11, 1989. Other
particular}y preferred male conlponents and methods for making the same are the
prongs described in U.S. Patent 5.058.247 entitled "Mechanical F~ctPning Prong"
issued to Thomas et al. on October 22, 1991; U.S. Patent 5,116.563 entitled "Process
for Producing a Mechanical Fastener" issued to Thomas et al. on May 26. 1992: U.S.
Patent 5.180.534 entitled "Process of ~f~nllf~tllring A Refastenable Mechanical
F~ct~ n;ne System", which issued to Thomas, et al. on January 19, 1993; and U.S.Patent 5.230,851 entitled "Process of Manufacturing a Ref~ctPn~hle Fact~nine
System" issued to Thomas on July 27. 1993. Each of these patents are hereby
incorporated by reference herein.
The male component 24 may be m~nllf~rt lred from a wide range of
~s m~t.ori~lc. Such suitable m~tf~ri~lc include, but are not limited to. nylon, polyester,
polypropylene. or any combination of these or other materials.

Exam~les Of Uses Of The Ref~cten~hle F~stenin~ Device
The ~cr;.~ ble (;~ device of the present invention is especially useful
as a f~ctenine device for disposable absorbent articles. The term "disposable
abs(.lbel.L article", as used herein. refers to articles which absorb and contain body
ex~lA~t~c 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 exn~i~tl~sdischar~ed from the body. The terrn "disposable" means that such articles are
2s int.on~ed to be discarded after a single use (i.e., they are not intPnfi~d to be laundered
or otherwise be used). Examples of disposable absorbent articles include diapers~
inco~ e~ y,,.. lc sanitary napkins. bandages, and the like.
FIGS. 7 and 8 show an ~oY~rnpl~ry disposable diaper 50 cc,.,.~ ing a
f~stPnine system 72 including the nonwoven female f~ctenin~ colllpoll~;llt 22 of the
present invention. The diaper 50 preferably co~ .,;cPs a body portion 51 and twowaise regions. a first waist region 56. and a second waist region 58. The body
portion 51 ~ bly compric~s a liquid pervious topsheet 64. a liquid impervious
b~c~ch~et 68. and an absolb~.lt core 66.
As shown in FIG. 7, t~e f~ctPning system 72 of the diaper 50 comprises the
female fz~ctening colllyol1e.lt 22 of the present invention. among other c}c,.nellL~. The
f~ctenine system 72 may take on a number of configurations and constructions. In

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. 19


one preferred embodiment, the first fastening element 7~a comprises a male
component 24. The male com~ol1el1t 24 provides hooks 78 that extend from the tab74 disposed in the second waist region 58. The nonwoven female component 22 of
the present invention comprises the second fastening element 72b disposed in thefirst waist region ~6. However, the positions of the components of the f~ctenin~device 20 of the present invention could be reversed so that the first ~ctening
element 72a comprises the nonwoven female component 2'7 and the second f~tening
element 72b comprises the male co"-pul~e.ll 24.
In an especially preferred embodiment of the disposable diaper 50~ the
fil~m~ntc 36 in the nonwoven web 30 of the female cu.llpone.lt 22 are aligned in a
single direction. The female component 22 is oriented so that the fi1~mentc 36 in the
nonwoven web 30 extend ~cc-onti~lly parallel to the lonEinlriin~l edges 60 of the
diaper 50. This orientation aligns the fil~m~n~c 36 generally perp~n~lic~ r to the
direction of shear forces applied to the f~ct~ning device 20 during use. In thisconfiguration the fil~m-ontc 36 provide the m~ximum peel and shear force r~Cict~n~e
Several examples of well known diaper configurations to which the present
invention can be readily adapted are described in U.S. Patents 5,151~092 and
5,221~274 both entitled "Abso.l,~ Article With Dynamic Elastic Waist Feature
Having A Predisposed Flexural Hinge", issued to Kenneth B. Buell, et al. on
September 29, 1992 and June 22, 1993, l~a~e~ ely; co-pending U.S. Patent
Application Serial No. 08/155,048 entitled "Absorbent Article With Multi-
Direction~l Fxtencible Side Panels", filed November 19. 1993: and co-pending U.S.
Patent Application Serial No. 08/203,456 entitled "Absu.be~-t Article With Multiple
Zone Structural Elastic-Like Film Web Extensible Waist Feature" filed on February
2~ 28, 1994. Each of the above mentioned patents and co-pending patent applications
are hereby incul~olaLed by reference herein. It should be understood. however. that
the r~ ..;..g device of the present invention is not limited to use with any specific
diaper structure or configuration.
The female f~ctening component 22 of the present invention may also be
used to provide an i~ ~n~i;ve w~ictb~nA or any other elastomeric element ~or a
portion thereof) of an abso.l,e--t article, capable of eng~ging the hooks 28 of a
complçnnent~ry male r~ co~ o~ 24. (As used herein. the terrn
"w~ictb~n~" refers to that portion of an absorbent article that partially or wholly
encircles the waist of the wearer.) FIG. 8 shows a diaper 50 having a w~ictb~nd 6 7
3s comprising the female r~ col..pol1c.,.l 22 of the present invention. Further
~Y~mples of diapers suitable for use with the present invention are described in U.S.

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- 20

Patent 4~699.62~ entitled "Disposable Diaper Having An Improved Side Closure"
which issued to J. W. Toussant. et al. on October 13. 1987: ~J.S. Patent 5.019.065
entitled "Disposable Absorbent Article With Combination Mechanical and Adhesive
Tape Fastener Svstem". issued to Scripps on May 28. 1991: and U.S. Patent
5.242.436 entitled "AbsolL.e-ll Article With F~ct~ning System Providing Dynamic
Elasticized W~ictb~n~ Fit". issued to Weil et al.. on September 7. 1993; each of which is hereby incul~olal~d by reference herein.

Method of Makin~ the Female Fastenin ~ Component
o The female facIening component 22 of the present invention is made by
cont~ting a nonwoven web comprising inter-fiber bonds with an elastomeric
pressure sensitive adhesive film. The adhesive film is formed and elongated in at
least the cross m~rhine direction before it is brought in contact with the nonwoven
web. When the adhesive film and the nonwoven web are brought into contact with
each other~ they are joined to form a l~min~te comprising the nonwoven web and an
elastomeric adhesive b~kin~ The l~min~t~ is then col.lld~;led such that regions of
the nonwoven web become shirred and thus capable of ent~ngiing the hooks of a
compl~ c..~ male r;.~,~"i,.g component.
The following is a detailed description of the process for making the female
f~ct~nin~ component 22 of the present invention. Although the description refers to
the ela~loll,~.;c adhesive backing as an "adhesive film", this terrninology should not
be construed to limit the scope of the invention. As mentioned above. the adhesive
barking 34 may take on a number of different configurations including films.
Iz~rnin~tec webs. strands. or the like.
The female col~ ol,c.ll 22 of the present invention may be produced on the
illustrated apparatus 110, as shown in FIG. 9. The a~l,~dl~ls 110 comprises two
separate process m~ es~ process module 111 for the elastomeric adhesive backing
34 (or "adhesive film"), and process module 112 for the nonwoven web 30. The
process module 111 co~ ses an extrusion head 116 and a release surface upon
which the extruded adhesive is formed. such as the forming belt 117, to forrn the
elastomeric adhesive backing film 3$. (In an ~it~rn~tive embodiment, the
elastomeric adhesive b~rkin~ could be pre-forrned and supplied to the line from a
roll. This would el;min~te the extrusion head 116 and the forming belt 117.)
F~minin~ process module 111 in greater detail. the extrusion head 116 has a
3~ slot through which the molten elastic adhesive of the adhesive film 34 is extruded to
forrn a thin film of about 0.03 to about 1.0 millimt-ters (about 0.001 in. to about 0.04

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~1

in.) in thickness. and of any desired width. onto the forming belt 117. An adhesive
film 34 having a thickness of about 0.025 to about 0.3.~ millimeters (0.001 - 0.015
inches) is particularly preferred. Generally a thicker adhesive film 34 is preferred as
the thickness and stiffness of the nonwoven web 30 increases. It will be a~yal~llL to
one skilled in the art that increasing the thickness of the adhesive film 34 will
generally provide a ~lopo,lional increase in the ultimate strength of the femalef~c~ening component 2~. An adhesive film 34 of about 8.4 g/cm~ has been found tobe suitable.
The extrusion head 116 extrudes the molten adhesive onto the forming belt
o 117 which cools the molten adhesive into an adhesive film 34 suitable for processing
and transports the adhesive film 34 to the tentering belts 135. A roll may be utilized
in conjunction with the belt 117 to provide additional cooling and a nip for
col,lyles~ion of the adhesive film 34. Further, the adhesive film 34 may be seya dLed
from the forming belt 117 by a doctor blade (not shown).
After being removed from the forming belt 117~ the application roll 131
guides spaced apart regions of the adhesive film 34 onto the surface of the tentering
belts 135. (As used herein. the term "spaced apart" refers to regions of the adhesive
film 34 that are spaced apart in the cross machine direction form each other.) The
adhesive nature of the adhesive film 34 permits the adhesive film 34 to be secured to
20 the tentering belts 135 without any additional se~ ,.,.cnt means. as are generally
used in the art. Preferably, only about 1/4 inch to about 3/4 inch of the edges of the
adhesive film 34 should be secured to the working surface of each tentering belt 135.
(It should be noted, however, that the n~ntPrin,, belts could be fiesignecl such that a
vacuum assists in holding the film in contact with the tentering belts.) The spaced
25 apart regions of the adhesive film 34 are adhered to the working surfaces of the
tentering belts 135 forming continuous lap joints. ~As used herein, the term
"continuous" means relatively unbroken or without interruption.) The continuous
nature of the lap joint helps to ensure that the adhesive film 34 will be more evenly
stretched than films that are elongated by stretching means comprising discrete
30 me~h~nical cl~lly;llg devices.
The tcnterinD belts 135 are spaced apart in the cross m~ehint- direction and
diverge as they move in the m~rhin~ direction. The tentering belts 135 preferably
comprise a 5~lh5t~nti~11y flat working surface to which the adhesive film 34 is
adhered, and members that help provide positive control of the belts in both the35 m~hin.~ and the cross mzlrhine directions. The working surface of each tentering
belt 135 iS preferably comprised of any material. such as TEFLON. to which the

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W O 97/25893 PCTrUS97/00635
22

adhesive film 34 will adhere sufficiently in shear to stretch the adhesive film 34. and
from which the adhesive film 34 can peeled off without ~ ging the adhesive film
3~ when it is removed. One belt with a suitable working surface is available from
F. M. Sheppard & Co. of Erlanger? Kentucky. Belt Stvle No. 3W1 1-2A.
Each tentering belt 13~ travels about a pair of pulleys. As shown in FI&. 13,
belts 140 and 142 travel about pulleys 141a and 141b. Pulley 141a defines the
converging end 146 of the belts 140 and 142 while pulley 141b defines the diverging
end 144 of the belts. In one preferred embodiment~ the pulleys 141a and 141b
comprise V shaped grooves and the tentering belts 140 and 142 comprise V shaped
~o extensions that ride in the complementary V shaped grooves of the pulleys 141a and
141b. to provide m~r~line direction control ofthe belt in the cross m~rhine direction.
The tentering belts 135 may be driven bv any driving means well known in
the art and are preferably not driven by the adhesive film 31. In one pler~..cd
embodiment. each tentering belt 135 co~ ises teeth and grooves that coact with the
compll ."~ y driving means to provide cross m~rl1in.o directional control of thebelt as it is driven Çu~ lly.
One embodiment of the present invention, as shown in FIG. 10. comprises
two tentering belts 135, a first belt 140 and a second belt 142. A first region 159 of
the second surface 33 of the adhesive film 34 is adhered to t}~e first belt 140~ and a
second region 160 of the second surface 33 of the adhesive film 34 is adhered to the
second belt 142. The first belt 140 and the second belt 142 diverge as they move in
the m~rhine direction, stretching the adhesive film 34 in the cross machine direction.
(The cross m~- hin-- direction is denoted by the arrow C in FIG. 10.) This
configuration is ~ f~ d when it is desired that the adhesive film 34 be evenly
2~ stretched. (Alternative embo-limentc COl~l~vl;sillg more than two tentering belts are
fiicCllcce~l below.)
As shown in FIG. 9, the ~I~JlIWU~,.l web 30 is taken from the unwind roll 126
and plcr~:~ably passes through the S-wrap tensioning roll 128 to provide for proper
tensioning and to prevent puckering or bl-nrhin~ of the nonwoven web 30. Guide
30 roll 130 guides the nonwoven web 30 into the nip between the combining rolls 124.
~f l-~c~c~,..y, a tracking system (not shown) as is commonly utilized and known in
the art, may be empioyed in the process module 112 to optimally track and adjust the
webs of nonwoven web 30 into the nip between the combining rolls 124. A ~r~,ckinE~ -
system m~nnf~rtllred by the Fife Corporation of Oklahoma City. Oklahoma, and
33 sold as Model Op6 LRA may be suitable.

CA 02243390 1998-07-17

W O 97/25893 PCTrUS97100635
23




The nip between the combining rolls 124 compresses the nonwoven w-eb 30
into superposing cont~rinP relationship with the elastomeric adhesive backing 34~
causing the pressure sensitive adhesive backing 34 to bond to the nonwoven web 30.
joining the two materials to form the female f~ctening component 22 As used
herein. the term "superpose" or "superposing" will refer to one layer of material
having a particular geometric shape being laid upon another laver of material having
a sl-hsr~nti~lly similar geometric shape such that all like parts of the two layers of
material ~ubst~nti~llv coincide.
The combining rolls 124 may take on any number of different configurations
o as are known in the art For example, the combining rolls 124 may have smooth
surfaces or may have grooves. teeth or any patterns of in-ient~tionS and/or raised
areas on their surfaces. Further. the combining rolls 124 mav be identical or may
have different surface characteristics. as described above.
Once the nonwoven web 30 and the elastomeric adhesive b~cking 34 have
been joined to form the female f~ctening component 22. the l~min~t~ 90 is returned
to a relaxed condition In this configuration. the nonwoven web 30 will become
gathered in at least the direction parallel to the path of response of the adhesive film
34, which will form ridges, wrinkles, or furrows ext~nriing outwardly from the first
surface 31 of the female component 22 capable of entzlnglinçr the hooks 28 of a
complement~ry male f~c~ning comporlent24. The elastomeric l~min~te 90 will be
el~cti~liy extensible in the direction parallel to the path of ~.a~onse of the adhesive
film 34 Up to about the free length of the nonwoven web 30.
Co..l,~ g the i~min~te 90 to a relaxed condition can be accomplished in a
number of ways, including simply removing the ~ AI~' 90 from the tentering belts135 and allowing it to contract More preferably. however. as shown in FIG. 13, the
l~min~te 90 can remain adhered to the belts 140 and 142 as they travel from the
diverging end 144 towards the converging end 146 of their cycle. As the belts 140
and 142 travel from the diverging end 144 toward the converging end 146, the belts
140 and 142 converge, and thus contract the i~min,.te 90. (As used herein, the terms
"converge" and "converging" mean to move closer together.) Alternatively~ as
shown in FIG. 11, the l ~min~te 90 may be removed from the belts 140 and 142 andtransported to a separate configuration of converging belts 158. Although the
converging belts 158 may take on a number of different configurations. a detailed
description of one l,.e~lled embodiment of the converging belts is described in the
co-pending U S. Application Serial No. ~8/254,812, entitled "A~d~s For
CoMinuously Stretching or Continuously P~ele~cing Stretching Forces From A Web

CA 02243390 1998-07-17

W O 97125893 PCTrUS97100635
24

Usin_ Two Pairs of Opposing ~ion-Planar Belts". filed on June 6. 1994. in the names
of L John Viltro. et al. which is incorporated herein by reference.
After the l~min~te 90 is contracted. it is removed from either the tentering
belts 135 or the converging belts 158. Ieaving e~posed the pressure sensitive
adhesive of the second surface 33 of the adhesive b~king 34 The exposed surface
may be used to bond the female f~t~ning component 22 to an absorbent article or
any other desired article. or may be deactivated by blocking as is commonly known
in the art so that the adhesive of the e~astomeric adhesive backing 34 does not bond
to other materials through the Ple~ U1~ sensitive ~.lupe,Lies of the elastomericadhesive bacl~ing 34 Blocking is accomplished by an adhesive deactivation system(not shown~ applying a powder of resin to the exposed face of the elastomeric
adhesive backing 34 Suitable resin powders include talcum powder. polyolefinic
powders. and preferably a resin similar to that used for the nonwoven web 30
Alternatively, the e?cposed face of the ela~lu.l,~,.c a&esive backing 34 may be
deactivated by applying a non-adhesive elastomeric film. nonwoven. foam or any
other suitable non-adhesive material thereto. An exarnple of one suitable non-
adhesive elastomeric film is H2901 m~nllf~t--red by Findley Adhesives Corporation
of Wauwatosa, Wisconsin.
One preferred alternative embodiment of the present invention provides
regions of differential stretch throughout the adhesive film 34. as shown in FIG. I l.
comprises three tentering belts. a first belt 140a~ a second belt l42a. and a third belt
143a As ~ cucced above, spaced apart regions of the second surface 33 of the
adhesive 34 are adhered to each of the tentering belts In this particular
embodiment. a first region 159a of the adhesive film 34 is adhered to the first belt
2~ 140a, a second region 160a of the adhesive film 34 is adhered to the second belt
142a and a third region 161a of the adhesive film is adhered to the third belt 143a.
As the belts move in the m~hinf~ direction, the first belt 140a and the second belt
142a diverge at a rate different from the rate at which the second belt 142a and the
third belt 143a diverge, thus producing two regions of differential stretch in the
adhesive film 34.
Another p.~;r~ ,d alternative embc!~lim~n~ as shown in FIG. 12, co,ll~lises a
first pair 180 of tentering belts colllpliseS belts 182 and 184, and a second pair 18~
of tentering belts comprises belts 187 and 189 Each of said belts contacts a
different spaced apart region of the second surface 33 of the adhesive film 34. As
3~ the pairs of belts move in the m~hine direction, they diverge at dirr~ rates
producing areas of differential stretch throughout the adhesive film 34 (Of course

CA 02243390 1998-07-17

W O 97/2S893 PCT~US97/00635

the first pair 180 could comprise tentering belts 184 and 187 and the second pair 185
couid comprise the tentering belts 182 and 189.) Further. numerous other
confi~urations are contemplated wherein some of the tenterin_ belts diverge and
others run parallel to each other. thus producing an adhesive film 34 having portions
that are stretched between the diverging belts and other portions that are left
unstretched between the parallel belts. (Although some preferred embodiments have
been discussed. it should be noted that any number of tentering belts mav be used to
produce any combination of stretched and relaxed regions throughout the adhesivefilm 34.)
o Yet another alternative embodiment of the present invention provides a
female f~crtoninP component 27 with multi-directional stretch. In this embodiment.
the adhesive film 3~ may be drawn through the nip formed between a pair of
tensioning rolls. The tensioning rolls provide for m~rhine direction stretching the
adhesive film 34 prior to being applied to the tentering belts 135. this provides a
5 l~min~te which is elastically extensible in two directions, i.ethe m~hine direction
and the cross m~rhin~ direction. A l~min~t~ which is eiastically extensible in the
machine direction and methods of forming such a l~min~e are described in greaterdetail in U.S. Patent 5.032,120, entitled "Disposable Absorbent Article Having
Improved r eg Cuffs", issued July 16. 1991, to Mary E. Freeland and Patrick J.
20 Allen: which is incul~u.a~ed herein by ,efc.~.lce.

Method of Makin~ a ~ri-l~min~t~ Embodiment
The above-described method of producing a female f~ctening component
comprising a single nonwoven web 30 joined to the first surface , I of the
~s elastomeric adhesive film 34 can also be used to produce a tri-l~min~te female
r;.~ P CC~ pullc:l~t con~ g a nonwoven web 30. ioined to the first surface 31
of the backing 34 and a second lamina 80 joined to the second surface 33 of the
backing 34. As described above. the nonwoven web 30 and the backing 34 are
joined to form the l~min~te 90. However. when the l~min~te 90 exits the nip
30 between combining rolls 124, the exposed face of the adhesive b~king 34 is not
deactivated as described above. Rather. as sho~,vn in FIG. 14. the l~min~te 90 is
allowed to remain on the tentering belts 135 as the tentering belts 135 move from the
diverging end 144 of their cycle toward the converging end 146 of their cvcle.
~Itern~tively~ as is shown in FIG. IS, the l~min~te 90 may be transported to the35 separate converging belts 158. In either case. the l~min~t~ 90 mav be partiallv or
fully relaxed prior to application of a second lamina 80.

CA 02243390 1998-07-17
W O97/25893 PCTrUS97/00635
- 26

The second lamina 80 is provided by the additional process modu}e 1 13. as is
sho~n in FIGS. 14 and 1~. The second lamina 80 is taken from the unwind roll 150and preferably passes through the S-wrap tensioning roll 152 to provide for proper
tensioning and prevent puckering or bunching of the lamina 80. Guide roll 156
guides the second lamina 80 into the combining rolls 16Z. If n~ce~ry. a trackingsystem. not shown. as is comrnonly utilized and known in the art~ may be employed
in the process module 113 to optimally track and adjust the second larnina 80 into
the combining rolls 162.
After the l~m;n~t~ 90 CO~ liaillg the nonwoven 30 and the elastomeric
o adhesive backing 3~ exits the converging belts 158. the second surface 33 of the
adhesive backing 34 is brought into contact with the second larnina 80. The
l~min~te 90 and the second lamina 80 are passed through the nip of combining rolls
162 under sufficient plesaLI.~ for the adhesive 34 to adhere to the lamina 80. thus
forming the tri-l~min~t~ female f~ctenin~ CGnll~Ollent 100.
In a preferred embodiment, the second lamina 80 is joined to the adhesive
b~rl~ing 34 after the l~min~te 90 has been at least partially, yet not fully relaxed.
(This creates a tri-lz3min~t~ with the characteristics and benefits described above with
respect to one ~itern~tive embodiment of the present invention as shown in FIG. 6.
Preferably~ the second lamina 80 is joined to the adhesive backing 34 after the
20 l~min~tto 90 has been relaxed such that the lateral ~limen~ion5 of the l~min~te 90,
after converging, is between about 90% and about 50% of the lateral dimensions of
the larnina 22 when fully stretched. In an ~speri~lly yleç~ d emboc~im~nt the
second larnina 80 is joined to the adhesive b~rl~ing 34 after the l~min~te 90 has been
relaxed such that the lateral ~iimen~ions of the l~minzit~ 90. after converging. is about
~s 70% of the lateral rlim~n~ions of the l~min~te 90 when fully stretched. However.
emborlimPntc are co..~ .lated wherein the second lamina 80 is joined after the
klmin~tt? 90 is co.,~ ly relaxed, or while the l~min~te 90 is fully alle~ched.
After the tri-l~min~te 100 has been formed, as described above, the tri-
l~min~te 100 may be adhered to an abso-l.~ nL article or any other desired object.
The process of forming the tri-l~min~te 100 leaves exposed the portions of the
second surface 33 that were adhered to the tentering belts 35. Thus, the portions of
the second surface 33 of the adhesive film that were adhered to the tentering belts 35
can be used to join the tri-l~min~te 100 to any desired object without the use of any
additional adhesive.
3s While particu}ar embo-lim~nt~ of the present invention have been illustrated
and described. it would be obvious to those skilled in the art that various other

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W O 97/25893 27 PCTrUS97/00635


chan~es and modifications can be made without departing from the spirit and scope
~ of the invention. It is therefore inten~led to cover in the appended Claims all such
chan~es and modifications that are within the scope of this invention.

WE~AT IS CLAIMED IS:

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date Unavailable
(86) PCT Filing Date 1997-01-16
(87) PCT Publication Date 1997-07-24
(85) National Entry 1998-07-17
Examination Requested 1998-07-17
Dead Application 2001-11-05

Abandonment History

Abandonment Date Reason Reinstatement Date
2000-11-06 R30(2) - Failure to Respond
2001-01-16 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Request for Examination $400.00 1998-07-17
Registration of a document - section 124 $100.00 1998-07-17
Application Fee $300.00 1998-07-17
Maintenance Fee - Application - New Act 2 1999-01-18 $100.00 1998-07-17
Maintenance Fee - Application - New Act 3 2000-01-17 $100.00 2000-01-11
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
THE PROCTER & GAMBLE COMPANY
Past Owners on Record
ALLEN, PATRICK JAY
WEIRICH, DAVID MICHAEL
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 1998-07-17 1 71
Claims 1998-07-17 3 105
Drawings 1998-07-17 7 182
Description 1998-07-17 27 1,537
Cover Page 1998-11-04 2 83
Representative Drawing 1998-11-04 1 16
Assignment 1998-07-17 6 216
PCT 1998-07-17 10 299
Prosecution-Amendment 2000-05-05 2 73