Disposable hygiene article, surgical covering item, or surgical garment

Abstract

A disposable hygiene article ( 2 ), surgical covering item, or surgical garment, such as an incontinence diaper, incontinence pad, surgical drape, or surgical coat, has a composite non-woven fabric ( 38 ) that is provided with at least one non-woven fabric component ( 16 ) and another non-woven fabric or foil component ( 10, 12 ). The first non-woven fabric component ( 14 ) is attached to the other non-woven fabric or foil component ( 10, 12 ) in at least some areas by means of a joining pattern ( 36 ) encompassing discrete ultrasonic welding points ( 30 ) in order to form the composite non-woven fabric ( 38 ). The joining pattern ( 36 ) extends in a first direction ( 32 ) and a second direction ( 34 ) that runs perpendicular thereto, the distance in the first direction ( 32 ) being longer than the distance in the second direction ( 34 ). At least some sections of the joining pattern ( 36 ) are not rectilinear. In order to make the formation of the welded joint a secure process, the joining pattern is embodied such that the maximum index (I) of variation of the area seized by the ultrasonic welding points is 40 percent.

1 - 31 . (canceled) 
     
     
         32 . A hygiene article, surgical covering item, surgical garment for single use, incontinence diaper, incontinence pad, surgical drape or surgical coat, the article comprising:
 at least one first nonwoven fabric component;   a second nonwoven fabric or foil component; and   a joining pattern having discrete ultrasonic welding points, said joining pattern disposed, structured and dimensioned to attach said first nonwoven fabric component to said second nonwoven fabric or foil component, thereby forming a composite nonwoven fabric, wherein said joining pattern extends in a first direction and a second direction that runs perpendicular to said first direction, an extension of said joining pattern in said first direction being longer than an extension of said joining pattern in said second direction, wherein at least some sections of said joining pattern are non-rectilinear and an index of variation of an area seized by said ultrasonic welding points is no more than 40%.   
     
     
         33 . The article of  claim 32 , wherein said index of variation of said area seized by said ultrasonic welding points is no more than 35%, no more than 30% or no more than 25%. 
     
     
         34 . The article of  claim 32 , wherein said composite nonwoven fabric comprises at least one cuff element forming a leakage barrier on both sides thereof and extending substantially in said first direction, wherein said cuff element stands at least in some sections. 
     
     
         35 . The article of  claim 34 , wherein said cuff element comprises said first nonwoven fabric component. 
     
     
         36 . The article of  claim 35 , wherein the article comprises a topsheet that is permeable at least in some areas, a backsheet that is impermeable at least in some areas, and a storage core that absorbs body fluids and is disposed between said top sheet and said back sheet. 
     
     
         37 . The article of  claim 36 , wherein said second nonwoven fabric or foil component is said topsheet or said backsheet, wherein said cuff element with said first nonwoven fabric component is attached to said topsheet or said backsheet by said joining pattern. 
     
     
         38 . The article of  claim 32 , wherein at least some areas of a first partial joining pattern constitute a cuff base. 
     
     
         39 . The article of  claim 38 , wherein some areas of said cuff base are constituted by a second partial joining pattern that is largely rectilinear or largely parallel to said first direction. 
     
     
         40 . The article of  claim 39 , wherein at least some sections of said cuff base are formed by said first partial joining pattern, said second partial joining pattern, and a third non-rectilinear partial joining pattern. 
     
     
         41 . The article of  claim 40 , wherein, in said first direction, said second partial joining pattern is disposed between said first and said third partial joining pattern. 
     
     
         42 . The article of  claim 32 , wherein, in said first direction, said joining pattern has a first section, a second center section and a third section adjoining said center section, wherein said first section, said center section and said third section have substantially equal lengths, an index of variation of an area of said first section and/or of said third section of said joining pattern seized by said ultrasonic welding points being no more than 40%, no more than 35%, no more than 30% or no more than 25%. 
     
     
         43 . The article of  claim 32 , wherein a distance between discrete said ultrasonic welding points in a first area is less than that in a second area. 
     
     
         44 . The article of  claim 43 , wherein a distance between individual said ultrasonic welding points is 0.1 to 2.5 mm, 0.2 to 2.3 mm or 0.2 to 1.5 mm in said first area and 2 to 20 mm, 3 to 15 mm or 4 to 10 mm in said second area. 
     
     
         45 . The article of  claim 32 , wherein a density per unit area of said ultrasonic welding points in a first area is greater than that in a second area. 
     
     
         46 . The article of  claim 43 , wherein said first area forms at least one partial area of a first and/or second and/or third partial joining pattern of a cuff base. 
     
     
         47 . The article of  claim 43 , wherein a first and/or third partial joining pattern comprises a set of at least two, at least three, at least four or at least five curves. 
     
     
         48 . The article of  claim 47 , wherein at least two of curves of said set are separated by a small maximum distance of 2 to 20 mm, 2 to 15 mm or 3 to 10 mm. 
     
     
         49 . The article of  claim 48 , wherein at least two curves of said set are separated by a greater maximum distance of 10 to 70 mm, 15 to 60 mm or 20 to 50 mm. 
     
     
         50 . The article of  claim 47 , wherein one or more of said curves has a radius of at least 60 mm, at least 70 mm, at least 80 mm, at least 90 mm, at least 100 mm or of no more than 150 mm. 
     
     
         51 . The article of  claim 47 , wherein said curves have a variable distance between them. 
     
     
         52 . The article of  claim 32 , wherein said joining pattern comprises first discrete ultrasonic welding points with an area of 0.3 to 4 mm 2 , 0.3 to 3 mm 2 , 0.3 to 2 mm 2 , 0.5 to 1.1 mm 2  or of 0.7 to 0.9 mm 2 . 
     
     
         53 . The article of  claim 32 , wherein said joining pattern comprises first and second discrete ultrasonic welding points, an area of said first discrete ultrasonic welding points being smaller than that of said second discrete ultrasonic welding points. 
     
     
         54 . The article of  claim 32 , wherein an area of individual ultrasonic welding points is circular, oval, triangular, polygonal, sickle-shaped, dot-and-dashed, star-shaped or linear. 
     
     
         55 . The article of  claim 32 , wherein a sum of areas of said ultrasonic welding points of a 5-mm long section of said joining pattern in said first direction is on average 2 to 25 mm 2 , 3 to 18 mm 2 , 4 to 12 mm 2  or 6 to 10 mm 2 . 
     
     
         56 . The article of  claim 32 , wherein an average sum of areas of said ultrasonic welding points of a 5-mm long section of said joining pattern in said first direction is no more than 30 mm 2 , no more than 23 mm 2 , no more than 18 mm 2 , no more than 16 mm 2  or no more than 15 mm 2 . 
     
     
         57 . The article of  claim 32 , wherein a deviation of a sum of areas of said ultrasonic welding points of each 5-mm long section of said joining pattern in said first direction from a sum of areas of said ultrasonic welding points of a directly adjacent 5-mm long section of said joining pattern is less than 70%, less than 60%, less than 50% or less than 40%. 
     
     
         58 . The article of  claim 32 , wherein a deviation of a sum of areas of said ultrasonic welding points of at least 50%, of at least 60%, of at least 70%, of at least 80% or of at least 90% of 5-mm long sections of said joining pattern from a sum of areas of said ultrasonic welding points of a directly adjacent 5-mm long section of said joining pattern is less than 40%, less than 30% or less than 25%. 
     
     
         59 . The article of  claim 32 , wherein said joining pattern extends 300 to 2000 mm, 350 to 1500 mm, 400 to 1200 mm, 450 to 1100 mm or 500 to 1000 mm in said first direction and 10 to 1200 mm, 15 to 1000 mm, 20 to 500 mm, 30 to 200 mm, 40 to 150 mm or 50 to 130 mm in said second direction. 
     
     
         60 . A method for the production of the hygiene article, surgical covering item, surgical garment for single use, incontinence diaper, incontinence pad, surgical drape or surgical coat of  claim 32 , the article comprising a composite a nonwoven fabric having at least one first nonwoven fabric component and a second nonwoven fabric or foil component, the method comprising the step of:
 welding said first nonwoven fabric component to said second nonwoven fabric or foil component by means of an ultrasonic welding device in at least some areas to form a joining pattern encompassing discrete ultrasonic welding points, said joining pattern extending in the first direction and in the second direction, an extension in the first direction being greater than an extension in the second direction, wherein at least some sections of the joining pattern are not rectilinear and an index of variation of an area seized by the ultrasonic welding points is no more than 40%.   
     
     
         61 . The method of  claim 60 , wherein the ultrasonic welding device comprises a sonotrode or a stationary sonotrode and a contour roller. 
     
     
         62 . The method of  claim 60 , wherein welding of components is performed at a path velocity of 100 to 1000 m/min.