Mechanical restoration of a deformed loop structure

Abstract

An improved process for making disposable diapers, and the like, having hook-and-loop fastening systems, and disposable diapers made by the improved process. The loop structure of the hook-and-loop fastening system used in this invention is substantially free of article attachment adhesive and comprises loop elements affixed to a support structure. The loop elements are deformed when the loop structure is wound onto a parent roll. At least a portion of the deformed loop elements are restored to essentially their original, undeformed, state after the loop structure is unwoundfrom the parent roll. The restoration is accomplished by contacting the loop elements with a mechanical restoration device which comprises either a brush or a scarfing surface. The brush preferably has a plurality of bristles having an average free length greater than about three times the average undeformed height of the loop elements and an average bending modulus less than the average modulus of elasticity of the loop elements. The scarfing surface preferably has an average roughness of at least about 500 RMS.

What is claimed is:  
     
       1. In a process for the manufacture of an article comprising a hook-and-loop fastening system, the improvement comprising the steps of: 
       a) Providing a loop structure comprising a plurality of loop elements, said loop elements being affixed to a support substrate, said support substrate being substantially free of article attachment adhesives;  
       b) Deforming at least a portion of said loop elements by winding said loop structure upon itself to form a parent roll;  
       c) Unwinding said loop structure from said parent roll;  
       d) Restoring at least a portion of said deformed loop elements by contacting said deformed loop elements with a mechanical restoration device;  
       e) Providing an article; and  
       f) Introducing said loop structure comprising said restored loop elements onto the article.  
     
     
       2. The process of claim  1  wherein said mechanical restoration device comprises a brush. 
     
     
       3. The process of claim  2  wherein said brush comprises a rotating cylinder. 
     
     
       4. The process of claim  2  wherein said brush is a substantially flat brush. 
     
     
       5. The process of claims  2 ,  3 , or  4  wherein said brush comprises a plurality of bristles, said bristles having an average free length greater than about three times the average undeformed height of said loop elements. 
     
     
       6. The process of claim  5  wherein said bristles have an average bending modulus less than the average modulus of elasticity of said loop elements. 
     
     
       7. The process of claim  1  wherein said mechanical restoration device comprises a rotating cylinder provided with a scarfing surface. 
     
     
       8. The process of claim  1  wherein said mechanical restoration device comprises a substantially flat plate provided with a scarfing surface.