Note: Descriptions are shown in the official language in which they were submitted.
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PATENT
MULTIFUNCTIONAL DISPOSABLE TRAINING PANT
FIELD OF THE ~v~.llON
The present invention relates generally to disposable
absorbent garments. More particularly, the invention
pertains to an advanced disposable training garment with
releasably attachable pant and training panel portions.
BACKGROUND OF THE INVENTION
Training pants are useful during the stage between
diapers and underpants. To promote the transition to
underpants, it is important for training pants to be
three-dimensional articles like underpants, rather than
two-dimensional articles like disposable diapers. A
suitable disposable training pant, therefore, is an article
having closed sides and defining waist and leg openings.
Hopefully, the child will raise and lower the pant whenever
necessary without requiring the aid of a parent. To wear
the training pant, the child places his or her feet in the
waist and respective leg openings and pulls the pant
upwardly along the legs to raise the pant to the crotch.
This is significantly different from the way a
two-dimensional diaper is secured to a child.
Toilet training typically begins when the child reaches
an age in the range of about 15 to 36 months. The ultimate
goal is for the child to become independent of the parent
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or caretaker in using the toilet. From the time training
begins until this goal is achieved, there are hopefully a
progression of levels of increasing success. Each level
represents a development in the child's ability to
anticipate and communicate the need to use the toilet.
There are certain times within each level, however, when
the child is less likely to be successful, for example when
the child is playing, napping/sleeping, restrained in a car
seat for extended periods or located where toilet access is
limited.
Existing disposable training pants fulfill the general
need for a three-dimensional absorbent garment to promote
the transition from diapers to underwear. Unfortunately,
however, existing training pants are not tailored to
specific levels of success in toilet training and are not
adaptable to specific times when a child is more likely or
less likely to be successful. Thus, there is a need for an
advanced disposable training garment to address these
needs.
SUMMARY OF THE Ihv~NllON
In response to the diccllcfie~ deficiencies of existing
training pants, a new absorbent garment has been
discovered. An absorbent garment according to the
invention includes a three-dimensional pant defining a
waist opening with front and back edges, two leg openings,
a crotch region between the leg openings, and front and
back waist regions between the crotch region and the
respective front and back edges. The pant includes an
outer cover having a thickness of less than about
2 millimeters and a circular bend value of not more than
about 6.5 grams. A reinforcement region of the pant
includes a protection panel permanently bonded to a portion
of the outer cover. The reinforcement region has a
thickness of not more than about 7 millimeters and a
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circular bend value of less than about 200 grams. The
protection panel is formed of an absorbent structure having
a saturated retention capacity of less than about 200 grams
and which includes a high-absorbency material. The pant
also includes means for preventing liquid migration from
the absorbent structure into the outer cover. The garment
has a training panel with opposite longitudinally spaced
end portions and a central absorbent portion therebetween.
The training panel, which includes an absorbent core with
a saturated retention capacity of at least about 300 grams,
is adapted to be releasably attached to the pant.
This aspect of the invention provides a pant that can
be employed as a toilet training device either alone or in
combination with the training panel. The pant is
constructed to be thin, flexible and breathable so that the
child likes to wear the pant alone. This preference may
provide additional motivation for success. The flexibility
of the pant is defined by its circular bend value,
described hereinafter. The pant can be used alone when the
child routinely anticipates and communicates the need to
use the toilet, and when the child is likely to be
successful. The protection panel, which is permanently
attached to the outer cover, provides a sufficient degree
of absorbent capacity, however, to handle any unanticipated
voids. Absorbent capacity is measured by the saturated
retention capacity value, explained hereinafter.
At particular times when the child may not be
successful, even though the child generally possesses the
ability to anticipate and communicate the need to use the
toilet, the pant can be used in combination with the
training panel. The training panel releasably attaches to
the pant and provides a higher saturated retention capacity
than the protection panel to accommodate large or multiple
voids. Further, the training panel and protection panel
are in liquid communication, so that the full absorbent
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capacity of both structures is potentially available for
absorbing voids.
In another aspect, an absorbent garment according to
the invention includes a three-dimensional pant that
consists essentially of an outer cover formed of a gas
permeable material. The outer cover defines opposite inner
and outer surfaces and has a thickness of not more than
about 2 millimeters, an average actual drape value of less
than about 2.6, and a circular bend value of not more than
about 6.5 grams. Elastic members are operatively joined to
the outer cover about the waist and leg openings. A
training panel of the garment has opposite longitudinally
spaced end portions and a central absorbent portion
therebetween. The training panel includes a liner, a
liquid impermeable backing sheet, and an absorbent core
sandwiched between the liner and the backing sheet. The
absorbent core has a saturated retention capacity of at
least about 300 grams. The training panel i8 adapted to be
releasably attached to the pant by two sets of first and
second releasably engageable fasteners. The first
fasteners are bonded to the inner surface of the front and
back waist regions of the pant, and the second fasteners
are bonded to the end portions of the training panel.
In one embodiment, the outer cover is formed of a gas
permeable laminated material that includes a prestretched
elastic inner layer sandwiched between and bonded to a pair
of spunbond webs. The spunbond webs include bicomponent
fibers formed of about 50 weight percent polypropylene and
about 50 weight percent polyethylene in a side-by-side
configuration. In particularly desirable embodiments, the
outer cover has a thickness of less than about
1 millimeter, a circular bend value of not more than about
5.5 grams, and an average actual drape value of less than
about 1.8.
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The garment of this aspect of the invention provides
additional training options. When a child normally does
not require an absorbent training device, the pant can be
used alone. Even at this advanced level of toilet
training, however, there are times when success is not
guaranteed. At these times, the training panel can be
releasably attached to the pant. The training panel
possesses sufficient absorbent capacity to accommodate a
void should it occur. Further, the garment provides the
option of using the training panel only for overnight use.
This option is useful with children who are at an advanced
stage of training and are being trained exclusively in the
daytime. During the day, the child may prefer and also
only need to wear the pant alone.
In another aspect, the invention pertains to a method
for making a three-dimensional absorbent garment. The
method includes the steps of: supplying an outer cover
having opposite inner and outer surfaces, opposite
longitudinally spaced ends, and side edges extending
between the ends, each side edge including a recesse~ area
and ear portions separated by the recessed area; forming a
protection panel comprising an absorbent structure
sandwiched between a cover and a moisture barrier, the
absorbent structure having a saturated retention capacity
of less than about 200 grams and comprising from about 40
to about 90 weight percent high-absorbency material:
permanently bonding the protection panel to a center
portion of the inner surface of the outer cover; bonding a
pair of first fasteners to the inner surface of the outer
cover, one fastener located in each of the front and back
waist regions; supplying a training panel having opposite
longitudinally spaced end portions with a central absorbent
portion therebetween, the training panel comprising an
absorbent core having a saturated retention capacity of at
least about 300 grams; bonding a second fastener to each
end portion of the training panel, the second fasteners
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being releasably engageable with the first fasteners;
bonding the ear portions of each side edge together to
define a waist opening and a pair of leg openings; and
positioning the training panel against the inner surface of
the outer cover and releasably attaching the first and
second fasteners.
In one particular embodiment of the method, the
protection panel includes at least about 10 weight percent
thermoplastic binder fibers, and the protection panel is
permanently bonded to the outer cover by applying heat and
pressure.
Numerous features and advantages of the present
invention will appear from the following description. In
the description, reference is made to the accompanying
drawings which illustrate preferred embodiments of the
invention. Such embodiments do not represent the full
scope of the invention. Reference should therefore be made
to the claims herein for interpreting the full scope of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
2SFig. 1 is a perspective view of a three-dimensional
absorbent garment according to the present invention.
Fig. 2 is a plan view of a pant portion of the
absorbent garment shown in Fig. 1, at an intermediate stage
of assembly and in a flat and stretched condition.
Fig. 3 is a perspective view of a training panel
portion of the absorbent garment shown in Fig. 1, with
portions broken away for the purposes of illustration.
Fig. 4 is a view in section taken generally from the
plane of the line 4-4 in Fig. 1.
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Fig. 5 is a plan view similar to Fig. 2, but showing a
pant portion of an alternate absorbent garment according to
the present invention, at an intermediate stage of assembly
and in a flat and stretched condition.
Fig. 6 is a perspective view of an alternate training
panel for use with the pant portion shown in Fig. 5.
Fig. 7 is a plan view of the training panel shown in
Fig. 6, in a flat and stretched condition.
DEFINITIONS
Within the context of this specification, each term or
phrase below will include the following meaning or
meanings:
(a) "bonded" refers to the joining, adhering, connecting,
attaching, or the like, of two elements. Two elements
will be considered to be bonded together when they are
bonded directly to one another or indirectly to one
another, such as when each is directly bonded to
intermediate elements.
(b) "disposable" includes being disposed of after use, and
not intended to be washed and reused.
(c) "disposed", "disposed on", "disposed with", "disposed
at", "disposed near", and variations thereof are
intended to mean that one element can be integral with
another element, or that one element can be a separate
structure joined to or connected to or placed with or
placed near another element.
(d) "elastic," "elasticized," and "elasticity" include that
property of a material by virtue of which it tends to
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recover its original size and shape after removal of a
force causing the deformation.
(e) "extension", "extend", and "extended" include the
change in length of a material due to stretching,
expressed in units of length.
(f) "force" includes a physical influence exerted by one
body on another which produces acceleration of bodies
that are free to move and deformation of bodies that
are not free to move. Force is expressed in-grams per
unit area.
(g) "front" and "back" are used to designate relationships
relative to the garment itself, rather than to suggest
any position the garment assumes when it is positioned
on a wearer.
(h) "liquid communication" and "liquid migration" refer to
the ability of a liquid to travel from one layer to
another layer.
(i) "member" when used in the singular can have the dual
meaning of a single element or a plurality of elements.
(j) "operatively joined", with reference to the attachment
of an elastic member to another element, means that the
elastic member when attached to or connected to the
element, or treated with heat or chemicals, by
stretching, or the like, gives the element elastic
properties; and with reference to the attachment of a
non-elastic member to another element, means that the
member and element can be attached in any suitable
manner that permits or allows them to perform the
3S intended or described function of the joinder. The
joining, attaching, connecting or the like can be
either directly, such as joining either member directly
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to an element, or can be indirectly by means of another
member disposed between the first member and the first
element.
(k) "permanently bonded" refers to the joining, adhering,
connecting, attaching, or the like, of two elements of
an absorbent garment such that the elements tend to be
and remain bonded during normal use conditions of the
absorbent garment.
(l) "releasably attached," "releasably engaged" and
variations thereof refer to two elements being
connected or connectable such that the elements tend to
remain connected absent a separation force applied to
one or both of the elements, and the elements being
capable of separation without substantial permanent
deformation or rupture. The required separation force
is typically beyond that encountered during normal use
of the absorbent garment.
(m) "rupture" includes the breaking or tearing apart of a
material; in tensile testing, rupture refers to the
total separation of a material into two parts either
all at once or in stages, or the development of a hole
in some materials.
(n) "stretch bonded" refers to an elastomeric member being
bonded to another member while the elastomeric member
is extended at least about 25 percent of its relaxed
length. Desirably, the term "stretch bonded" refers
to the situation wherein the elastomeric member is
extended elongated at least about lO0 percent, and more
desirably at least about 300 percent, of its relaxed
length when it is bonded to the other member.
(o) "stretch bonded laminate" refers to a composite
material having at least two layers in which one layer
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is a gatherable layer and the other layer is an elastic
layer. The layers are joined together when the layer
is in an extended condition so that upon relaxing the
layers, the gatherable layer is gathered.
(p) "three dimensional" refers to a garment similar to
underwear, shorts or pants in that it has continuous
leg and waist openings that are bounded by material of
which the garment is made. The garment may or may not
have manually tearable seams.
(q) "two dimensional" refers to a garment that can be
opened without destructively tearing any structure
while being laid in a flat condition. These garments,
such as diapers, do not have continuous leg and waist
openings, and require a fastening device, such as
adhesive tapes or hook-and-loop fasteners, to attach
the garment about the wearer.
These definitions are not intended to be limiting, and
these terms may be defined with additional language in the
remaining portion of the specification.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to Fig. 1, a disposable absorbent
garment 20 formed according to the present invention is
shown for purposes of illustration as a three-dimensional
toilet training garment for a child. The invention may
also be embodied in other types of garments, such as adult
incontinence products.
The absorbent garment 20 generally includes two
portions: a three-dimensional pant 22 and a training panel
24. The pant 22 desirably has a relatively modest
absorbent potential and may be used by itself as part of a
toilet training program. The training panel 24 provides a
-- 10 --
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relatively higher absorbent potential and can be attached
to the pant 22 and used in combination therewith as another
part of the toilet training program.
The pant 22 is illustrated at an intermediate stage of
assembly and in a flat and stretched condition in Fig. 2
and shown in section with the training panel 24 in Fig. 4.
As noted, the pant 22 is three-dimensional and thus defines
a waist opening 26 and two leg openings 28 (Fig. 1).
The pant 22 is constructed from an outer cover 30
having opposite inner and outer surfaces 31 and 32. The
outer cover 30 has opposite longitudinally spaced ends 34
and 35, and opposite side edges 36 extending between the
ends. Each side edge 36 is desirably shaped to form a
recessed area 38 with ear portions 40 on either end of the
recessed area (Fig. 2).
The pant 22 is assembled from the intermediate stage
shown in Fig. 2 by permanently bonding the ear portions 40
of each side edge 36 together. This is illustrated in
Fig. 1 by non-refastenable seams 42. The seams 42, which
may be manually tearable, may be formed by any suitable
means such as ultrasonic sealing, adhesive bonding, heat
sealing, adhesive coated tapes, or the like. One suitable
method for forming such seams is disclosed in U.S.
Patent 4,938,753 issued July 3, 1990, to Van Gompel et al.,
which is incorporated herein by reference.
In the assembled pant 22, one end 34 of the outer cover
30 defines a front edge of the waist opening 26, while the
opposite end 35 defines a back edge of the waist opening.
Further, the recessed areas 38 of the outer cover side
edges 36 define the leg openings 28 of the pant 22. A
crotch region 44 of the pant 22 is generally located
between the leg opening 28 and comprises that portion of
the pant which, when worn, is positioned between the legs
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of the wearer and covers the lower torso of the wearer. A
front waist region 45 of the pant 22 extends generally from
the crotch region 44 to the front end 34 of the outer cover
30. Similarly, a back waist region 46 extends from the
crotch region 44 to the back end 35 of the outer cover 30.
In general, the longitudinal extent of the waist regions 4S
and 46 is related to the distance between the ends 34 and
35 of the outer cover 30 and the recessed areas 38,
measured along the side edges 36.
As previously noted, the pant 22 may be used by itself
during the later stages of a toilet training program. The
pant 22 desirably approximates the size, shape, feel and
appearance of underwear, while also providing a relatively
15 modest amount of absorbent capacity. Use of the pant 22 by
itself is thus particularly desirable at training stages
between use of a standard disposable training pant and use
of underwear, at times when the child is likely to be
successful.
In keeping with the intended use of the pant 22, the
outer cover 30 should possess certain characteristics.
First, the outer cover 30 desirably has a thickness of less
than about 2 millimeters, and more desirably less than
25 about 1 millimeter, such as about 0. 76 millimeter. The
thickness of the outer cover 30 is the average calculated
from five individual sample measurements determined under
a restr~ini~ pressure of 100 grams per square centimeter.
The thickness of each outer cover sample of at least
2.54 centimeters in diameter is determined using a
commercially available thickness indicator, such as Ames
Model 16 available from Production Tool and Gage, located
at 6557 Watson Street, Union City, Georgia 30291. After
being conditioned in a room which is 21 + 1 degree Celsius
35 and 50 + 2 percent relative humidity for a period of two
hours, the samples are individually tested and each
thickness value recorded. The thickness of the outer cover
2~211~9
is determined by totalling the thickness values of the five
samples and dividing the total by five.
It is also desirable for the outer cover 30 to have
sufficient flexibility to conform to the shape of the body
and facilitate the psychological transition to the use of
underwear. In this regard, the outer cover 30 desirably
has a circular bend value of not more than about 6.5 grams,
and more desirably not more than about 5.5 grams, and an
average actual drape value of less than about 2.6, and more
desirably less than about 1.8. The circular bend value
indicates the stiffness of the material, simultaneously
averaging stiffness in all directions. The average actual
drape value also provides an indication of the stiffness of
the material, but of the single-direction type.
The test procedure for determining the circular bend
value is based on ASTM Standard D 4032-92 titled "Stiffness
of Fabric by the Circular Bend Procedure" but is modified
as follows. Equipment used in the test procedure includes
an Instron Model 5213 actuator (available from Instron
Engineering Corporation, Canton, Massachusetts); a
2,000 gram inverted load cell; a smooth polished aluminum
plate platform having a 38.1 millimeter diameter orifice,
the lap edge of which is at a 45 degree angle to a depth of
4.8 millimeters; and a plunger with a diameter of
25.4 millimeters, a length of 72 millimeters, and a needle
point. In performing this test, five outer cover material
samples are cut into strips having a length of
204 millimeters and a width of 204 millimeters. The
samples are folded to form a square measuring 102 by
102 millimeters. After being conditioned in a room which
is 21 + 1 degree Celsius and 50 + 2 percent relative
humidity for a period of two hours, a sample is centrally
positioned over the orifice beneath the plunger. The
plunger has a stroke length of 57 millimeters and speed of
1.7 + 0.3 seconds per full stroke. Each sample is
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individually tested and the maximum force reading recorded.
The circular bend value of the outer cover is determined by
totalling the values for the five samples and dividing the
total by five.
The test procedure for determining the average actual
drape value is ASTM Standard D-1388 titled "Stiffness of
Fabrics" and Method 5206 Federal Test Method Standard
#19lA. Equipment used in the test procedure includes a
Cantilever Bending Tester Model 79-10 available from
Testing Machines, Inc., 400 Bayview Avenue, Amityville, New
York, 11701; a 30 inch by 30 inch precision paper cutter
with sample holder; and a cutting press with a 1/2 inch by
6 inch rectangular cutting die. In performing this test,
five outer cover material samples are cut into strips
having a length of 6 inches and a width of 1/2 inch. Each
strip is moved at a rate of 4 and 3/4 inches per minute in
a direction parallel to its long dimension, so that its
leading edge projects from the edge of a horizontal
surface. The length of the overhang is measured when the
tip of the strip depresses under its own weight to a point
where the line joining the tip to the edge of the platform
makes an angle of 41.5 degrees with the horizontal. Once
a strip is pressed to the angle of 41.5 degrees, its length
is measured, and the actual drape value is calculated by
dividing the measured length in inches by 2 inches. After
performing this test on each of the five samples, the five
actual drape values are averaged to determine the average
actual drape value.
The outer cover 30 may comprise, for example, a single
layer of film, a woven material, a nonwoven material or
another suitable liquid permeable or liquid impermeable
material. The outer cover 30 may also comprise a laminate
material, such as a stretch bonded laminate formed of a
prestretched elastic inner layer sandwiched between and
attached to a pair of spunbond polypropylene nonwoven webs
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having a basis weight of about 13.6 grams per square meter.
Particular laminate materials are disclosed in U.S.
Patent 4,692,368 issued September 8, 1987, to Taylor et
al., which is incorporated herein by reference. Suitable
elastic materials can be purchased from the Shell Chemical
Company of Houston, Texas, under the tradename Kraton. In
particularly desirable embodiments, the outer cover 30
comprises a gas pervious material, referred to as a
breathable material.
In one embodiment, the outer cover 30 is formed of a
laminated material comprising a prestretched elastic
meltblown inner layer having a basis weight of about
18 grams per square meter sandwiched between and stretch
bonded to a pair of spunbond webs each having a basis
weight of about 14.9 grams per square meter. The spunbond
webs comprise bicomponent fibers formed of about 50 weight
percent polypropylene and about 50 weight percent
polyethylene in a side-by-side configuration. Alternately,
suitable elastic strands may be substituted for the elastic
meltblown layer.
Elastic members 48 and 49 may be bonded to the outer
cover 30 to enhance the fit and underwear-like appearance
of the pant 22. In particular, leg elastic bands 48
(Fig. 2) are operatively joined to the outer cover 30 along
the recessed areas 38 of each side edge 36. Also, waist
elastic bands 49 are operatively joined to the outer cover
30 along the longitll~inAl ends 34 and 35. The elastic
members 48 and 49 may be bonded to the inner and/or outer
surfaces 31 and 32 of the outer cover 30 using adhesives,
thermal bonds, ultrasonic bonds, stitching, or other
suitable means. The elastic bands 48 and 49 may be stretch
bonded to the outer cover 30, bonded in a relaxed state to
a gathered portion of the outer cover, or a combination of
the two. One suitable method for attaching the elastic
members 48 and 49 is disclosed in U.S. Patent 4,639,949
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issued February 7, 1987, to Ales et al., which is
incorporated herein by reference.
The leg and waist elastic members 48 and 49 may be
formed of a stretch bonded laminate. In particular, the
stretch bonded laminate may comprise at least one nonwoven
gatherable layer and an elastic layer. Alternatively, the
leg and waist elastic bands 48 and 49 may be formed of a
dry-spun coalesced filament elastomeric thread sold under
the trade name LYCRA and available from E.I. Du Pont de
Nemours and Company. Still alternatively, the elastic
members may be formed of other typical elastics utilized in
making disposable absorbent garments, such as a thin ribbon
of elastic material as disclosed in U.S. Patent 4,940,464
issued July 10, 1990, to Van Gompel et al., which is
incorporated herein by reference. Elasticity could also be
imparted by extruding a hot melt elastomeric adhesive to
the outer cover 30. Other suitable elastic gathering means
are disclosed in U.S. Patents 4,938,754 to Mesek and
4,388,075 to Mesek et al.
The pant 22 also includes a protection panel 50
(Figs. 2 and 4) that is permanently bonded to a center
portion of the inner surface 31 of the outer cover 30. The
protection panel 50 is designed to absorb and retain
liquids such as urine, so that the pant 22 functions as an
absorbent toilet training garment when used by itself,
despite having the appearance and fit of underwear. The
protection panel 50 as illustrated includes an absorbent
structure 52 sandwiched between a substantially liquid
permeable cover 54 and a substantially liquid impermeable
moisture barrier 56. The protection panel 50 may be
permanently bonded to the inner surface 31 of the outer
cover 30 using ultrasonic bonds, thermal bonds, adhesives,
or other suitable means.
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As suggested by Fig. 2, the absorbent structure 52,
cover 54 and moisture barrier 56 are each generally
rectangular in shape, with the cover and moisture barrier
being longer and wider than the absorbent structure. The
longitudinal sides of the moisture barrier 56 desirably
include a marginal portion measuring from about 1 to about
1.6 centimeters in width that is folded over the bodyside
surface of the absorbent structure 52 along its side edges.
The cover 54 is positioned over the absorbent structure 52
and the marginal portions of the moisture barrier 56, and
may alternately fully wrap the absorbent structure and
moisture barrier. The absorbent structure 52, cover 54 and
moisture barrier 56 may be bonded together using ultrasonic
bonds, thermal bonds, adhesives or other suitable means.
The protection panel 50 may be rectangular with a
length from about 30 to about 40 centimeters, particularly
from about 35 to about 36 centimeters, and a width from
about 6 to about 12 centimeters, particularly from about 7
to about 9 centimeters. Alternately, the protection panel
may be T-shaped, I-shaped, hourglass shaped or
irregularly shaped. The pant 22 is desirably sized such
that the protection panel 50 fits traversely between the
recessed areas 38 and between the leg elastic members 48.
In the longit~ n~l direction, the protection panel 50
desirably extends through the crotch region 44 and
partially through the front and back waist regions 45 and
46. Particularly, the protection panel 50 extends
longitudinally to within 5 to 7 centimeters, such as about
6.4 centimeters, of the front and back edges 34 and 35 of
the waist opening 26.
The components of the protection panel 50 are desirably
selected to enhance the overall thinness and flexibility of
the pant 22, as well as provide a relatively modest amount
of absorbent capacity. The cover 54, for instance,
desirably serves to insulate the wearer from absorbed
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2l2ll~9
fluids, and in particular embodiments also serves to
quickly collect and temporarily hold discharged liquids,
transport such liquids from the point of initial contact to
other parts of the cover, and then release such liquids
into the absorbent structure 52. To enhance liquid
movement into the absorbent structure 52, the cover 54 is
desirably less hydrophilic than the absorbent structure,
and creates a capillary force differential such that the
cover provides and maintains a relatively lower capillary
attraction for the discharged liquid as compared to that
exhibited by the absorbent structure.
Various woven and nonwoven fabrics can be used to
construct the cover 54. For example, the cover 54 may
comprise one or more distinct layers, such as a meltblown
or spunbonded web of polyolefin fibers or a bonded-carded
web composed of natural or synthetic fibers. In one
embodiment, the cover 54 comprises a spunbond web of
polypropylene fibers which is through air bonded and
surfactant treated, and has a basis weight of about
26 grams per square meter.
The cover 54 may also comprise an additional layer
formed of any suitable material for managing, transporting,
accommodating, permitting, or directing rapid and/or sudden
flow of urine therethrough and into contact with the
absorbent structure 52. The additional layer desirably
functions to draw liquid from the bodyside surface of the
cover and then permit desorption by the absorbent structure
52. One suitable additional layer is a surge layer which
can comprise a through-air, bonded carded web, a spunbond
bicomponent nonwoven web, a web of cross-lined cellulosic
fibers, or the like. The surge layer can have an overall
basis weight of about 50 grams per square meter and an
overall density of about 0.03 grams per cubic centimeter.
The surge layer can be a two-layered composite in which the
first layer, which is the layer that will be toward the
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wearer's body, is a 15 gram per square meter layer composed
of 100 percent polyethylene/polyester, sheath-core
bicomponent fibers having a fiber denier of about 1.8 to
about 3 d. The second layer, which is the outermost layer
in the composite, is a 35 gram per square meter layer
composed of a mixture of bicomponent fibers and single
component fibers. The bicomponent fibers form about
40 percent by weight of the outermost layer. More
particularly, 35 percent by weight of the outermost layer
is composed of about 1.8 d polyethylene/polyester sheath
core fibers with flat crimp, and about 5 percent by weight
of the outermost layer is composed of about 2 d
polyethylene/polypropylene sheath core fibers with helical
crimp. Suitable bicomponent fibers are available from
CHISSO, Osaka, Japan. The single component fibers form
about 60 percent by weight of the outermost layer, and are
about 6 denier polyester fibers configured with a flat
crimp and not hollow core fibers. The surge layer is
permeable to liquid when compressed under loads experienced
during the wear of the absorbent garment. Other suitable
materials are disclosed in U.S. Patent 4,798,603 issued
January 17, 1989, to Meyer et al. and European Patent
Application EP 0 539 703 Al, published May 5, 1993, to
Hanson et al., which patent and application are
incorporated herein by reference.
In one particular embodiment, the cover 54 comprises a
composite web having a bodyside layer and an outerside
layer. The layers can be separately laid and have
different compositions, but be suitably interconnected such
as by powder bonding, point bonding, adhesive bonding,
latex bonding, or through-air or infrared thermal bonding
to form a composite web.
The outerside layer may have a basis weight within the
range of about 17 to 50 grams per square meter and include
at least about 25 weight percent of bicomponent fibers to
-- 19 --
2121149
provide a desired bicomponent fiber bond-matrix. The
outerside layer may comprise a blend of smaller diameter
fibers having a denier within the range of about 0.9 to 3 d
and larger diameter fibers having a denier within the range
of about 3 to 15 d. The bond-matrix and blend of fiber
deniers can advantageously provide for and substantially
maintain a desired pore size structure within the outer
layer.
For example, the outerside layer may be composed of a
carded web which has a basis weight of about 34 grams per
square meter and includes a mixture of polyester (PET)
single-component fibers, available from Hoechst-Celanese,
and polyethylene/PET (PE/PET) sheath-core bicomponent
fibers, available from BASF Corp., Fibers Division, a
business having offices in Enka, North Carolina. The PET
fibers can comprise about 60 weight percent of the
outerside layer and have a denier of about 6 with an
average fiber length of about 2 inches. The PE/PET
bicomponent fibers can comprise about 40 weight percent of
the outerside layer, and have a denier of about 1.8 with an
average fiber length of about 1.5 inches. Optionally, the
larger-sized PET single-component fibers may be replaced by
bicomponent fibers. As a further option,
polyethylene/polypropylene (PE/PP), sheath-core bicomponent
fibers may be employed to form the bicomponent fiber
portion of any of the described fabrics. Suitable PE/PP
bicomponent fibers are available from Chisso Corp., a
business having offices in Osaka, Japan.
The bodyside layer of such cover material can include
at least about 90 weight percent, and desirably 100 weight
percent of bicomponent fibers to provide desired levels of
tactile softness and abrasion resistance. The bodyside
layer desirably has a basis weight of at least about
10 grams per square meter, and the bicomponent fiber size
is within the range of about 0.9 to 3 denier with a fiber
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2121149
length within the range of about 2.5 to 7.6 centimeters.
For example, the bodyside layer of the cover 54 may
comprise a carded web which has a basis weight of about
17 grams per square meter and is composed of one hundred
weight percent PET/PE, sheath-core bicomponent fibers,
obtained from BASF Corp., with a fiber denier of about 1.8
and fiber length of about 1.5 inches.
In particular embodiments of such composite cover
materials, the outerside layer forms approximately 65
weight percent of the composite web and is composed of a
blend of polyester fibers and bicomponent fibers. At least
about 60 weight percent of the blended outerside layer is
composed of polyester fibers of at least about 6 denier and
with a fiber length of about 1.5 to 2 inches. The
remaining 40 percent of the blended outerside layer is
composed of bicomponent fibers of not more than about
3 denier with fiber length within the range of about 1.5 to
2 inches. The bodyside layer comprises the remaining
35 weight percent of the composite web, and is composed of
bicomponent fibers having a denier within the range of
about 0.9 to 3 to provide a soft liner type material
appointed for placement against the wearer's skin. The
bodyside layer of the composite cover may have a basis
weight of about 15 grams per square meter and be composed
of bicomponent fibers of about 2 denier.
The absorbent structure 52 is desirably constructed to
be thin, flexible and provide a saturated retention
capacity of less than about 200 grams, and more desirably
less than about 175 grams, such as less than about
150 grams. Saturated retention capacity is a measure of
the total absorbent capacity of an absorbent garment,
material or structure.
Saturated retention capacity of the protection panel 50
may be determined as follows. The material to be tested,
having a moisture content of less than about 7 weight
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percent, is weighed and submerged in an excess quantity of
room temperature (about 23 degrees Celsius) synthetic
urine. The material to be tested is allowed to remain
submerged for 20 minutes. After 20 minutes, the material
is removed from the urine and placed on a Teflon~ coated
fiberglass screen having 0.25 inch openings (commercially
available from Taconic Plastics Inc., Petersburg, New York)
which, in turn, is placed on a vacuum box and covered with
a flexible rubber dam material. A vacuum of
3.5 kilopascals (0.5 pounds per square inch) is drawn in
the vacuum box for a period of 5 minutes. The material is
weighed. The amount of fluid retained by the material
being tested is determined by subtracting the dry weight of
the material from the wet weight of the material (after
application of the vacuum) and is reported as the saturated
retention capacity in grams of fluid retained. For
relative comparisons, this value can be divided by the
weight of the material to give the saturated retention
capacity in grams of fluid retained per gram of tested
material.
The synthetic urine composition referenced herein
comprises 0.31 grams monobasic calcium phosphate
monohydrate (CaH4(P04)2H20), 0.68 grams monobasic potassium
phosphate (KH2PO4), 0.48 grams magnesium sulphate
heptahydrate (MgSO4 7H2O), 1.33 grams potassium sulphate
(K2SO4), 1.24 grams tribasic sodium phosphate dodecahydrate
(Na3P04 12H2O), 4.4 grams sodium chloride (NaCl), 3.16 grams
potassium chloride (KCl), 8.56 grams of urea (CO(NH2)2),
0.1 grams Pluronic lOR8 surfactant (a non-ionic surfactant
commercially available from BASF-Wyandotte Corporation) and
1 gram methyl paraben and 1 gram Germall 115 preservative
(commercially available from Santell Chemical Company,
Chicago, Ill.) per liter using distilled water as the
solvent. The components are added to 900 milliliters of
distilled water in the order given and each dissolved
2I21149
before the next component is added. The solution is
finally diluted to one liter.
If material, such as high-absorbency material or fiber
is drawn through the fiberglass screen while on the vacuum
box, a screen having smaller openings should be used.
Alternatively, a piece of tea bag material can be placed
between the material and the screen and the final value
adjusted for the fluid retained by the tea bag material.
Suitable tea bag material is a heat sealable tea bag
material grade 542, commercially available from
Kimberly-Clark Corporation. The amount of fluid absorbed
by the tea bag material is determined by performing the
saturated retention capacity test on an empty tea bag.
Testing high-absorbency materials or fibers alone can be
accomplished using a sealed pouch of tea bag material.
To provide the desired thinness of the pant 22, the
protection panel 50 is configured with a thickness which is
less than about 5 millimeters. Desirably, the thickness
is less than about 3.5 millimeters, and particularly about
2.3 millimeters. The thinness of the protection panel 50
contributes to the pant 22 having a comfortable fit and the
desirable appearance of underwear. The thickness is
determined using the average of 5 samples measured under a
restraining pressure of 100 grams per square centimeter.
The absorbent structure 52 desirably comprises an
air-laid nonwoven composite comprising high-absorbency
materials and polyolefin binder fibers. Typically,
high-absorbency materials are capable of absorbing at least
about 15 times their weight in water, and desirably capable
of absorbing more than about 25 times their weight in
water. High-absorbency materials typically are in the form
of particles in a variety of shapes, including spiral,
semi-spiral, cubic, rod-like, polyhedral, conglomerates or
the like. Given the overall thinness of the pant 22, it is
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2121149
particularly desirable for the high-absorbency material to
be in shapes having a large ratio of the greatest dimension
to the smallest dimension, such as needles, flakes or the
like. Even more desirably, the high-absorbency material is
in the form of fibers that may be intermingled with binder
fibers to form a thin, bonded absorbent structure.
Suitable absorbent structures 52 for use in the
protection panel 50 may include more than about 40 weight
percent high-absorbency material, based on the total weight
of the absorbent structure. Desirably, the absorbent
structure 52 includes more than about 60 weight percent
high-absorbency material, and particularly about 80 weight
percent high-absorbency material. The absorbent structure
52 may also include from about lO to about 60 weight
percent polyolefin binder fibers, and desirably from about
10 to about 30 weight percent polyolefin binder fibers, and
particularly about 20 weight percent polyolefin binder
fibers. Suitable absorbent structures 52 for use in the
protection panel 50 may have a basis weight of from about
50 to about 300 grams per square meter, desirably from
about 150 to about 250 grams per square meter, and
particularly about 200 grams per square meter.
In one embodiment of the invention, the absorbent
structure 52 comprises an air-laid nonwoven web comprising
about 80 weight percent fibrous high-absorbency material
and about 20 weight percent polyolefin binder fibers. The
fibrous high-absorbency materials have a denier of about
9 d and a length of about 12 millimeters. Suitable fibrous
high-absorbency materials are available from Technical
Absorbents Ltd. of the United Kingdom under the tradename
OASIS. The polyolefin binder fibers have a denier of about
3 d and a length of about 6 millimeters. Such binder fiber
may be bicomponent fibers comprising 50 weight percent
polyethylene and 50 weight percent polypropylene in an
concentric sheath configuration. Suitable bicomponent
- 24 -
21~1149
binder fibers are available from Danaklon a/s of Varde,
Denmark, under the tradename Danaklon AL Thermal-C. Such
a composite web may be oven fused after air-laying for five
minutes at a temperature of about 150 degrees Celsius. The
composite web may have a basis weight of about 200 grams
per square meter.
In alternate embodiments, the absorbent structure 52
may include cellulosic fibers (i.e., wood pulp fluff) or a
coform material composed of a mixture of cellulose fibers
and synthetic polymer fibers. For example, the coform
material may comprise an air-laid blend of cellulosic wood
fibers and meltblown polyolefin fibers, such as
polyethylene or polypropylene fibers.
The high-absorbency materials may be organic or
inorganic. Suitable inorganic high-absorbency materials
include, for example, absorbent clays and silica gels.
Organic high-absorbency materials can include natural
materials, such as pectin, guar gum and peat moss, as well
as synthetic materials, such as synthetic hydrogel
polymers. Such hydrogel polymers may include, for example,
carboxymethylcellulose, alkali metal salts of polyacrylic
acids, polyacrylamides, polyvinyl alcohol, ethylene maleic
anhydride copolymers, polyvinyl ethers, hydroxypropyl
cellulose, polyvinyl morpholinone, polymers and copolymers
of vinyl sulfonic acid, polyacrylates, polyacrylamides,
polyvinyl pyridine or the like. Other suitable polymers
can include hydrolyzed acrylonitrile grafted starch,
acrylic acid grafted starch, and isobutylene maleic
anhydride copolymers, and mixtures thereof. The hydrogel
polymers are preferably sufficiently cross-linked to render
the materials substantially water-insoluble. Cross-linking
may, for example, be by irradiation or by covalent, ionic,
van der Waals, or hydrogen bonding. Suitable materials are
available from various commercial vendors, such as
- 25 -
2121149
Technical Absorbents Ltd., Dow Chemical Company, Hoechst
Celanese Corporation, and Allied Colloid, Inc.
The high-absorbency materials can be distributed or
otherwise incorporated into the absorbent structure 52
employing various techniques. For example, the
high-absorbency material can be substantially uniformly
distributed among the fibers comprising the absorbent core.
The materials can also be non-uniformly distributed within
the absorbent core fibers to form a generally continuous
gradient with either an increasing or decreasing
concentration of high-absorbency material, as determined by
observing the concentration moving inward from the moisture
barrier 56. Alternatively, the high-absorbency material
can comprise a discrete layer of the absorbent structure
52.
The absorbent structure 52 may also include a tissue
wrap layer to help maintain the integrity of the fibrous
core. This tissue wrap typically comprises a hydrophilic
cellulosic material, such as creped wadding or a high
wet-strength tissue.
The moisture barrier 56 may comprise a thin,
substantially liquid impermeable web or sheet of plastic
film such as polyethylene, polypropylene, polyvinyl
chloride or similar material. In one embodiment, the
moisture barrier 56 comprises a polyethylene film having a
thickness of about 0.025 millimeter. Alternately, the
moisture barrier 56 may comprise a nonwoven, fibrous web
which has been suitably constructed and arranged to be
substantially liquid impermeable. Still alternately, the
moisture barrier 56 may comprise a layered or laminated
material, such as a thermally bonded plastic film and
nonwoven web composite.
The portion of the pant 22 that includes both the
protection panel 50 and the outer cover 30 to which it is
- 26 -
2121149
permanently bonded, defines the reinforcement region 60 of
the pant (Fig. 2). In the illustrated embodiment, the
reinforcement region 60 is coterminous with the perimeter
of the protection panel 50. For desirable fit and
appearance benefits, the reinforcement region 60 suitably
has a thickness of not more than about 7 millimeters, and
desirably not more than about 4.5 millimeters, such as not
more than about 3.1 millimeters. Thickness is the average
calculated from five individual sample measurements
determined under a restraining pressure of 100 grams per
square centimeter. Further, the reinforcement region
60 suitably has a circular bend value of less than about
200 grams, and desirably less than about 175 grams, and
particularly less than about 150 grams. The circular bend
value of the reinforcement region 60 is based on the
average value of three measurements from the reinforcement
region taken along the longitudinal centerline and spaced
equally along the length of the reinforcement region,
although avoiding permanent folds attributable to packaging
the garment 20. Thus, the reinforcement region 60 is
located in at least the central portion of the crotch
region 44 and desirably extends at least partially into the
front and back waist regions 45 and 46. In alternate
embodiments, the outer cover 30 may include a central
aperture or comprise multiple panels (not shown). The
protection panel 50 may then be bonded along its periphery
to the outer cover 30. In such embodiments, the
reinforcement region 60 includes only the protection panel
50, which by itself possesses the desired thinness and
flexibility.
In an alternate embodiment, the protection panel 50
need not include a moisture barrier 56 (not shown). In
such embodiment, an alternate mechanism for preventing
liquid migration into and through the outer cover 30 would
be desirable. For instance, at least the portion of the
outer cover 30 disposed against the protection panel 50 may
- 27 -
21~1149
be treated or formed to be substantially liquid
impermeable. Still alternately, the outer cover 30 could
include or be formed from a liquid impermeable material.
To further enhance the structural similarities between
the pant 22 and underwear, the pant desirably includes
substantial portions which are pervious to gases. As
previously noted, the outer cover 30 is desirably formed of
a breathable material. While the protection panel 50 may
or may not be gas permeable, at least about 65 percent, and
desirably at least about 80 percent, of the surface area of
the pant 22 is gas permeable. This percentage is based on
the total surface area of gas permeable portions of the
pant 22 when in a flat, stretched condition as illustrated
in Fig. 2. The breathability of the pant 22 is another
feature which furthers the physical and psychological
transition to underwear.
Referring again to Figs. 2 and 4, a pair of first
fasteners 66 are bonded to the inner surface 31 of the
outer cover 30. The first fasteners 66 as illustrated
include a loop material and comprise the loop component of
a hook-and-loop fastening system. The first fasteners 66
may be identical in shape and formed of any suitable loop
material. The term loop material is intended, in one
embodiment, to mean a structure having a base portion, and
a plurality of loop members extending upwardly from at
least one surface of the base portion. The loop material
can comprise a fabric material manufactured to have a
raised loop construction, stabilized through napping and
thermal setting so that the individual loops are erect from
the fabric base. The loop material may be formed of any
suitable material, such as acrylic, nylon, polypropylene,
or polyester, and may be formed of methods such as warp
knitting, stitch bonding, extruding, or needle punching.
The first fasteners 66 can also comprise any suitable
material having nonwoven loops, with or without a base
- 28 -
2121149
portion. One suitable loop material is available from
Guilford Mills of Greensboro, North Carolina, under the
trade designation No. 18903.
The first fasteners 66 as illustrated include a loop
patch 67 formed of loop material and a carrier web 68
(Fig. 2). The loop patch 67 is bonded using ultrasonic
bonds, thermal bonds, adhesives or other suitable means to
the carrier web 68, which may comprise a spunbond web of
polypropylene fibers having a basis weight of about
28 grams per square meter. The carrier web 68 provides a
compatible surface for bonding the loop material.
Alternately, the loop patch 67 could be bonded directly to
the outer cover 30 (not shown).
The first fasteners 66 are bonded to the outer cover 30
in the front and back waist regions 45 and 46 of the pant
22. In particular, one first fastener 66 is bonded to the
outer cover 30 along the longitudinal centerline of the
garment 20 at a location between the protection panel 50
and the front end 34 of the outer cover 30. Similarly, the
other first fastener 66 is bonded to the outer cover 30
along the longitudinal centerline of the pant 22 between
the protection panel 50 and the back end 35 of the outer
cover. Desirably, the first fasteners 66 are spaced from
the waist opening 26 by from about 2.5 to about
7 centimeters, and in particular spaced to be located
inward of the waist elastic members 49.
The geometric shape of the loop patches 67 may take any
form, such as square, rectangular, oval, round, or
irregular. Desirably, each loop patch 67 is rectangular
in shape, measuring about 4 by about 11 centimeters, with
the long dimension aligned with the transverse axis of the
pant 22, as illustrated best in Fig. 2.
The first fasteners 66 may be attached to the outer
cover 30 using ultrasonic bonds, thermal bonds, stitching,
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2l2lll9
adhesives, or other suitable means, so that the loops of
the loop patches 67 extend outwardly from the outer cover.
As an alternative to employing separate first fasteners 66,
the inner surface 31 of the outer cover 30 could be
constructed to function as the loop component of the
hook-and-loop fastening system (not shown).
The detachable training panel 24 of the absorbent
garment 20 is shown separately in Fig. 3 and releasably
attached to the pant 22 in Figs. 1 and 4. The training
panel 24 includes opposite longitudinally spaced end
portions 70 which are separated by a central absorbent
portion 71. As illustrated (Fig. 3), each end portion 70
includes a tab portion 73 at the distal end of the training
panel 24 and an attachment portion 74 between the tab
portion 73 and the central absorbent portion 71. A second
fastener 76 is bonded to each attachment portion 74 of the
training panel 24. The second fasteners 76 are formed of
a hook material that is releasably engageable with the
first fasteners 66, and forms the hook component of the
hook-and-loop fastening system.
The second fasteners 76 comprise a single-sided hook
material which may be formed in a variety of shapes, such
as rectangular and measuring about 2.5 by about
9 centimeters. The shape of the second fasteners 76
desirably corresponds generally to the shape of the first
fasteners 66. Each second fastener 76 may be bonded to the
training panel 24 by ultrasonic bonds, thermal bonds,
adhesives, stitches, or other suitable means. The hook
material may be molded or extruded of nylon, polypropylene,
or another suitable material. The second fasteners 76
desirably contain bi-directional hooks, with the machine
direction of the hooks aligned perpendicular to the
longitudinal axis of the training panel 24. One suitable
single-sided hook material for the second fasteners 76 is
available from Velcro Industries BV, Amsterdam,
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2121149
Netherlands, or affiliates thereof, and is identified as
HTH 708 with No. CFM-22-1056 bi-directional hook pattern.
Other suitable hook material would include woven materials
with monofilaments forming hooks.
The shape, density, and polymer composition of the
hooks may be selected to obtain desirable peel and shear
force resistance values between the second fasteners 76 and
the first fasteners 66. For instance, a more aggressive
hook material may comprise a material with a greater
average hook height, a greater percentage of
directionally-aligned hooks, or a more aggressive hook
shape. The hook members may be hook-shaped,
mushroom-shaped, arrow-shaped or any other desired shape.
Again referring to Fig. 3, the training panel 24 as
illustrated includes a substantially liquid permeable liner
80 and an absorbent core 82. The liner 80 is longer and
wider than the absorbent core 82 so that it can be wrapped
about the absorbent core 82 and define the end portions 70
of the training panel 24. The second fasteners 76 are
attached to the end portions 70 on one of the major surface
of the training panel 24. The liner 80 may be bonded to
itself and/or bonded to the absorbent core 82 using
ultrasonic bonds, adhesives, or other suitable means.
The absorbent core 82 desirably comprises an airlaid
batt of wood pulp fibers and high-absorbency materials. To
provide the requisite absorbent capacity for use as a
toilet training garment, the absorbent core 82 suitably has
a saturated retention capacity of at least about 300 grams,
and desirably at least about 350 grams. The absorbent core
82 may comprise from 0 to about 95 weight percent
high-absorbency materials, and desirably at least about
20 weight percent high-absorbency materials. In one
particular embodiment, the absorbent core 82 comprises an
airlaid mixture of 50 weight percent wood pulp fluff and
2121149
50 weight percent high-absorbency material, with the
mixture having a basis weight of about 600 grams per square
meter.
In an alternate embodiment, the absorbent core 82
comprises a coform material comprised of a mixture of
cellulosic fibers and synthetic polymer fibers. For
example, coform material may comprise an air-laid blend of
cellulosic wood pulp fibers and meltblown polyolefin
fibers, such as polyethylene or polypropylene fibers. The
absorbent core 82 may also include a tissue wrap layer to
help maintain the integrity of the fibrous core. Further,
the absorbent core 82 may include additional components to
assist in the acquisition, distribution, and storage of
waste material. For example, the absorbent core 82 may
include a transport or surge type layer, such as described
in U.S. Patent 4,798,603 issued January 17, 1989, to Meyer
et al., or European Patent Application EP O 539 703 Al,
published May 5, 1993, to Hanson et al.
The liner 80 may be any soft, flexible, porous sheet
which passes fluids therethrough. The liner 80 may
comprise, for example, a nonwoven web or sheet of wet
strength tissue paper, a spunbonded, meltblown or
bonded-carded web composed of synthetic polymer filaments,
such as polypropylene, polyethylene, polyesters or the
like, or a web of natural polymer filaments such as rayon
or cotton. The liner 80 has a pore size that readily
allows the passaqe therethrough of liquids, such as urine
and other body exudates. The liner 80 may be selectively
embossed or perforated with discrete slits or holes
extending therethrough. Optionally, the web or sheet may
be treated with a surfactant to aid in liquid transfer.
One suitable liner material is a wettable spunbonded
polypropylene web produced by the methods and apparatus
described in U.S. patents 4,340,563 issued July 20, 1982,
- 32 -
21211~9
and 4,405,297 issued September 23, 1983, to Appel et al.,
which are incorporated herein by reference.
The illustrated training panel 24 is generally
rectangular and has a longitudinal length dimension
extending in the long dimension of the panel. The length
of the training panel 24 is selected in relation to the
distance between the ends 34 and 35 of the outer cover 30.
In particular, the length of the training panel 24 is
generally at least about 12 centimeters, and particularly
from about 14 to about 16 centimeters, shorter than the
unstretched length of the outer cover 30. This difference
in lengths between the training panel 24 and the outer
cover 30 allows the crotch region 44 of the pant 22 to move
generally independently of the central absorbent portion 71
of the training panel. However, it is not necessary to
allow the crotch region 44 of the pant 22 to move
independently of the central absorbent portion 71 of the
training panel. The training panel 24 may be fastened to
the crotch region 44 of the pant 22 with a hook-and-loop
fastening system as well (not shown). Desirably, the tab
portions 73 of the training panel 24 are positioned
adjacent the waist elastic members 49 when the first and
second fasteners 66 and 76 are attached as shown in Figs. 1
and 4.
In one embodiment, the outer cover 30 is generally
nonstretchable along its longitudinal axis and has a length
of about 47 centimeters. The first fasteners 66 are
separated from one another by about 38 centimeters.
Correspondingly, the training panel 24 has a length of
about 33 centimeters, and the second fasteners 76 are
separated by about 27 centimeters.
35The absorbent garment 20 can be formed in a continuous
process by supplying an outer cover material including
individual portions that define a single outer cover 30
- 33 -
2121149
having opposite longitudinally spaced ends 34 and 35 and
opposite side edges 36 extending between the ends. The
side edges 36 can be shaped by die cutters, water jet
cutters, or other suitable means to define the recessed
areas 38 and ear portions 40. Leg and waist elastic
members 48 and 49 can be stretch bonded to the outer cover
material along the recessed areas 38 and longitudinal ends
34 and 35, respectively.
The protection panel S0 can be constructed by supplying
the cover and moisture barrier material and sandwiching
individual absorbent structures 52 between the cover and
moisture barrier. Prior to bonding the protection panel
components together, the side edges of the moisture barrier
56 can be folded over onto the bodyside surface of the
absorbent structure 52, and the cover 54 can be wrapped
about the absorbent structure and moisture barrier.
Individual protection panels 50 can then be cut from the
continuous supply of cover and moisture barrier materials
and permanently bonded to the inner surface 31 of the outer
cover 30.
In a preferred embodiment, the outer cover 30 and the
components of the protection panel 50 all comprise
thermoplastic materials and may be permanently bonded
together by the application of heat and pressure. For
example, the outer cover 30, absorbent structure 52, cover
54 and moisture barrier 56 may each include or be formed
from polyolefin materials. These components may then be
permanently bonded together by means of a heated and
embossed compression roll, a calender, ultrasonic bonding,
or the like.
Preassembled and shaped first fasteners 66 can be
bonded to the inner surface 31 of the outer cover 30 at the
front and back waist regions 45 and 46. Alternately,
fasteners can also be applied in the crotch region 44 (not
- 34 -
2121149
shown). Thereafter, the ear portions 40 of each side edge
36 can be bonded together by seams 42 so that the outer
cover 30 defines the waist opening 26 and leg openings 28.
Training panels 24 may be separately assembled
beginning with a continuous supply of liner material.
Individual preformed and pre-cut absorbent cores 82
(Fig. 3) can be positioned on the liner material and the
liner folded around the absorbent cores. Portions of the
liner 80 may then be bonded to itself and/or to the
absorbent cores 82. The second fasteners 76 may then be
bonded to the liner 80, and individual training panels 24
cut from the continuous supply of liner material.
The separately formed training panel 24 and pant 22 may
then be releasable attached together by positioning the
training panel in the pant. Each second fastener 76 can be
releasably attached to a corresponding first fastener 66,
as shown in Fig. 4.
In use, the three-dimensional pant 22 may be fitted by
inserting the wearer's feet through the waist opening 26
and respective leg openings 28. The pant 22 is then
grasped near the waist opening 26 and pulled upwardly along
the legs until fit comparably to underwear. The pant 22 is
maintained in place by the elasticity of the outer cover 30
and/or the elastic members 48 and 49.
As noted previously, the pant 22 can be employed as a
toilet training device without using the training panel 24.
This is particularly useful during stages of toilet
training when the child can anticipate and communicate the
need to use the toilet and when the child is likely to be
successful, such as while at home with a parent.
Nevertheless, the protection panel 50 of the pant 22
provides up to about 200 grams, more desirably up to only
about 150 grams, of absorbent capacity. This capacity
- 35 -
21211~9
level is sufficient to accommodate a void, in the event the
child was unable to anticipate needing to use the toilet.
Additional absorbent capacity is unnecessary, however,
because the child, at this stage of training and during the
specified times, can communicate or remedy the situation.
The physical characteristics of the pant 22 are
believed to function to promote toilet training. In
particular, the thinness and flexibility of the
reinforcement region 60 and the breathability of the pant
22 likely represent a marked departure from previous
absorbent products worn by the child. This may lead to a
preference by the child for wearing the pant 22 alone, and
thus provide motivation to be successful. Thus, the pant
22 facilitates both the physical and psychological
transition to the use of underwear.
Of course, the pant 22 can also be used with the
training panel 24 releasably attached to it. This
combination is useful when the child has the ability to
anticipate and communicate the need to use the toilet, but
when the likelihood of success is low. For instance, the
pant 22 and training panel 24 could be used in combination
during playtime, while napping or sleeping, or during
periods of long travel. The training panel 24 has a
saturated retention capacity of at least about 300 grams,
and particularly at least about 350 grams, which is
sufficient capacity to accommodate large or multiple voids.
Further, the training panel 24 desirably does not
incorporate a liquid impermeable layer, such as the
moisture barrier 56 of the protection panel 50, except as
described hereinafter in relation to Figs. 6 and 7. Thus,
the absorbent core 82 of the training panel 24 and the
absorbent structure 52 of the protection panel 50 are in
liquid communication, and potentially the full absorbent
capacity of both the training panel and the protection
panel are available for absorbing large or multiple voids.
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21211~9
The training panel 24 may be formed to be relatively
thick compared to the thin pant 22. For example, the
training panel 24 may have a thickness more than twice or
three times that of the reinforcement region 60. The child
may come to appreciate being able to wear the pant 22
without the training panel 24, thereby encouraging the
child to rapidly progress through the training program.
The training panel 24 may also be designed to generate an
uncomfortable bulky feeling when wet, further encouraging
progression through the training panel.
The hook-and-loop fasteners 66 and 76 provide a
convenient means of releasably attaching the training panel
lS 24 to the pant 22. By locating the relatively-soft loop
patch 67 on the inner surface 31, the pant 22 is not
uncomfortable when used without the training panel 24.
Alternate fasteners, such as snaps, positioning adhesives,
cohesives or the like could also be used (not shown).
Mounting the first fasteners 66 in the waist regions 45 and
46 and the second fasteners 76 in the end portions 70, has
the benefit of minimizing the transference of forces from
the pant 22 to the training panel 24. Because the training
panel 24 is connected to the pant 22 only at its end
portions 70 and is not bonded to the outer cover 30 in the
crotch region 44, the outer cover can move generally
independently of the training panel 24. This design is not
mandatory, however.
An alternate absorbent garment according to the present
invention will now be described with reference to Figs. 5-7
which illustrate components of the garment. Components
similar to those previously described have been given the
same reference numeral. The alternate garment includes a
three-dimensional pant 92 which is shown at an intermediate
stage of assembly and in a flat and stretched condition in
Fig. 5. The pant 92 is formed of an outer cover 30 having
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- 2 1 ~ 9
inner and outer surfaces 31 and 32, ends 34 and 35 and side
edges 36. Each side edge 36 includes a recessed area 38
and ear portions 40. Non-refastenable seams 42 (not shown)
are employed to permanently bond the ear portions 40 of
each side edge 36 together, thus defining a waist opening
26 and leg openings 28 (not shown) of the pant 92. Elastic
members 48 and 49 are desirably bonded to the outer cover
30 to elasticize the waist and leg openings 26 and 28.
The outer cover 30 desirably has a thickness of less
than about 2 millimeters, and more desirably less than
about 1 millimeter, and particularly less than about
0.76 millimeter; a circular bend value of less than about
6.5 grams, and more desirably less than about 5.5 grams;
and an average actual drape value of less than about 2.6,
and more desirably less than about 1.8.
The pant 92 has front and back waist regions 45 and 46
which are separated by a crotch region 44. First fasteners
66 are bonded to the inner surface 31 of the outer cover 30
in the front and back waist regions 45 and 46. Each first
fastener 66 includes a loop patch 67 and optionally a
carrier web 68. The geometric shape of the loop patches 67
may take any form, for example rectangular and measuring
about 4 by about 11 centimeters. Desirably, the long
dimension of each loop patch 67 is aligned with the
transverse axis of the pant 92, as illustrated in Fig. 5.
It is again desirable for the pant 92 to include
substantial portions which are pervious to gases. Provided
the outer cover 30 is formed of a breathable material, more
than about 65 percent, and desirably more than about
80 percent, of the surface area of the pant 92 may be gas
permeable. The percentage is based on the total surface
area of gas permeable portions of the pant 92 when in a
flat, stretched condition as illustrated in Fig. 5. The
pant 92 in this embodiment has substantially no or little
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21 21149
absorbency by itself, and in particular has a saturated
retention capacity of 0 to about 20 grams.
With reference to Figs. 6 and 7, the absorbent garment
also includes a training panel 93 that may be releasably
attached to the pant 92. The training panel 93 has end
portions 70 separated by a central absorbent portion 71.
Each end portion 70 includes a tab portion 73 and an
attachment portion 74 between the tab portion 73 and the
central absorbent portion 71. A second fastener 76 is
bonded to each attachment portion 74. The second fasteners
76 are formed of a hook material that is releasably
engageable with the first fasteners 66.
The illustrated training panel 93 includes a
substantially liquid permeable liner 80, a substantially
liquid impermeable backing sheet 95, and an absorbent core
82 sandwiched between the liner and the backing sheet. The
liner 80 and the backing sheet 95 are desirably longer and
wider than the absorbent core 82. In the illustrated
embodiment, the liner 80 is wrapped around the absorbent
core 82 and bonded to itself and/or the absorbent core.
Longitudinal side edges 96 of the backing sheet 95 are
folded partially over the bodyside surface of the liner 80
and absorbent core 82. Elastic members 97, which may
include a plurality of elastic strands, are operatively
joined to these side edges 96. As suggested in Fig. 6, the
elastic members 97 cause the side edges 96 of the backing
sheet 95 to form raised flaps which retard transverse
movement of solid and liquid waste. Alternately, such
flaps may be separately formed and attached to the training
panel 93 or also include marginal portions of the liner 80
(not shown). The portions of the liner 80 and backing
sheet 95 that extend beyond the longitudinal ends of the
absorbent core 82 define the end portions 70, with the
second fasteners 76 being attached to the backing sheet
side of the training panel 93.
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- 212~l~9
The absorbent core 82 of the training panel 93
desirably has a saturated retention capacity of at least
about 300 grams, and desirably at least about 350 grams,
such as about 450 grams. The absorbent core 82 may
comprise from o to about 95 weight percent high-absorbency
materials, and desirably at least about 20 weight percent
high-absorbency materials.
The backing sheet 95 may comprise a thin, substantially
liquid impermeable web or sheet of plastic film such as
polyethylene, polypropylene, polyvinyl chloride or similar
material. Alternately, the backing sheet 95 may comprise
a nonwoven, fibrous web which has been suitably constructed
and arranged to be substantially liquid impermeable. Still
alternately, the backing sheet may comprise a layered or
laminated material, such as a thermally bonded plastic film
and nonwoven web composite.
The pant 92 and training panel 93 may be constructed in
a continuous process similar to that employed for
constructing the garment 20 of Figs. 1-4. The principle
differences include the absence of a protection panel 50
and the structure of the training panel 93. The training
panels 93 may be separately assembled from continuous
supplies of liner and backing sheet materials. Individual
preformed and pre-cut absorbent cores 82 can be covered or
wrapped in liner material and positioned against the
backing sheet material. A plurality of elastic member 97
may be stretch bonded to the side edges 96 of the backing
sheet 95, and the side edges folded over the bodyside
surface of the absorbent core 82 and the liner 80. The
second fasteners 76 can be bonded to the outer surface of
the backing sheet 95, and individual training panels 93 cut
from the continuous supply of liner and backing sheet
materials.
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21211~9
The described garment including the pant 92 and
detachable training panel 93 provide additional training
options. When the child reaches the stage of not requiring
an absorbent training device during certain times of the
day, such as after waking in the morning or after a nap,
the pant 92 can be used without the training panel 93. In
this case, the pant 92 provides the comfort and appearance
of underwear. The pant 92 of Fig. 5 would be thinner and
more flexible than the pant 22 of Fig. 2 due to the absence
of the protection panel 50. At other times, however, when
success is not guaranteed such as at night, the training
panel 93 can be releasably attached to the pant 92. The
training panel 93, which desirably has a saturated
retention capacity of at least about 300 grams, and
particularly at least about 350 grams, is sufficient to
accommodate any void that may occur. Further, the outer
cover 30 will remain dry because the training panel 93
includes the liquid-impermeable backing sheet 95. Despite
the availability of the training panel 93, however, it is
believed that the child's preference for the thinness,
flexibility and breathability of the pant 92 alone,
although not necessarily expressed in such terms, may
provide further motivation to advance rapidly to requiring
only underwear.
The foregoing detailed description has been for the
purpose of illustration. Thus, a number of modifications
and changes may be made without departing from the spirit
and scope of the present invention. For instance,
alternative or optional features described as part of one
embodiment can be used to yield another embodiment. Also,
materials described in the aforementioned U.S. patents and
applications incorporated by reference herein may be
substituted for those referenced herein. Therefore, the
invention should not be limited by the specific embodiments
described, but only by the claims.
