Multilayer pads and methods of manufacture employing thermal bonding

Abstract

In-line methods for manufacturing a plurality of multilayer pads and the resultant pads. Various embodiments of the invention employ one or two thermal bonding stations, such as ultrasonic bonding stations, along with handle folding tooling, to produce two- or three-layer pads in various configurations, without the use of adhesive. Following bonding and handle folding, a cutter, such as a die cutter, is employed to cut through the layers to form individual pads. Pads of various configurations are manufactured, including pads with “L”-shaped handles, handles of “wing” configuration, and “folded” handles.

What is claimed is: 
     
         1 . A multilayer pad comprising:
 an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite said applying/wiping surface, and an outer periphery;   a barrier layer having a lower surface attached by fusing to said base pad layer attachment surface, an upper surface, and an outer periphery coextensive with said outer periphery of said base pad layer;   a handle including an attached portion fused to a portion of said barrier layer upper surface, and including at least one graspable free portion joined to said handle attached portion along a fold line defining an axis of said multilayer pad; and   said handle attached portion being attached to said barrier layer upper surface along at least one bond line parallel to the pad axis.   
     
     
         2 . The multilayer pad of  claim 1 , wherein said handle attached portion is attached to said barrier layer upper surface at least by a bond line adjacent the fold line. 
     
     
         4 . The multilayer pad of  claim 1 , wherein
 said handle has a pair of attached portions and an intermediate graspable portion in the form of a fold; and wherein   each of said handle attached portions is attached to said barrier layer upper surface at least by a bond line adjacent the fold line.   
     
     
         5 . A multilayer pad comprising:
 an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite said applying/wiping surface, and an outer periphery;   a barrier layer having a lower surface attached by fusing to said base pad layer attachment surface, an upper surface, and an outer periphery coextensive with said outer periphery of said base pad layer;   a handle including an attached portion fused to a portion of said barrier layer upper surface, and including at least one graspable free portion joined to said handle attached portion along a fold line defining an axis of said multilayer pad; and   said handle attached portion being attached to said barrier layer upper surface and said barrier layer lower surface being attached to said base pad layer attachment surface along bond lines parallel to the pad axis.   
     
     
         6 . The multilayer pad of  claim 5 , wherein said handle attached portion is attached to said barrier layer upper surface at least by a bond line adjacent the fold line. 
     
     
         7 . The multilayer pad of  claim 6 , wherein said barrier layer lower surface is attached to said base pad layer attachment surface at least by a bond line which does not attach said handle attached portion. 
     
     
         8 . The multilayer pad of  claim 5 , wherein
 said handle has a pair of attached portions and an intermediate graspable portion in the form of a fold; and wherein   each of said handle attached portions is attached to said barrier layer upper surface at least by a bond line adjacent the fold line.   
     
     
         9 . The multilayer pad of  claim 8 , wherein the same bond lines which attach said handle attached portions to said barrier layer upper surface attach said barrier layer lower surface to said base pad layer attachment. 
     
     
         10 . The multilayer pad of  claim 5 , wherein said handle graspable portion has a height less than one-half the width of a pad so that a bond line attaching said handle attached portion to said barrier layer upper surface can be formed at the same time as a bond line attaching said barrier layer lower surface to said base pad layer attachment surface. 
     
     
         11 . The multilayer pad of  claim 5 , wherein
 said handle has a pair of attached portions and an intermediate graspable portion in the form of a fold; wherein   each of said handle attached portions is attached to said barrier layer upper surface at least by a bond line adjacent the fold line; and wherein   said handle graspable portion has a height less than one-half the width of a pad so that bond lines attaching said handle attached portions to said barrier layer upper surface can be formed at the same time as bond lines attaching said barrier layer lower surface to said base pad layer attachment surface.   
     
     
         12 . A multilayer pad comprising:
 an absorbent base pad layer having an applying/wiping surface, an attachment surface opposite said applying/wiping surface, and an outer periphery;   a barrier layer having a lower surface attached by fusing to said base pad layer attachment surface, an upper surface, and an outer periphery coextensive with said outer periphery of said base pad layer;   a handle including an attached portion fused to a portion of said barrier layer upper surface, and including at least one graspable free portion joined to said handle attached portion along a fold line defining an axis of said multilayer pad;   said barrier layer being continuously fused to said base pad layer; and   said handle attached portion being attached to said barrier layer upper surface along at least one bond line parallel to the pad axis.   
     
     
         13 . The multilayer pad of  claim 12 , wherein said handle attached portion is attached to said barrier layer upper surface at least by a bond line adjacent the fold line. 
     
     
         14 . The multilayer pad of  claim 12 , wherein
 said handle has a pair of attached portions and an intermediate graspable portion in the form of a fold; and wherein   each of said handle attached portions is attached to said barrier layer upper surface at least by a bond line adjacent the fold line.