Note: Descriptions are shown in the official language in which they were submitted.
- 213~2~5
PATENT
GRADATED CONTAINMENT FLAPS IN A DISPOSABLE ABSORBENT
CHILD'S TRAINING PANT
Backaround of the Invention
S ~his invention pertains to dlsposable absorbent artlcles, and more
partlcularly to a chlld's trainlng pant having improved containment
flaps for provid1ng improved containment and absorbency of waste
matter.
~ ,
Currently, disposable absorbent articles find widespread use in the
areas of adult care, infant care, and child care, and have generally
replaced reusable cloth articles. Disposable diapers, for example,
have met a part~cular need and have become very popular. However,
once a child reaches an age of about 15 to 30 months, a parent or
caretaker generally deslres to start tollet tralnlng so the chlld can
become independent of the parent or caretaker. A tralning pant is
used for toilet training when the child has reached an age at which
he or she is ready to graduate to underpants as a replacement for
disposable diapers. A suitable disposable traln~ng pant is an
article having closed sldes so that a child can raise and lower the
pant without requiring any assistance. A child puts the training
pant on by placing his or her feet through the waist and leg openings
, .. ,,. r t , . , ,., ~ "",, ~ ".. , ";,,~",.",, ., ~ .,.,."~" , .
-- 213~5
and pulling the pant upwardly to fit snugly at the crotch. This is
significantly different from the way a diaper is fitted.
Although it is desired by the parent that the child not have an ~
5 accident while wearing a training pant, accidents will occur and, -~ ~-
during those times when the pant cannot be replaced, multiple ~-
accidents can occur that exceed the containment capacity of current
training pants. Thus, there is a need to provide a chlld's train1ng
pant with improved containment.
: '
Summarv of the Invention ;~
In one embodiment of the present invention there is provided a ~ ~
disposable absorbent article having a waste containment assembly ~;; ;including an outer cover and an absorbent composite on the outer
cover. A pair of containment flaps are Joined to the waste
contalnment assembly. Each contalnment flap has a prox1mal edge and
a gradatet distal edge with an apex. The apexes of the distal edges
are in contact w1th each other when the containment flaps are in a
stretched, flat cond1tlon.
In another embodlment of the present lnvent10n there is provided a
dlsposable absorbent article having a waste containment assembly
including side panels, a waist opening, and a pair of leg openings.
A pair of gradated containment flaps are ~oined to the waste
containment assembly.
. - .
In still another embodiment of the present invention there is
provlded a method of maklng a disposable absorbent article comprising
- 2 -
'
- -` 21~2~
the steps of providing a waste containment assembly, supplying a pair
of containment flaps having distal edges with apexes, placing the ~ ~
containment flaps with the waste containment assembly so that $he ~ ; apexes are in contact when stretched flat, and joining the
containment flaps to the waste containment assembly.
Brief DescriDtion of the Drawinas
~he above-mentioned and other features of the present invention and
the manner of attaining them wilt become more apparent, and the
invention itself will be better understood by reference to the
following description of the invent1On, taken in con~unction with the
accompanying drawings, wherein:
Fig. 1 is a top plan view of a diaper having conventional containment
flaps;
Fig. 2 is a cross-sectional view through the crotch area of the
diaper in Fig. 1 with the containment flaps vertically oriented;
Fig. 3 is a perspective view illustrating a step in fitting the
diaper of Fig. 1 on an infant;
Fig. 4 is an elevational, part~ally broken-away view of a training
pant at an intermed1ate point of its being pulled on and having the
same type of containment flaps as the diaper of Fig. l;
- - ` 2 ~ 3 ~
Fig. 5 ;s an eleYational, part;ally broken-away view at the crotch
area typifying an embodiment of the present invention fitted on a
child;
Fig. 6 is a stretched-flat top plan view of the embodiment in Fig. 5
typifying two different configurations of a containment flap in a
flat state;
Fig. 7 is a cross-secttonal view of Fig. 6 taken along line 7-7 and
viewed in the direction of the arrows;
Fig. 8 is a cross-sectional view of Fig. 6 taken along line 8-8 and
viewed in the direction of the arrows with the containment flaps in a
generally uprlght orientation;
Fig. 9 is an exploded, fragmentary view similar to the view of
Fig. 8, but with containment flaps in a flat state; and
Flg. 10 typ~f1es one method of maklng a conta~nment flap of the
present 1nvention.
pefinitions
~ithin the context of this specification, each term or phrase below
will include the following meaning or meanings:
~ ~-
(a) ~SBL~ means a stretch bonded laminate that is at least a ~ -
two-layered composite in which one layer is a gatherable layer
and the other layer is an elast1c layer. The layers are Joined
- 4 -
2~ 3~2~5
together when the elastic layer is in a stretched condition so
that, upon relaxing the layers, the gatherable layer is
gathered.
(b) ~Two-dimensional~ refers to a garment, such as a diaper, that
can be opened and laid in a flat condition without destructively
tearing any structure. This type of garment does not have
continuous leg and waist openings when opened and laid flat, and
requires a fasten~ng device, such as adheslve tapes, to attach
the garment about the wearer.
(c) ~Three-dimensional~ refers to a finished garment similar to
shorts or pants ln that they have continuous leg and waist
open~ngs that are bounded by the material of which the garment
is made. This type of garment can be opened and laid flat only
by destructively tearing it. This type of garment may or may
not have manually tearable seams.
(d) ~ember~ when used ~n the singular can have the dual meaning of
a single element or a plural1ty of elements.
(e) ~Operatively ~olned~ with reference to the attachment of an g
elast1c member to another element means that the elastic member
when attached to or connected to or treated with heat with the
element gives that element elast1c properties. With reference
to the attachment of a non-elast1c member to another element, it
means that the member and element can be attached in any
suitable manner that permits or allows them to perform the
2 1 3 ~ 2 '~
,
intended or described function of the joinder. The joining,
attaching, connecting or the like can be either directly, such
as joining either member directly to an element, or can be
indirectly by means of another member or element disposed ~-
s between the first member and the first element.
''~,.'-'
~f) ~Disposed~, ~disposed onn, ~disposed with", "disposed at",
~disposed near~, and variations thereof are intended to mean -that one element can be 1ntegral or un1tary with another
element, or that one element can be a separate structure ~oined
to or connected to or placed with or placed near another
element. ~ `;
(g) ~Disposable~ includes being disposed of after use, and not
intended to be washed and reused.
.
(h) ~Gradated~, ~gradat10n~, and ~gradating" includes to curve,
slope, deflect, 1ncl1ne, step, or the like, in gradual,
successive stages or degrees.
(1) ~Force~ 1ncludes a phys1cal 1nfluence exerted by one body on
another wh1ch produces acceleration of bod1es that are free to
move and deformat10n of bodies that are not free to move. Force
ls expressed in grams-force. ;~
~ -;
Tension~ includes a uniaxial force tending to cause the
extens~on of a body or the balancing force with1n that body
res1sting the extension. -~
- 6 -
~` 21 3~ r~
(k) "Extensionn, "extend", and "extended" include the change in
length of a material due to stretching. Extension is expressed
in units of length.
(1) ~Elongation~ includes the ratio of the extension of a material
to the length of a material prior to the extension. Elongation
is e~pressed in percent.
0 (m) ~RuptureH 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.
S (n) ~Ultimate elongation~ includes the elongation at the point of
rupture.
(o) ~Elasticity~ and ~elast~c~ include that property of a mater~al
by virtue of whtch it tends to recover 1ts origlnal slze and
shape after removal of a force causing the deformat1On.
~hese definitions are not ~ntended to be limiting, and these terms
may be defined with additional language in the remaining portion of
the specif~cation.
pescriDt~on of a Preferred Embodiment
Referring primarily to Figs. 1-3, a disposable, two-dimensional
garment such as diaper 10 comprises front waist section 12 including
~ ~,
- 7 - ~ ~
. ~. ~ .. , . , .. .. , ~. i .. . .
2 ~ 3 ~ 2 !~ ~
oppositely disposed front ear sections l4, back waist section 16
including adhesive tapes 18 on respective oppositely disposed back
ear sections 20, and crotch section 21 between front waist section 12
and back waist section 16. Diaper 10 further comprises a backsheet
22, a liner 24, and an absorbent pad 26 disposed between backsheet 22
and liner 24. Extensions of backsheet 22 and liner 24 beyond the
longitudinal edges or absorbent sides 38 of absorbent pad 26 form
oppositely disposed side sections 28. Sections 28 individually
include an elastic member 30 adhesively attached between backsheet 22
and liner 24. Disposed with each side section 28 is a containment
flap 32 having elastic members 34 attached thereto. Each containment
flap 32 can be one or more layers of desired material that encloses
elastic members 34 in any suitable manner known in the art. Elastic
members 30 and elastic members 34 are attached in diaper 10 while 1n
an extended condition in order to provide an elastic effect at side
sections 28 and at the distal ends 40 of conta1nment flaps 32,
respect1vely. A more detailed description of the structure of a
typical diaper lO, its process of manufacture, and method of use are
containet in U.S. Pat. No. 4,704,116, wh1ch is ass19ned to the
ass1gnee of the present 1nvent10n.
Referring specifically to Fig. 2, crotch width WD is measured between
oppos1te proximal ends 41 of containment flaps 32 and along a line
transverse, i.e., perpendicular, to the longitudinal direction of
centerline CL. Each flap 32 has a height HD measured between distal
end 40 and proximal end 41~at which flap 32 is joined or adhered to
liner 24. A proximal end is identified as that line or point of
~3~2~
attachment or joining that is closest to its respective distal end.
For example, if a containment flap is attached or adhered by three
parallel lines of adhesive beads, then the proximal end is coincident
with or starts at the adhesive bead closest to the distal end.
Similarly, .f the containment flap is adhered by a ribbon of
adhesive, then the proximal end is coincident with or starts at the
edge of the adhesive ribbon closest to the distal end. Height HD is
much less in dimension than the width WD 1n diaper lO; the
significance of th~s relat~onship w~ll be descr~bed hereafter.
Referring now to Fig. 3, torso 36 of an infant has been placed upon
back waist section 16 of diaper lO in preparation of fitting and
attaching diaper 10 to torso 36. Legs 44 of the infant are spread
far apart so that front section 12 can be easily folded upwardly over
the front of torso 36 in a manner that snugly fits crotch section 21
aga~nst the infant. Thereafter, adhesive tapes 18 are attached to
the outermost surface of respective front ear sections 14. Because
of the wide crotch dimension of diaper 10, wh1ch generally is about 6
to about 8 1nches, the narrow crotch d~mens1On of the infant, which
generally 1s about 2 to about 4 1nches, and the large d~stance
between conta1nment flaps 32, flaps 32 contact lnitially the inner
leg surfaces 52 of the thighs when diaper 10 1s folded upwardly to
fit between the legs. Containment flaps 32, upon contacting the
inner leg surfaces 52 can bend or turn outwardly away from the center
of the diaper. This is not the desired position or shape of flaps 32
for optimum waste containment. In order for containment flaps 32 to
perform optimally, it is important they do not turn or bend
~ :. '
, .. . ~, . ... . .
g
2 1 3 ~ 7 !~ ~
outwardly, since urine can wick along flaps 32, out of the confines
of diaper 10, and along the legs of the wearer.
Turning now to Fig. 4, a disposable, three-dimensional garment such
as training pant 46 is partially fitted, i.e., not pulled fully
upwardly to the waist, on a child's torso 48. Torso 48 includes legs
50 that have respective inner surfaces 52. Training pant 46 can be
made or constructed in a variety of ways, one of which is described
in U.S. Pat. Application Serial No. 043,132 filed on March 25, 1993,
which is incorporated by reference herein. Other training pant
designs are described in U.S. Pat. Nos. 4,938,757, 4,747,846, and
4,940,464
Training pant 46 generally comprises waste containment section 54 and
side panels 56, which may or may not have elastic characterlstics.
Side panels 56, which can be rendered elastic by elastic members 55,
are ultrasonically bonded to form manually tearable, non-refastenable
seams 58. Elast~c ~embers 55 (Fig. 6) can be a layer of elastic
mater~al or an SBL. Tra1n~ng pant 46 ~urther 1ncludes front end
portion 49, back end portion 5l, and crotch area 53 between end
port1cns 49 and 51. Waste containment section 54 includes the
containment n aps 32 earlier described with reference to diaper 10, -~
backsheet 22, liner 24, absorbent pad 26, and side sections 28.
Containment flaps 32 have respective distal ends 40.
Several differences, both structural and functional, exist between a
diaper, su.h as diaper 10, and a training pant, such as training pant
- 10 - ''
- ~13Q2~
46. One of the differences is in the method of fitting a diaper on a
baby and a training pant on a child. As described above, diaper l0,
which is a two-dimensional article, is fitted on an infant by placing
the infant on back waist section 16 ( Fig. 3) and then folding front
waist section 12 upwardly to be joined with back waist section 16 by
adhesive tapes 18. In contrast, training pant 46, which is a
three-dimensional article, is not fitted in the same manner.
Training pant 46 is fitted by inserting the child's feet through
waist opening 60 and respective leg openings 62 (Fig. 4J, then
grasping training pant 46 near waist opening 60, and pulling upwardly
along the legs until crotch area 53 is snugly fit against the crotch. ~-
During the travel of training pant 46 upwardly along legs 50 and - `
their inner surfaces 52, distal ends 40 of flaps 32 begin to turn or
bend outwardly away from each other and then bend downwardly due to
15 the sliding contact or friction between legs 50 and flaps 32. This `
position of flaps 32 is undesirable since urine can wick or transfer
along and over contatnment flaps 32 and beyond side sections 28,
thereby soiling the child's clothes.
, ~,."
20 It has been discovQred that a mechanism causing this outward turning ~
or bend1ng of containment flaps 32 as they move upwardly along inner ~ -
~ . ....:.. . -
leg surfaces 52 is the relatively very short height dimension HD
(Fig. 2) of containment flaps 32 in relation to width dimension WD,
and the elastic1ty and tension provided by the flap elastics.
Referring now to Fig. 6, another disposable, three-dimensional
garment such as training pant 47 is shown with two configurations or
designs of gradated containment flaps 64, 64' of the present
... ...
- 11 -
., . ~
': :
2 ~ ~ ~ 2 ~
invention operatively joined therewith. Hereafter, the description
will refer at ti~es collectively to flaps 64, 64', but it should be
understood that these two different configurations or designs
generally would not be used together. Rather, reference to flaps 64,
64' collectively is tG be interpreted and understood that the flap
configuration or design can be, in one example, a pair of containment
flaps 64 or, in another example, a pair of containment flaps 64'.
Waste containment assembly 61 includes liner 66, absorbent compos~te
70, and outer cover 88. Alternatively, waste conta~nment assembly 61
can include absorbent composite 70 and outer cover 88 without liner
66. ~aste conta~nment assembly 61 also can include structures such ~ ~
as a surge management or other type of layer (not shown). Training ~ ~;
pant 47 also comprises side panels 56 joined by seams 58 to form
waist opening 60 and leg openings 62 (Fig. 5). Side panels 56 can be
extensions of outer cover 88 and/or liner 66, or separate elements,
and may be elasticized by, for example, elastic members 55.
Conta~nment flap 64 is ~llustrated on the left side of centerline C/L
1n F~g. 6t and contalnment flap 64' is illustrated on the right s1de
of centerl1nQ C/L. Conta1nmQnt flap 64', on the right side of
centerl1ne C/L of Fig. 6, is similar in construction to containment
n ap 64 except that d1stal edge 65' has a different gradation than
that of distal edge 65. At front end portion 71', distal edge 65' is
generally parallel to proximal edge 63' or centerline C/L.
Sim11arly, back end portion 73' of containment flap 64' is generally
parallel to proximal edge 63' or centerline C/L.
'~ ~ . ,:
- 12 -
2~ 332~
Training pant 47 has each containment flap 64, 64' attached to waste
containment assembly 61, and although flaps 64, 64' can be attached
to outer cover 88 or any other structure of training pant 47, they
are desirably attached to the top surface 68 of liner 66. Each
containment flap 64, 64' has proximal edge 63, 63' adhesively
attached to top surface 68. Flap elastics 67, 67' are integrated,
while ~n an extended condition, at respective gradated distal edges
65, 65' of flaps 64, 64'. Elastics 67, 67' can be attached in any
suitable manner known in the art so that ~ntermediate port~ons of
flaps 64, 64' are gathered. Pant 47 further includes front end
portion 49, back end portion 51, pant back edge 72, and pant front
edge 74. ~he distance between edges 72, 74 define the length of
training pant 47.
In Fig. 6, training pant 47 is in a flat state prior to being folded
to form seams 58 (Fig. 5), which result in the flnished tralning pant
47 havlng wa1st open1ng 60 and leg openings 62. The term ~f1nished
training pant' means a three-dimensional training pant that can be
used for ~ts intended purpose. Fig. 8 shows the generally upr19ht
poslt10n containment flaps 64, 64' assume when pant 47 1s be1ng
pulled on and worn. It is understood that, although waste
containment assembly 61 is illustrated here as being flat for ease of
understand1ng, waste contalnment assembly 61 in fact assumes a bowed-
or bucket like shape in the crotch as illustrated in Fig. 5.
Referring to Figs. 6, 7, and 8, each containment flap 64, 64' can
extend the longitudinal length of train1ng pant 47 between back edge ~-
72 and front edge 74, and is attached to liner 66 at proximal edges
63, 63'. Each containment flap 64, 64' has a front end portion 71,
- 13 -
2 ~ 3 ~
71' and a back end portion 73, 73' adhered to liner 66 such that
corresponding end portions of distal edges 65, 65' are adhered to
liner 66. Front end portions 71, 71' and back end portions 73, 73'
can be adhered or otherwise attached in any suitable manner known in
the art. One specific method of attachment is described in U.S.
Patent Application Serial No. 054,508 filed April 26, 1993 and
assigned to the assignee of this application.
Referring to Fig. 6, a description of conta1nment flap 64, which is
the containment flap on the left side of the centerline C/L, will be
made. Containment flap 64 extends the full length of training pant
47 between front edge 74 and back edge 72. Containment flap 64
comprises a generally straight proximal,edge 63 that is generally
parallel to the centerline C/L of the training pant 47 and is
desirably attached along its length to liner 66 by means of flap seam
adhesive 124 (Fig. 9). Containment flap 64 further includes a
gradated d1stal edge 65 having an apex 75 and a flap elastic 67
attached therein while in an extended state, so that upon relaxing
flap elast1c 67, elast1c 67 will gather distal edge 65. F1g. 6
illustrates containment flap 64 in a flat state to show that distal
edge 65 is gradated in a convex-manner relative to the centerline.
Gradated distal edge 65 can be formed or configured in any
curvilinear or non-curvilinear fashion so as to adjust the
longitudinal location of apex 75 relative to front edge 74 and back
edge 72. For example, a girl's training pant 47 can have apex 75
located generally a~ the widway point between front edge 74 and back
edge 72. For boys, apex 75 can be located closer to front edge 74.
- 14 -
- 213~2~S
The gradation of flaps 64 can be accomplished in at least two ways.
A first way is to cut the material, of which a flap 64 is made, to
form distal edge 65 with the desired gradation, and then attach flap
elastic 67 to distal edge 65. A second way is to cut the material in
a generally rectangular form, and then attach flap elast~c 67 in a
gradated manner to provide a gradation to the tension provided by the -
attached flap elastic 67.
Unique to the present invention is that apex 75 can contact or
overlap the centerline C/L and thus contact or overlap with a
corresponding apex 75 of a similar containment flap 64 attached to
the right side of centerline C/L, when the flaps 64 are stretched
flat as illustrated in Fig. 6. If apexes 75 overlap, it is desired
that they overlap less than about 1 centimeter. In accordance with
the present ~nvention, flap elastics 67 have a tension sufflcient to
gather or draw the corresponding contacting or overlapping apexes 75
apart so that they do not contact or overlap in use.
.
As described, each dlstal edge 65, 65' has been formed or conf~gured
to be gradated such that the front end portions 71, 71' and back end
portions 73, 73' of flaps 64, 64' and/or flap elastlcs 67, 67'
diverge or curve away from centerline C/L as illustrated in Fig. 6. ~-- ;
Each containment flap 64, 64' has a flap height HP (Fig. 8) that is
measured between apex 75, 75' and proximal edge 63, 63' along a line
25 transverse, i.e., perpendicular, to centerline C/L. Each proximal ~-
edge 63, 63' is identified as that line or point of attachment or
joining that is closest to its respective distal edge 65, 65'.
' ~,
- 15 -
.. . .
" . - . ., , . .. ., ,.- , , ., . ,..... , .-. ;.. , , .. ~, . . .
213~2~:~
As mentioned above, apexes 75, 75' can contact or overlap as
illustrated in Fig. 6, and with proper selection of tension on flap
elastics 67, 67', distal edges 65, 65' are gathered and drawn away
from each other so as not to overlap when training pant 47 is in use.
S This permits a pair of containment flaps 64, 64' to assume a higher
or taller upright orientation (Figs. 5 and 8) to assist in containing
urine and liquid bowel movements until absorbent composite 70 can
fully absorb these wastes. This is important since absorbent
compas1te 70 of training pant 47 has a w~dth that ls between about 2
inches to about 4 inches ln crotch area 53, as compared to a width of
about 6 to about 8 inches for a typical diaper absorbent.
In Fig. 8, each containment flap 64, 64' has a flap height HP
measured between apexes 75, 75' of respective distal edges 65, 65'
and respective proximal edges 63, 63', and a flap width WP measured
between proximal edges 63, 63' along a line perpend1cular to the
longitudinal centerline C/L of training pant 47. Flap height HP has
a range between about 25 mm to about 76 mm, and a desired range of
about 31 mm to about 51 mm. Flap width WP has a range between about
S0 mm to about 102 mm, and a des~red range of about 76 mm to about
90 mm. Overall product length is measured between back edge 72 and
front edge 74, and the length is between about 432 mm to about
1,067 m~.
Continuing to refer to Figs. 6-8, flap elastics 67, 67', which may be
a single ribbon of elastic material or a plurality of strands of
elastic material, have a predetermined elongation and tension in
order to assist in properly positioning containment flaps 64, 64',
- 16 -
r
2 1 ~ 5
and especially apexes 75, 75', at the crotch of the wearer. In order
for containment flaps 64, 64' to assume a desired upright
orientation, as shown in Fig. 8, to contact and seal against inner
surfaces 52 of legs 50 (Fig. 5), each flap elastic 67, 67' desirably
has a minimum of about 90 percent elongation when incorporated into
flap 64, 64' of a finished training pant 47. A desired range of
elongation is between about 90 percent to about 150 percent stretch. ;~
A desired tension range for each flap elastic 67, 67' is between
about 90 grams-force to about 200 grams-force at 90 percent of
ultimate elongation.
Flap height HP, flap width ~P, and the elastic characteristics of
f~ap elastics 67, 67' determine the anatomical location of distal
edges 65, 65' and well 86 at the crotch of the wearer. If the
elastic characteristics of flap elastics 67, 67' are not within the
desired ranges, there ~s inconsistency in proper or correct flap
positioning at the crotch of the wearer. For example, distal edges
65, 65' can shift too close together such that flaps 64, 64' form a
tent over absorbent compos1te 70, thereby prevent~ng absorptlon of
29 ur1ne or other waste matter. ~ ~
:.
The present invention provides consistent containment flap
positioning within the crotch of the wearer as shown in Fig. 5.
Additionally, because of the relatively large dimension of flap
height HP, when absorbent composite 70 becomes heavier due to the
absorption of waste matter and begins to sag downwardly, containment -~
flaps 64, 64' will extend to maintain their seal, thereby containing
- 17 -
2~3~2~;~
liquid and other waste matter in well 86 until absorbent composite 70
has time to fully absorb the waste matter.
~ ~'
Anotner unique feature of the present invention is a containment flap
5 softness quality measured as the average actual drape value. The ~-
materials of which containment flaps 64 are made desirably have an
average actual drape value less than about 1.83. This softness
reduces red marking, irritation, and other effects at the sensitive
crotch area. The test procedure for determ1ning the average actual
drape value 1s ASTM Standard D-1388 entltled ~Stlffness of Fabrlcs~
and Method 5206 Federal Test Methods Standard #19lA. Equipment used
was a Cantilever Bend1ng Tester, Model 79-10 ava~lable from Testing
Machines Inc., 400 Bayview Avenue, Amityville, New York. l170l; a
30~ x 30~ precis1On paper cutter with sample holder; and a cutting
press with l/2~ x 6~ rectangular cutting d~e. In performing this
test, 5 products were selected and, prior to perform1ng the test,
each of the conta1nment flaps were 1dentified as the "left~ and
~r1ght~ conta~nment flap. The conta1nment flaps were then removed
from the 5 products to g1ve a total of 10 conta1nment flaps, wh1ch
were cut 1nto str1ps hav1ng a length of 6 1nches and a wldth of l/2
1nch. ~hese str1ps d1d not 1nclude the flap elast1cs. Each str1p
was moved at a rate of 4 3/4 1nches per minute in a direction
parallel to its long dimens1On, so that its lead1ng edge pro~ected
from the edge of a horizontal surface. The length of the overhang
was measured when the t1p of the strip depressed under 1ts own we19ht
to a point where the line ~oining the tip to the edge of the platform
made an angle of 41.5 degrees w~th the horizontal. Once a strip
depressed to the angle of 41.5 degrees, its length was measured, and
- 18 -
.- . ,, , .. ~ ., ,., ., .,, . , . .. ;. * ., .. . ,.", .. .. .. .......
``,,- - ,p:
213~2~;)
the actual drape value was calculated by dividing the measured length
in inches by 2. After performing this test on each of the l0 flaps
from the 5 products, the 10 actual drape values were averaged to
determine the average actual drape value.
~ ~
In use, the child will position his or her feet through waist opening ;~ ~-
60 and leg openings 62 and then grasp pant 47 and pull upwardly along
legs 50. As pant 47 moves upwardly, there is an increase in the
sliding contact pressure or frlct~on between containment flaps 64,
10 64' and inner surfaces 52 of legs 50. However, because of the
above-described features of the containment flaps of the present
invention, flaps 64, 64' w~ll maintain their upright orientation ~ ~
while pant 47 is pulled snugly into the ch11d's crotch. Containment ~ ;
flaps 64, 64' will then be properly posltioned, as shown in Fig. 5,
in order to form well 86. As absorbent composite 70 becomes heavier
due to lts absorbing waste, absorbent composite 70 will tend to sag
or move downwardly, away from the crotch. However, containment flaps
64, 64' wlll be able to extend in he19ht, as shown in Fig. S, to
ma1ntaln ~he seal agalnst the crotch.
Fig. 9 shows outer cover 88, which desirably is a two-layer composite
1nclud1ng liquid permeable nonwoven layer 90 and liquid impermeable
f~lm layer 92 suitably ~olned together by adhesive 94. Outer cover
88 can also be a single layer compris~ng film layer 92, nonwoven
layer 951 or any other suitable liquid permeable or liquid
imper~eable material. Carrier sheet 98 has 3 strands of leg elastic
96 adhesively attached thereto, while in a stretched condition, in ~ -~
any su~table manner known in the art. Carrier sheet 98, with leg
,,, ' "
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''13~2'~;~
elastics 96 attached thereto in a stretched condition, is adhesively
attached to fi~m layer 92 by leg adhesive 100. Absorbent composite
70 comprises a mixture of cellulosic pulp fluff and superabsorbent
materials that are wrapped in tissue wrap 102 to provide integrity to : .
the fluff/superabsorbent material mixture. Absorbent composite 70
can comprise only cellulosic pulp fluff, only superabsorbent
materials, or a combination of both with other absorbent or
non-absorbent materials. Absorbent composite 70 ~s adhes~vely
attached to f11m layer 92 by absorbent construction adhes~ve 104.
Liner 66 is adhesively attached to absorbent compos~te 70 and fllm
layer 92 by liner adhesive 108, and by adhesive bead 110 to carrier
sheet 98.
Referring specifically to a single containment flap 64, flap elast~cs
67, which are 3 strands of elastic material, are adhesively attached,
while in an extended condition, to nonwoven layer 112 by elastic
adhesive 114. Flap adhesive 116 is applied in any suitable manner to
nonwoven layer 112, and f11m layer 118 ~s attached to nonwoven layer
112 by flap adhesive 116. Nonwoven layer 112, at ~ts end near flap
elast1cs 67, 1s folded over flap elastics 67 and film layer 118, and
attached to film layer 118 by flap fold adhesive 120. Flap 64 is
then attached to liner 66 by means of flap seam adhesive 124, which
runs the full length of containment flap 64. The end portions of
flap 64 adjacent back edge 72 and front edge 74 are adhered to l~ner
66 by flap end adhesive 126 to provide attachment of that
corresponding portion of distal edge 65 and flap elastic 67, thereby
anchoring elastic 67 in place so that its remaining portion that is
unattached to liner 66 gathers flap 64.
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.: X ; ` ~ s ~ :~`3 - ` .,
13~2~5
The materials of which training pant 47 are made, including
co~tainment flaps 64, 64', can be any materials specifically desired
by the user or manufacturer. Numerous examples of materials used in
5 constructing training pant 47 are described in the aforementioned ;
U.S. patents and patent applications.
~ .'';
In one embodiment, elastic members 55 can be a stretch bonded
laminate comprising an inner layer of a prestretched elastic
meltblown core sandwiched between and attached to a pair of spunbond
polypropylene nonwoven webs having a basis weight of about 0.4 oz/yd
(13.6 gsm). Elastic wembers 55 can be incorporated with or into ;
training pant 47 in any suitable manner, such as those described in ~ :15 the aforement1cned U.S. patents and patent applications. Suitable ~
elastic polymers can be purchased from the Shell Chemical Company of `
Houston, ~exas under the trade name Kraton. Suitable adhesives can
be obtained from Findley Adheslves, Inc. of Wauwatosa, Wisconsin.
,,
Flap elast~cs 67, 67' ~n containment flaps 64, 64' are strands of
Lycra ~151 940 decitex elastic which can be obtained from E. I. du
Pont de Nemours Co., ~ilmington, Oelaware. Nonwoven layer 112 is a
spunbond polypropylene nonwoven web having a basis weight of about
0.7 oz/yd2 (23.7 gsm), and film layer 118 is a 0.6 mil polyethylene
film which can be obtained from Filmtech Corp. of Easton,
Pennsylvania. It is desired that nonwoven layer 112 be liquid
. ..
permeable, and that film layer 118 be liquid impermeable. Film layer -~
118 may also be vapor permeable, liquid impermeable, and film layer
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213~2~5
118 may have portions thereof that are liquid impermeable with the
other remaining portions being liquid permeable.
Bodyside liner 66 is liquid permeable and is a spunbonded
polypropylene nonwoven web having a basis weight of about 0.75 oz/yd2
(25.4 gsm). Outer cover nonwoven layer 90 is a spunbonded
polypropylene nonwaven web having a basis weight of about 0.8 oz/yd2
(27.2 gsm), and outer cover film layer 92 ~s a 1.0 mil polyethylene
film obta~nable from Edison Plastlcs Co. of South Pla~nfleld, New
Jersey.
Carr1er sheet 98 ~s a 0.75 mil polypropylene film which is liquid
~mpermeable and can be obta~ned from Edison Plastics Co. of
South Plainf1eld, New Jersey, and leg elast~cs 96 are 3 strands of
bycra T151 940 dec1tex elast1c which can be obta~ned from E. I. du
Pont de Nemours, ~llm1ngton, Delaware.
F19. 10 typ1f~es one way of mak1ng conta1nment flaps 64. A
cont~nuously movlng web 78 has parallel flap elastlcs 67 stretched
and selecttvely attached thereto 1n a des1red gradated conf~guratton
or des19n. After flap elast~cs 67 have been attached, web 78 can be
cut between flap elast~cs 67 along cut~line 128, and transversely cut
along cut-l~nes 130 to form separate gradated conta1nment flaps 64.
~hile thls invent~on has been described as having a preferred
embodlment, it w1ll be understood that it 1s capable of further
mod1f~cat~ons. This appl1cat~on is thereby 1ntended to cover any - -
var1ations, equ~valents, uses, or adaptat~ons of the ~nvention
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21302~5
following the general principles thereof, and including such
departures from the present disclosure as come within known or ;~;
customary practice in the art to which this invention pertains and -~:
fall within the limits of the appended claims. ` .:.
~"' ' ~'."''
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