Note: Descriptions are shown in the official language in which they were submitted.
CA 02240032 l998-07-02
~,
ABSORBENT ARTICLE WITH FLIP DOWN FASTENERS
Field of the Invention
The present invention relates to garment articles. More particularly, the present
invention relates to absorbent articles, especially disposable absorbent articles,
which have more secure fastening with improved fit and performance.
Background of the Invention
Conventional garment articles, such as disposable diapers and othe~ disposable
absorbent articles, have typically employed adhesive or mechanical fasteners which
attach appointed waistband sections of the articles around a wearer. In addition,
various configurations of waist elastics, leg elastics, elasticized liners, and elasticized
outercovers have been employed on garment articles to help produce and maintain
the fit of the articles about the body contours of the wearer.
Conventional garment articles, such as those described above, have not provided
desired levels of reliable fit, and have been susceptible to excessive sagging and
drooping during the period of wearing. The garment structures have not adequately
maintained the desired levels of fit and comfort, and where the garments are
configured as absorbent articles, the articles have been susceptible to excessive
leakage of liquids and other waste materials. As a result, there has been a
continued need for improved garments having more consistent fit and greater
resistance to sagging and drooping.
- 1 -
CA 02240032 l998-07-02
Brief DescriPtion of the Invention
Generally stated, the present invention provides a distinctive article which includes a
backsheet layer, a liquid permeable topsheet layer connected in superposed relation
s with the backsheet layer, and an absorbent structure sandwiched between the
backsheet and topsheet layers. A flip fastener is joined to each of a pair of laterally
opposed ends of a first waistband portion of the article. Each flip fastener includes a
longitudinally extending flip tab section which is joined to a longitudinally outboard
edge region of the first waistband portion to project longitudinally beyond and
10 outboard from the first waistband portion. Each flip tab section has a first fastening
component operatively joined to an appointed fastening surface of the flip tab
section, and has an appointed folding line which extends along a lateral direction of
the article. A first landing zone component is joined to a selected su,~face of a
second waistband portion of the article. The first landing zone component is
configured to provide a fastening attachment to each first fastening component when
each flip tab is operatively pivoted about its folding line to engage the first landing
zone component.
By incorporating its various aspects, the article of present invention can provide
more reliable and more consistent fit about the wearer with greater resistance to
sagging and drooping. The desired fit can be better maintained even when the
wearer is highly active. Where the garment is an absorbent article, the improvedresistance to drooping can reduce gapping between the garment and wearer, and
can reduce the leakage of liquid or semi-liquid waste materials.
Brief DescriDtion of the Drawings
The present invention will be more fully understood and further advantages will
become apparent when reference is made to the following detailed description of the
invention and the drawings, in which:
Fig. 1 representatively shows a top view of the outward surfaces of a diaper article of
the invention which incorporates the flip fastener;
CA 02240032 l998-07-02
Fig. 2 representatively shows a plan view of the inward, bodyside surfaces of the
diaper article illustrated in Fig. 1;
Fig. 3 representatively shows a schematic, longitudinal cross-sectional view of the
article illustrated in Fig. 1;
Fig. 4 representatively shows a perspective view of an article of the invention which
has been arranged for placement on a wearer;
10 Fig. 5 representatively shows another perspective view of the article of Fig. 4
wherein the back waistband section of the article has been positioned about the
wearer;
Fig. 6 representatively shows a further perspective view of the article of Fig. 5
wherein the front waistband section of the article has been aligned and mated with
the back waistband section;
Fig. 7 representatively shows a further perspective view of the article of Fig. 6
wherein the flip tab sections of the flip fasteners have been folded to operablyengage the appointed, primary landing zone region on the outer surface of the front
waistband section;
Fig. 8 representatively shows a top, plan view of the outward surfaces of a diaper
article of the invention which incorporates another arrangement of the flip fastener;
Fig. 9 representatively shows a plan view of the inward, bodyside surfaces of the
article of Fig. 8;
Fig. 10 representatively shows a schematic, longitudinal cross-sectional view of the
article illustrated in Fig. 8;
Fig. 11 representatively shows a perspective view of the article of Fig. 8 which has
been arranged for placement on a wearer;
CA 02240032 l998-07-02
Fig. 12 representatively shows a perspective view of the article of Fig. 11 wherein
the front waistband section of the article has been positioned about the wearer;
Fig. 13 representatively shows a further perspective view of the article of Fig. 12
wherein the back waistband section of the article has been aligned and mated with
the front waistband section; and
Fig. 14 representatively shows a further perspective view of the article of Fig. 13
wherein the flip tab sections of the flip fasteners have been folded to operably10 engage the appointed, primary landing zone region on the inner bodyside surface of
the front waistband section.
Detailed Description of the invention
15 The various aspects and embodiments of the invention will be described in thecontext of a disposable absorbent article, such as a disposable diaper. It is,
however, readily apparent that the present invention could also be employed withother articles, such as caps, gowns, shoe covers, feminine care articles, children's
training pants, incontinence garments and the like. Typically, the disposable articles
20 are intended for limited use and are not intended to be laundered or otherwise
cleaned for reuse. A disposable diaper, for example, is discarded after it has
become soiled by the wearer.
With reference to Figs. 1, 2 and 3, an article, such as the representatively shown
25 absorbent article of diaper 10, has a length-wise longitudinal direction 26, a
transverse lateral direction 24, and a first waistband portion 12 at the back or rear of
the diaper. The first waistband portion has an inward, bodyside surface 90 and an
outward surface 92 thereof. A second, front waistband portion 14 is positioned
longitudinally opposite of the first waistband portion 12 and has an inward, bodyside
30 surface 90 and an outward surface 92 thereof. An intermediate, crotch portion 16
interconnects the first and second waistband portion 12 and 14, respectively. The
article comprises a backsheet layer 30 which has an outward surface and an
opposed, inward or bodyside surface thereof. As representatively shown, the
outward surface of the backsheet layer may provide the outward surface 92 of the35 article. A substantially liquid permeable topsheet layer 28 is connected in a
CA 02240032 l998-07-02
superposed relation with the backsheet layer 30, and an absorbent structure 32 is
sandwiched between the backsheet and topsheet layers. A flip fastener 36 is joined
to each of a pair of laterally opposed end regions 86 of the first waistband portion 12,
and each flip fastener 36 includes a longitudinally extending flip tab section 60 which
iS joined to a longitudinally outboard edge region 82 of the first waistband portion 12
to project longitudinally beyond and outboard from the first waistband portion 12.
The flip tab section 60 has a distal end region 58, an inward surface 56, and anoutward surface 54. A first fastening component is operatively joined to an
appointed fastening surface of the flip tab section 60, and the flip fastener has an
10 appointed folding line 59 which extends along the lateral direction 24 of the article. A
first landing zone component, such as a first landing zone patch 50, is joined to a
selected surface, such as an inward surface 90 or the outward surface 92, of thesecond waistband portion 14. The landing zone component is configured to providea fastening attachment to each first fastening component 52 when each flip tab
section 60 is operatively pivoted about its folding line 59 to thereby engage the first
landing zone component.
In a particular aspect of the invention, the appointed fastening surface of at least one
of the flip tab sections 60 is the outward surface 54 of the flip tab section. With this
configuration, the first landing zone component can be operatively joined with the
outward surface 92 of the second waistband portion 14.
Another aspect of the invention can be configured with the appointed fastening
surface of at least one of the flip tab sections 60 provided by the inward surface 56 of
the flip tab section. With this configuration, the first landing zone component can be
operatively joined with the inward surface 90 of the second waistband portion 14.
In a desired aspect of the invention, the first waistband portion 12 of the article can
include at least one separately provided, base panel section 80 which is joined to
extend laterally outboard at a lateral side edge portion 86 of a first, back waistband
section 12 of the article to provide a carrier member. In the representatively shown
arrangements, the base panel section 80 is assembled to extend from a laterally
terminal edge of the backsheet layer 30. Each base panel section 80 has an
appointed inward, bodyside surface 106, an appointed outward side surface 108,
and a laterally extending, longitudinally outboard edge region 110. The longitudinally
CA 02240032 1998-07-02
extending flip tab section 60 is operatively joined to the longitudinally outboard edge
region 110 of the base panel section 80 to project longitudinally outboard from the
base panel section, and thereby project longitudinally outboard from and beyond the
longitudinally terminal edge of the first waistband portion 12.
s
The various aspects (individually and in combination) of the present invention can
advantageously help to better maintain the desired fit around the wearer. For
example, the aspects of the invention can help reduce the sagging and drooping of
the crotch region of the garment, and can help reduce roll-over and drooping at the
10 waist region. When incorporated into an absorbent article, the various aspects of the
invention can improve fit and appearance, and can reduce undesired gapping and
leakage.
A desired garment article of the invention can, for example, be the representatively
shown disposable diaper 10. The diaper can include a backsheet layer 30, a liquid
permeable topsheet layer 28 connected and integrated with the backsheet layer, and
an absorbent structure, such as a structure which includes absorbent body 32. The
absorbent structure is sandwiched between the backsheet and topsheet layers, andis operably held therebetween. A fastening system, such as a system including flip
fasteners 36, is configured to join together the front and back waistband portions 14
and 12 to encircle the wearer's body and hold the diaper secure on the wearer
during use.
As representatively shown, the front waistband section 14 of the diaper 10 has alaterally opposed, front pair of side edge regions 88, and the rear waistband section
12 has a laterally opposed, rear pair of side edge regions 86. The intermediate
section 16 interconnects the front and rear waistband section and provides a diaper
crotch region which is typically positioned between the legs of the wearer. The
article has an appointed fastener landing zone 50 which is disposed on the outward
surface 92 of the article. In the example shown in Fig. 1, for example, the landing
zone 50 is disposed on the outward surface of the backsheet layer 30. The liquidpermeable topsheet layer 28 is superposed in facing relation with the backsheet
layer 30, and the absorbent body 32 is operably connected and affixed between the
backsheet layer 30 and topsheet layer 28.
CA 02240032 1998-07-02
Figs. 1 and 2 show typical plan views of the representative disposable diaper 10 in
its generally flat-out, uncontracted state (i.e., with substantially all elastic induced
gathering and contraction removed). Portions of the structure are partially cut away
to more clearly show the interior construction of the diaper article, and the bodyside
surface of the diaper which contacts the wearer is facing the viewer. The outer
edges of the diaper define a periphery with longitudinally extending side edge
margins 20 and laterally extending end edge margins 22. The side edges define leg
openings for the diaper, and optionally, are curvilinear and contoured. The end
edges are shown as straight, but optionally, may be curvilinear.
With regard to the designated surfaces of the article, the various inward surfaces are
configured to face toward the body of the wearer when the article is placed about the
wearer. The outward surface of the article is configured to face awa~ from the
wearer's body when the article is placed about the wearer. With regard to the flip
fasteners, particularly the flip tab section 60, the inward surface 56 and the outward
surface 54 are detemmined when the flip tab section is in its substantially flat-out,
unfolded condition.
The diaper 10 typically includes a porous, liquid permeable topsheet 28; a
substantially liquid imperrneable backsheet 30; an absorbent structure 32 positioned
and connected between the topsheet and backsheet; a surge management
- portion 46 located adjacent the absorbent structure; and a system of elastomeric
gathering member;" such as a system including leg elastics 34 and waist elastics 42.
The surge management portion is positioned in a liquid communication with a
retention portion of the absorbent structure, and the topsheet 28, backsheet 30,absorbent structure 32, surge management portion 46 and elastic members 34
and 42 may be assembled together into a variety of well-known diaper
configurations. The diaper can additionally include a system of containment flaps 62,
and a system of ear region members 32 or side panels which may be elasticized orotherwise elastomeric
Examples of articles which include elasticize ;d side panels and selectively configured
fastener tabs are described in co-pending U.S. applications.
Various techniques for forming the desired fastening
CA 02240032 1998-07-02
~ I .
systems are described in U.S. Patent No. 5,399,219 of T. Roessler et al., entitled
METHOD FOR MAKING A FASTENING SYSTEM FOR A DYNAMIC Fll~ING
DIAPER and issued March 21, 1995 (attorney docket No. 11,186?, in U.S. Patent
Application Serial No. 286,086 of D. Fries, entitled A PROCESS FOR ASSEMBLING
ELASTICIZED EAR PORTIONS and filed August 3,1994 (attomey docket No.
11,169) which issued as U.S. Patent No. 5,540,796; and in U.S. Patent Application
Serial No. 08/415,383 of D. Fries, entitled AN ASSEMBLY PROCESS FOR A
lAMINATED TAPE and filed April 3, 1995 (attorney docket No. 11,950) which issuedas U.S. Patent No. 5,595,618.
Diaper 10 generally defines the longitudinally extending length directlon 26 and the
laterally extending width direction 24, as representatively shown in Fig.1. The
diaper may have any desired shape, such as rectangular, I-shaped, a generally
hourglass shape, or a T-shape With the T-shape, the crossbar of the ~T may
comprise the front waistband portion of the diaper, or may alternatively comprise the
rear waistband portion of the diaper
The topsheet 28 and backsheet 30 may be generally coextensive, and may have
length and width dimensions which are generally larger than and extend beyond the
corresponding dimensions of the absorbent structure 32 to provide for the
corresponding side margins 20 and end margins 22. Optionally, the topshe~t and
backsheet layers may not be coextensive. The topsheet 28 is operatively associated
with and superimposed on backsheet 30, thereby defining the periphery of the
diaper. The waistband regions comprise those portions of the diaper, which when
worn, wholly or partially cover or encircle the waist or mid-lower torso of the wearer
The intermediate, crotch region 16 lies between and interconnects the waistband
regions 14 and 12, and comprises that portion of the diaper which, when worn, ispositioned between the legs of the wearer and covers the lower torso of the wearer
Thus, the intermediate crotch region 16 is an area where repeated fluid surge
typically occur in the diaper or other disposable absorbent article
Backsheet 30 can typically be located along an outer-side surface of the absorbent
~ody 32 and may be composed of a liquid permeable material, but desirably
CA 02240032 1998-07-02
comprises a material which is configured to be substantially impermeable to iiquids.
For example, a typical backsheet can be manufactured from a thin plastic film, or
other flexible, substantially liquid-impermeable material. As used in the present
specification, the term "flexible" refers to materials which are compliant and which
will readily conform to the general shape and contours of the wearer's body.
Backsheet 30 prevents the exudates contained in absorbent body 32 from wetting
articles, such as bedsheets and overgarments, which contact diaper-10. In particular
embodiments of the invention, backsheet 30 can include a film, such as a
polyethylene film, having a thickness of from about 0.012 millimeters (0.5 mil) to
about 0.051 millimeters (2.0 mils). For example, the backsheet film can have a
thickness of about 1.25 mil.
Alternative constructions of the backsheet may comprise a woven or'nonwoven
fibrous web layer which has been totally or partially constructed or treated to impart
the desired levels of liquid impermeability to selected regions that are adjacent or
proximate the absorbent body. For example, the backsheet may include a
gas-permeable, nonwoven fabric layer laminated to a polymer film layer which mayor may not be gas-permeable. Other examples of fibrous, cloth-like backsheet
materials can comprise a stretch thinned or stretch thermal laminate material
composed of a 0.6 mil (0.015 mm) thick polypropylene blown film and a 0.7 ounce
per square yard (23.8 gsm) polypropylene spunbond material (2 denier fibers). A
- material of this type forms the outercover of a HUGGIES(~) SUPREME diaper, which
is commercially available from Kimberly-Clark Corporation. The backsheet 30
typically provides the outer cover of the article. Optionally, however, the article may
2 5 include a separate outer cover component member which is additional to the
backsheet.
Backsheet 30 may alternatively include a micro-porous, "breathable" material which
permits gases, such as water vapor, to escape from the absorbent body 32 while
substantially preventing liquid exudates from passing through the backsheet. Forexample, the breathable backsheet may be composed of a microporous polymer film
or a nonwoven fabric which has been coated or otherwise modified to impart a
desired level of liquid impermeability. For example, a suitable microporous film can
be a PMP-1 material, which is available from Mitsui Toatsu Chemicais, Inc., a
3s company having offices in Tokyo, Japan; or an XKO-8044 polyolefin film available
*denotes trademark
g
CA 02240032 l998-07-02
from 3M Company of Minneapolis, Minnesota. The backsheet may also be
embossed or otherwise provided with a pattern or matte finish to exhibit a more
aesthetically pleasing appearance.
In the various configurations of the invention, where a component such as the
backsheet 30 or the containment flaps 62 are configured to be permeable to gas
while having a resistance and limited permeability to aqueous liquid, the liquidresistant material can have a construction which is capable of supporting a
hydrohead of at least about 45 cm of water substantially without leakage
10 therethrough. A suitable technique for determining the resistance of a material to
liquid penetration is Federal Test Method Standard FTMS 191 Method 5514, dated
31 December 1968.
The size of the backsheet 30 is typically determined by the size of absorbent body
32 and the particular diaper design selected. Backsheet 30, for example, may have
a generally T-shape, a generally I-shape or a modified hourglass shape, and may
extend beyond the terminal edges of absorbent body 32 by a selected distance, such
as a distance within the range of about 1.3 centimeters to 2.5 centimeters (about 0.5
to 1.0 inch), to provide at least a portion of the side and end margins.
The topsheet 28 presents a body-facing surface which is compliant, soft-feeling, and
non-irritating to the wearer's skin. Further, the topsheet 28 can be less hydrophilic
than absorbent body 32, and is sufficiently porous to be liquid permeable, permitting
liquid to readily penetrate through its thickness to reach the absorbent body. Asuitable topsheet layer 28 may be manufactured from a wide selection of web
materials, such as porous foams, reticulated foams, apertured plastic films, natural
fibers (for example, wood or cotton fibers), synthetic fibers (for example, polyester
or polypropylene fibers), or a combination of natural and synthetic fibers. The
topsheet layer 28 is typically employed to help isolate the wearer's skin from liquids
held in absorbent body 32.
Various woven and nonwoven fabrics can be used for topsheet 28. For example, thetopsheet may be composed of a meltblown or spunbonded web of the desired fibers,and may also be a bonded-carded-web. The various fabrics can be composed of
natural fibers, synthetic fibers or combinations thereof.
-10-
CA 02240032 l998-07-02
For the purposes of the present description, the term "nonwoven web" means a webof fibrous material which is formed without the aid of a textile weaving or knitting
process. The term "fabrics" is used to refer to all of the woven, knitted and
nonwoven fibrous webs.
The topsheet fabrics may be composed of a substantially hydrophobic material, and
the hydrophobic material may optionally be treated with a surfactant or otherwise
processed to impart a desired level of wettability and hydrophilicity. In a particular
10 embodiment of the invention, topsheet 28 is a nonwoven, spunbond polypropylene
fabric composed of about 2.8 - 3.2 denier fibers formed into a web having a basis
weight of about 22 gsm and density of about 0.06 gm/cc. The fabric can be surface
treated with an operative amount of surfactant, such as about 0.28~/O~Triton X-102
surfactant. The surfactant can be applied by any conventional means, such as
15 spraying, printing, brush coating or the like.
The topsheet 28 and backsheet 30 are connected or otherwise associated together
in an operable manner. As used herein, the term "associated" encompasses
configurations in which topsheet 28 is directly joined to backsheet 30 by affixing
20 topsheet 28 directly to backsheet 30, and configurations wherein topsheet 28 is
indirectly joined to backsheet 30 by affixing topsheet 28 to intermediate members
which in turn are affixed to backsheet 30. Topsheet 28 and backsheet 30 can, forexample, be affixed directly to each other in the diaper periphery by attachmentmeans (not shown) such as adhesive bonds, sonic bonds, thermal bonds, pinning,
25 stitching or any other attachment means known in the art, as well as combinations
thereof. For example, a uniform continuous layer of adhesive, a patterned layer of
adhesive, a sprayed pattern of adhesive or an array of separate lines, swirls or spots
of construction adhesive may be used to affix topsheet 28 to backsheet 30. It should
be readily appreciated that the above-described attachment means may also be
30 employed to suitably interconnect, assemble and/or affix together the various other
component parts of the articles which are described herein.
The absorbent body 32 provides an absorbent structure which can include a
retention portion, such as the shown absorbent pad composed of selected
35 hydrophilic fibers and high-absorbency particles, for holding and storing absorbed
- 11 -
CA 02240032 1998-07-02
liquids and other waste materials. The absorbent body is positioned and sandwiched
between the topsheet 28 and backsheet 30 to form the diaper 10. The absorbent
body has a construction which is generally compressible, conformable, non-irritating
to the wearer's skin, and capable of absorbing and retaining body exudates. It
should be understood that, for purposes of this invention, the absorbent body
structure may comprise a single, integral piece of material, or alternatively, may
comprise a plurality of individual separate pieces of material which are operably
assembled together.
10 Various types of wettable, hydrophilic fibrous material can be used to form the
component parts of absorbent body 32. Examples of suitable fibers include naturally
occurring organic fibers composed of intrinsically wettable material, such as
cellulosic fibers; synthetic fibers composed of cellulose or cellulose d~erivatives, such
as rayon fibers; inorganic fibers composed of an inherently wettable material, such
as glass fibers; synthetic fibers made from inherently wettable thermoplastic
polymers, such as particular polyester or polyamide fibers; and synthetic fiberscomposed of a nonwettable thermoplastic polymer, such as polypropylene fibers,
which have been hydrophilized by appropriate means. The fibers may be
hydrophilized, for example, by treatment with silica, treatment with a material which
has a suitable hydrophilic moiety and is not readily removable from the fiber, or by
sheathing the nonwettable, hydrophobic fiber with a hydrophilic polymer during or
after the formation of the fiber. For the purposes of the present invention, it is
contemplated that selected blends of the various types of fibers mentioned abovemay also be employed.
As used herein, the term "hydrophilic" describes fibers or the surfaces of fibers which
are wetted by the aqueous liquids in contact with the fibers. The degree of wetting of
the materials can, in turn, be described in terms of the contact angles and the
surface tensions of the liquids and materials involved. Equipment and techniquessuitable for measuring the wettability of particular fiber materials or blends of fiber
materials can be provided by a Cahn SFA-222 Sur~ace Force Analyzer System, or a
substantially equivalent system. When measured with such system, fibers having
contact angles less than 90~ are designated "wettable", while fibers having contact
angles greater than 90~ are designated "nonwettable".
CA 02240032 l998-07-02
The absorbent body structure 32 can comprise a matrix of hydrophilic fibers, such as
a web of cellulosic fluff, mixed with particles of high-absorbency material. In
particular arrangements, absorbent body 32 may comprise a mixture of
superabsorbent hydrogel-forming particles and synthetic polymer meltblown fibers,
s or a mixture of superabsorbent particles with a fibrous coform material comprising a
blend of natural fibers and/or synthetic polymer fibers. The superabsorbent particles
may be substantially homogeneously mixed with the hydrophilic fibers, or may be
nonuniformly mixed. For example, the concentrations of superabsorbent partides
may be arranged in a non-step-wise gradient through a substantial portion of the10 thickness (z-direction) of the absorbent structure, with lower concentrations toward
the bodyside of the absorbent body and relatively higher concentrations toward the
outerside of the absorbent structure. Suitable z-gradient configurations are
described in U.S.P. 4,699,823 issued October 13, 1987 to Kellenberger et al.
Alternatively, the
concentrations of superabsorbent particles may be arranged in a non-step-wise
gradient, through a substantial portion of the thickness (z-direction) of the absorbent
structure, with higher concentrations toward the bodyside of the absorbent body and
relatively lower concentrations toward the outerside of the absorbent structure. The
superabsorbent partides may also be arranged in a generally discrete layer within
the matrix of hydrophilic fibers. In addition, two or more different types of
superabsorbent may be selectively positioned at different locations within or along
the fiber matrix. "
The high-absorbency material may comprise absorbent gelling materials, such as
superabsorbents. Absorbent gelling materials can be natural, synthetic and modified
natural polymers and materials. In addition, the absorbent gelling materials can be
inorganic materials, such as silica gels, or organic compounds such as cross-linked
polymers. The term "cross-linked" refers to any means for effectively rendering
normally water-soluble materials substantially water insoluble but swellable. Such
means can include, for example, physical entanglement, crystalline domains,
covalent bonds, ionic complexes and associations, hydrophilic associations, such as
hydrogen bonding, and hydrophobic associations or Van der Waals forces.
- 13-
CA 02240032 1998-07-02
Examples of synthetic absorbent gelling material polymers include the alkali metal
and ammonium salts of poly(acrylic acid) and poly (methacrylic acid),
poly(acrylamides), poly(vinyl ethers), maleic anhydride copolymers with vinyl ethers
and alpha-olefins, poly(vinyl pyrrolidone), poly(vinylmorpholinone), poly(vinyl
alcohol), and mixtures and copolymers thereof. Further polymers suitable for use in
the absorbent body include natural and modified natural polymers, such as
hydrolyzed acrylonitrile-grafted starch, acrylic acid grafted starch, methyl cellulose,
chitosan, carboxymethyl cellulose, hydroxypropyl cellulose, and the natural gums,
such as alginates, xanthan gum, locust bean gum and the like. Mixtures of natural
10 and wholly or partially synthetic absorbent polymers can also be useful in the present
invention. Other suitable absorbent gelling materials are disclosed by Assarsson et
al. in U.S. Patent No. 3,901,236 issued August 26, 1975. Processes for preparingsynthetic absorbent gelling polymers are disclosed in U.S. Patent ~o. 4,076,663
issued February 28, 1978 to Masuda et al. and U.S. Patent No. 4,286,082
issued August 25, 1981 to Tsubakimoto et al.
Synthetic absorbent gelling materials typically are xerogels which form hydrogels
when wetted. The term "hydrogel", however, has commonly been used to also refer
to both the wetted and unwetted forms of the material.
As mentioned previously, the high-absorbency material used in absorbent body 32 is
generally in the form of discrete particles. The particles can be of any desiredshape, for example, spiral or semi-spiral, cubic, rod-like, polyhedral, etc. Shapes
having a large greatest dimension/smallest dimension ratio, like needles, flakes, and
25 fibers, are also contemplated for use herein. Conglomerates of particles of
absorbent gelling material may also be used in absorbent body 32. Desired for use
are particles having an average size of from about 20 microns to about 1 millimeter.
"Particle size" as used herein means the weighted average of the smallest dimension
of the individual particles.
The hydrophilic fibers and high-absorbency particles can be configured to form an
average composite basis weight which is within the range of about 400 - 900 gsm.In certain aspects of the invention, the average composite basis weight is within the
range of about 500 - 800 gsm, and alternatively is within the range of about
35 550 - 750 gsm to provide desired performance.
- 14-
CA 02240032 l998-07-02
To improve the containment of the high-absorbency material, absorbent body
structure 32 can include an overwrap, such as wrap sheet 70, which is placed
immediately adjacent and around absorbent body 32 and may be bonded to the
absorbent structure and to the various other components of the article. The wrapsheet is preferably a layer of absorbent material which covers the major bodyside
and outerside surfaces of the absorbent body, and preferably encloses substantially
all of the peripheral edges of the absorbent body to form a substantially complete
envelope thereabout. Alternatively, the wrap sheet can provide an absorbent
10 wrapping which covers the major bodyside and outerside surfaces of the absorbent
body, and encloses substantially only the lateral side edges of the absorbent body.
Accordingly, both the linear and the inwardly curved portions of the lateral side edges
of the wrap sheet would be closed about the absorbent body. In suc'h an
arrangement, however, the end edges of the wrap sheet may not be completely
closed around the end edges of the absorbent body at the waistband regions of the
article.
For example, the complete wrap sheet 70, or at least the bodyside layer of the wrap
sheet, may comprise a meltblown web composed of meltblown fibers, such as
meltblown polypropylene fibers. Another example of absorbent wrap 70 may
comprise a low porosity cellulosic web, such as a tissue composed of an
approximately 50/50 blend of hardwood/softwood fibers.
The absorbent wrap 70 may comprise a multi-element wrapsheet which includes a
separate bodyside wrap layer and a separate outerside wrap layer, each of which
extends past all or some of the peripheral edges of absorbent body 32. Such a
configuration of the wrap sheet can, for example, facilitate the formation of a
substantially complete sealing and closure around the peripheral edges of absorbent
body 32. In the back waistband portion of the illustrated diaper, the absorbent wrap
may also be configured to extend an increased distance away from the periphery of
the absorbent body to add opacity and strength to the back side-sections of the
diaper. In the illustrated embodiment, the bodyside and outerside layers of
absorbent wrap 70 can extend at least about 1/2 inch beyond the peripheral edges of
the absorbent body to provide an outwardly protruding, flange-type bonding area
over which the periphery of the bodyside portion of the absorbent wrap may be
CA 02240032 1998-07-02
completely or partially connected to the periphery of the outerside portion of the
absorbent wrap.
The bodyside and outerside layers of wrap sheet 70 may be composed of
s substantially the same material, or may be composed of different materials. For
example, the outerside layer of the wrap sheet may be composed of a relatively
lower basis weight material having a relatively high porosity, such as a wet strength
cellulosic tissue composed of softwood pulp. The bodyside layer of the wrap sheet
may comprise one of the previously described wrap sheet materials which has a
10 relatively low porosity. The low porosity bodyside layer can better prevent the
migration of superabsorbent particles onto the wearer's skin, and the high porosity,
lower basis weight outerside layer can help reduce costs.
Diaper 10 can also include a surge management layer 46 which helps to decelerateand diffuse surges of liquid that may be introduced into the absorbent body of the
article. In the illustrated embodiment, for example, surge layer 46 can be located on
an inwardly facing body side surface of topsheet layer 28. Alternatively, surge
layer 46 may be located ad3acent to an outer side surface of topsheet 28.
Accordingly, the surge layer would then be interposed between topsheet 28 and
20 absorbent body 32. Examples of suitable surge management layers 46 are
described in U.S. Patent Application Serial No. 206,986 of C. Ellis and D. Bishop,
entitled FIBROUS NONWOVEN WEB SURGE LAYER FOR PERSONAL CARE
ABSORBENT ARTICLES AND THE LIKE, filed March 4, 1994 (attorney docket No.
11,256) which issued as U.S. Patent No. 5,486,166; and U.S. Patent Application
25 Serial No. 206,069 of C. Ellis and R. Everett, entitled IMPROVED SURGE
MANAGEMENT FIBROUS NONWOVEN WEB FOR PERSONAL CARE --
ABSORBENT ARTICLES AND THE LIKE, filed March 4, 1994 (attorney docket No.
11,387) which issued as U.S. Patent No. 5,490,846 .
The leg elastic members 34 are located in the lateral side margins 20 of diaper 10,
and are arranged to draw and hold diaper 10 against the legs of the wearer. The
elastic members are secured to diaper 10 in a,n elastically contractible condition so
that in a norma! under strain configur3tion, the elastic members effectively contract
3~ against diaper 10. The elastic members can be secured in an elastically contractible
- 16-
CA 02240032 1998-07-02
condition in at least two ways, for example, the elastic members may be stretched
and secured while diaper 10 is in an uncontracted condition. Alternatively, diaper 10
may be contracted, for example, by pleating, and the elastic members secured andconnected to diaper 10 while the elastic members are in their relaxed or unstretched
condition. Still other mechanisms, such as heat-shrink elastic material, may be used
to gather the garment.
In the embodiment illustrated in Fig. 1, the leg elastic members 34 extend essentially
along the complete length of the intermediate crotch region 16 of diaper 10.
10 Alternatively, elastic members 34 may extend the entire length of diaper 10, or any
other length suitable providing the arrangement of elastically contractible lines
desired for the particular diaper design.
The elastic members 34 may have any of a multitude of configurations. For
example, the width of the individual elastic members 34 may be varied from about0.25 millimeters (0.01 inch) to about 25 millimeters (1.0 inch) or more. The elastic
members may comprise a single strand of elastic material, or may comprise several
parallel or non-parallel strands of elastic material, or may be applied in a rectilinear
or curvilinear arrangement. Where the strands are non-parallel, two or more of the
strands may intersect or otherwise interconnect within the elastic member. The
elastic members may be affixed to the diaper in any of several ways which are
known in the art. For example, the elastic members may be ultrasonically bonded,heat and pressure sealed using a variety of bonding patterns, or adhesively bonded
to diaper 10 with sprayed or swirled patterns of hotmelt adhesive.
In particular embodiments of the invention, the leg elastic members 34 may include a
carrier sheet to which are attached a grouped set of elastics composed of a plurality
of individual elastic strands. The elastic strands may intersect or be interconnected,
or be entirely separated from each other. The carrier sheet may, for example,
comprise a 0.002 cm thick polymer film, such as a film of unembossed polypropylene
material. The elastic strands can, for example, be composed of Lycra elastomer
available from DuPont, a business having offices in Wilmington, Delaware. Each
elastic strand is typically within the range of about 470 - 1500 decitex (dtx), and may
be about 940 - 1050 dtx. In particular embodiments of the invention, for example,
three or four strands can be employed for each elasticized legband.
In addition, the leg elastics 34 may be generally straight or optionally curved. For
example, the curved elastics can be inwardly bowed toward the longitudinal
centerline of the diaper. In particular arrangements, the curvature of the elastics
5 may not be configured or positioned symmetrically relative to the lateral centerline of
the diaper. The curved elastics may have an inwardly bowed and outwardly bowed,
reflex-type of curvature, and the length-wise center of the elastics may optionally be
offset by a selected distance toward either the front or rear waistband of the diaper
to provide desired fit and appearance. In particular embodiments of the invention,
10 the innermost point (apex) of the set of curved elastics can be offset towards the
front or rear waistband of the diaper, and the outwardly bowed reflexed-portion can
be positioned toward the diaper front waistband.
As representatively shown, the diaper 10 can include a waist elastic 42 positioned in
15 the longitudinal margins of either or both of the front waistband 14 and the rear
waistband 12. The waist elastics may be composed of any suitable elastomeric
material, such as an elastomer film, an elastic foam, multiple elastic strands, an
elastomeric fabric or the like. For example, suitable elastic waist constructions are
described in U.S. Patent No. 4,916,005 to Lippert et al.
With reference to the representative conhgurations shown in Figs. 1 and 8, the article
can include a system of ~ear" regions or ear members 38. In particular
arrangements, each ear region or member 38 extends laterally at the opposèd,
2 5 lateral ends of at least one waistband portion of backsheet 30, such- as therepresentatively shown rear waistband portion 12, to provide terminal side -sections
of the article. In addition, each ear region can substantially span from a laterally
extending, terminal waistband edge 82 to approximately the location of its associated
and corresponding leg opening section of the diaper. The diaper 10, for example,30 has a laterally opposed pair of leg openings provided by the curved margins of the
ear regions in combination with the correspondingly adjacent, medial sections of the
shown pair of longitudinally extending, side edge regions 20 (Fig. 1).
In the various configuratior.s of the invention, ihe ear regions may be integrally
3 5 formed with a selected diaper component. For example, ear regions 38 can be
- 18 -
integrally formed from the layer of material which provides backsheet layer 30, or
may be integrally fomled from the material employed to provide topsheet 28. In
alternative configurations, the ear regions 38 may be provided by one or more
separate members that are connected and assembled to the backsheet 30, to the
topsheet 28, in between the backsheet and topsheet, or in various fixedly attached
combinations of such assemblies.
In particular configurations of the invention, each of the ear regions 38 may beformed from a separately provided piece of material which is then suitably
assembled and attached to the selected front and/or rear waistband portion of the
diaper article. For example, each ear region 38 may be attached to the rear
waistband portion of the backsheet 30 along a ear region attachment zone, and can
be operably attached to either or both of the backsheet and topsheet components of
the article. The inboard, attachment zone region of each ear region can be
overlapped and laminated with its corresponding, lateral end edge region of the
waistband section of the article. The ear regions extend laterally to form a pair of
opposed waist-flap sections of the diaper, and are attached with suitable connecting
means, such as adhesive bonding, thermal bonding, ultrasonic bonding, clips,
staples, sewing or the like. Desirably, the ear regions extend laterally beyond the:
terminal side edges of the backsheet layer and topsheet layer at the corresponding,
attached waistband section of the article.
The ear regions 38 may be composed of a substantially non-elastomeric material,
such as polymer films, woven fabrics, nonwoven fabrics or the like, as well as
combinations thereof. In particular aspects of the invention, ear regions 38 may be
composed of a substantially elastomeric material, such as a stretch-bonded-laminate
(SBL) material, a neck-bonded-laminate (NBL) material, an elastomeric film, an
elastomeric foam material, or the like, which is elastomerically stretchable at least
along the lateral direction 24. For example, suitable meltblown elastomeric fibrous
webs for forming ear regions 38 are described in U.S P. 4,663,220 issued May 5,
1987 to T. Wisneski et al.
-rcfcrcnc~. Examples of composite fabrics comprising at least one layer of nonwoven
textile fabric secured to a fibrous elastic layer are described in European Patent
Application EP 0 217 G32 A2 published on April 8,1987 which has the listed
3 5 inventors of J. Taylor et al
- 19-
Examples of NBL materials are described in U.S. Patent No. 5,226,992
issued July 13, 1993to Mormon .
5 As previously mentioned, various suitable constructions can be employed to attach
the ear regions 38 to the selected waistband portions of the article. Particularexamples of suitable constructions for securing a pair of elastically stretchable
members to the lateral, side portions of an article to extend laterally outward beyond
the laterally opposed side regions of the outer cover and liner components of anarticle can be found in U.S. Patent No. 4,938,753 issued July 3, 1990 to P.
VanGompel et al.
Each of the ear regions 38 extends laterally at a one of the opposed lateral ends of
at least one waistband section of the diaper 10. In the shown embodiment, for
example, a first pair of ear regions extend laterally at the opposed lateral ends of the
back waistband section of the backsheet 30, and a second pair of ear regions extend
laterally at the opposed lateral ends of the front waistband section of the backsheet.
The illustrated ear regions have a tapered, curved or otherwise contoured shape ir;
20 which the length of the base region is smaller than the length of its relatively
outboard end region. Alternatively, the ear regions may have a substantially
rectangular shape or a substantially trapezoidal shape.
Diaper 10 can also include a pair of elasticized containment flaps 62 which extend
25 generally length-wise along the longitudinal direction 26 of the diaper. The
containment flaps are typically positioned laterally inboard from leg elastics- 34, and
substantially symmetrically placed on each side of the lengthwise, longitudinal
centerline of the diaper. In the illustrated arrangements, each containment flap 62
has a substantially fixed edge portion 64 and a substantially moveable edge
3 o portion 66, and is operably elasticized to help each containment flap to closely
contact and conform to the contours of the wearer's body. Examples of suitable
containment flap constructions are described in U.S. Patent No. 4,704,116 issuedNovember 3, 1987, to K. Enloe .
The containment flaps may be
35 composed of a wettable or a non-wettable material, as desired. In addition, the
- 20 -
CA 02240032 l998-07-02
containment flap material may be substantially liquid-impermeable, may be
permeable to only gas or may be permeable to both gas and liquid. Other suitablecontainment flap configurations are described in U.S. Patent Application Serial
No. 206,816 of R. Everett et al., filed March 4, 1994 and entitled ABSORBENT
s ARTICLE HAVING AN IMPROVED SURGE MANAGEMENT (attorney docket
No. 11,375), now U.S. Patent 5,562,650
In optional, alternative configurations of the invention, diaper 10 may include internal,
10 elasticized, containrnent waist flaps, such as those described in U.S. Patent No. 4,753,646 issued June 28, 1988, to K. Enloe .
Similar to
the construction of the containment flaps, the containment waist flaps may be
composed of a wettable or non-wettable material, as desired. The waist flap material
may be substantially li~uid-impermeable, permeable to only gas, or permeable to
both gas and liquid.
To provide a desired refastenable fastening system, diaper 10 can include one or- more appointed landing zone regions, such as a first, primary landing zone 50 (e g
Figs.1 and 9 ), which can provide an operable target area for receiving a releasable
and re-attachable securement of the fastener tabs 36 thereon. In particular~
embodiments of the invention, the landing zone patch can be positioned on the front
waistband portion 14 of the diaper and is located on the outward surface of the
backsheet layer 30 Alternatively, the landing zone patch can be positioned on anappointed inward surface of the diaper, such as the bodyside surface of the
topsheet layer 28. The fastening mechanism between the landing zone and the
fastener tabs 36 may be adhesive, cohesive, mechanical or combinations thereof. In
the context of the present invention, a mechanical fastening system is a system
which includes cooperating components which mechanically inter-engage to providea desired securement.
CA 02240032 l998-07-02
A configuration which employs a releasable, interengaging mechanical fastening
system can, for example, locate a first element of the mechanical fastener on the
landing zone 50 and a second, cooperating element of the mechanical fastener on
the fastener tab 36. For example, with a hook-and-loop fastener, the hook material
can be operably connected and affixed to the fastener tabs 36 and the loop material
can be operably connected and affixed to the landing zone 50. Alternatively, theloop material can be operably connected to the fastener tabs 36 and the hook
material can be operably connected to the landing zone.
10 In the various embodiments of the invention, a separately provided tape fastener
tab 36 can be located at either or both of lateral end regions 86 and 88 of either or
both of the waistbands 14 and 12. The representatively shown embodiment, for
example, has one of the fastener tabs 36 located at each of the dis~al side edges of
the rear waistband 12. More particularly, each of the fasteners 36 is assembled and
attached to extend from a corresponding, immediately adjacent ear region at one of
the opposed lateral ends of the back waistband section 12.
With reference to Figs. 1 and 2, a further aspect of invention can include at least one
pair of transversely opposed, laterally extending carrier members, such as provided
by the shown arrangement of base tab or panel sections 80. In the shown
configuration, a base panel section is joined to the diaper at each lateral end of the
appointed first waistband portion 12. In the shown configurations, each base panel
section 80 is affixed to an associated, corresponding ear region 38, and extendslaterally outboard from its corresponding, immediately adjacent ear region. The
shown arrangement has the transversely extending, longitudinally terminal
edges 110 of the base panel sections 80 positioned substantially collinear and
aligned with the transversely extending, longitudinally terminal edge 82 the back
waistband 12. Additionally, the longitudinally terminal edges 110 of the base panel
sections 80 can be substantially collinear and aligned with the transversely
extending, longitudinally terminal edge of the backsheet layer 30. When the diaper
article is typically worn, the total cross-directional width of the overall article is
desirably insufficient to allow the back waistband section of the diaper to completely
encircle the wearer's waist. More particularly, the opposed base panel sections 80
will substantially avoid overlapping each other when the article is worn. Accordingly,
CA 02240032 l998-07-02
the diaper construction can provide improved fastening with an improved economy of
material.
The base panel section 80 of each fastener can have any desired shape. The
shown arrangement has generally rectangular-shaped base panel sections, but other
suitable base panel shapes may be tapered, bell-shaped, trapezoidal and the like, as
well as combinations thereof. In the representatively shown configurations, the base
panel section 80 can be composed of a polymer film material, or may be composed
of woven or nonwoven fabric and the like, as well as combinations thereof. In
10 particular aspects of the invention, the material of base panel section 80 can be
composed of a substantially non-elastomeric material, such as polymer films, woven
fabrics, nonwoven fabrics or the like, as well as combinations thereof. Alternatively,
the base panel material may be composed of a substantially elastonleric material,
such as a stretch-bonded-laminate (SBL) material, a neck-bonded-
laminate (NBL) material, an elastomeric film, an elastomeric foam material, or thelike, as well as combinations thereof. The elastomeric material can be
elastomerically stretchable at least along the longitudinal direction 26. For example,
the base panel material may be composed of a spunbond-meltblown-spunbond
(SMS) fabric having a core of meltblown fibers sandwiched between two facing
layers of spunbond fibers to provide a total composite basis weight within the range
of about 50 - 67 g/m2 (about 1.5 - 2 oz/yd2). As another example, the base panelmaterial may be entirely composed of a nonwoven spunbond fabric having a basis
weight within the range of about 50 - 67 g/m2 (about 1.5 - 2 oz/yd2).
The flip tab section 60 of each fastener has an areal extent which extends
longitudinally outboard and away from a laterally extending, longitudinally outboard
edge region of the article. In the illustrated arrangements, for example, the flip tab
section extends longitudinally away from a laterally extending, longitudinally outboard
edge region 110 of its corresponding base panel section 80. The shown
configuration has the outer-most side edge of the flip tab section located
substantially collinear and aligned with the outer-most side edge of its corresponding
base panel section 80. Accordingly, the flip tab section and corresponding base
panel section form a generally L-shaped intersection. Optionally, the flip tab section
and corresponding base panel section can be arranged to form a generally T-shaped
intersection or other configuration, as desired.
- 23 -
CA 02240032 l998-07-02
With respect to each individual flip fastener 36, the flip tab section 60 may be a
separately provided element which is operatively assembled and affixed to its
associated base panel section 80. Alternatively, the flip tab section 60 may be
integrally formed from the same piece of material employed to construct the basepanel section 80. It should be readily appreciated that the flip tab section 60 can
have any desired shape. The shown arrangement has generally rectangular flip tabsections, but other suitable flip tab shapes may be tapered, bell-shaped, trapezoidal
and the like, as well as combinations thereof.
The flip tab section 60 of each fastener extends longitudinally beyond the
transversely extending, longitudinally terminal edge 82 of the back waistband
portion 12, and includes an appointed folding line 59. The folding line extends
transversely along the flip tab section, and in desired configurations, can be
substantially collinear and aligned with the terminal edge 82 of the back waistband
portion 12.
The representatively shown configurations of the flip tab sections 60 can be
composed of a polymer film material, or may be composed of a woven or nonwoven
fabric, and the like, as well as combinations thereof. It should be readily appreciated
that the flip tab sections 60 may be elastomeric or substantially non-elastomeric, and
that the flip tab sections may be constructed of materials that are similar or dissimilar
to those employed to construct the base panel sections 80. Where the flip tab
section is composed of an elastomeric material, the material can be elastomerically
stretchable at least along the longitudinal direction 26 of the article.
In its various arrangements, the flip fastener, particularly the flip tab section 60, is
desirably configured to be soft and substantially non-irritating to the wearer's skin.
With reference to the configuration representatively shown in Fig. 1, the inward,
bodyside surface 56 of the flip fastener 36 is desirably composed of a material which
is nonirritating to the wearer's skin. For example, the initially inward, bodyside
surface of the flip tab section 60 and the inward surface 106 of the base panel 80
can be composed of a soft, resilient, nonirritating, woven or nonwoven fabric, such
as a spunbond fabric.
- 24 -
CA 02240032 l998-07-02
With respect to the configurations representatively shown in Fig. 8, the outwardsurface 54 of the flip fastener 36 is desirably composed of a material which is
nonir,il~ling to the wearer's skin. For example, the initially outward surface of the flip
tab section 60 may be composed of a soft, resilient, nonirritating, woven or
nonwoven fabric, such as a spunbond fabric. Similarly, the outward surface 108 of
the base panel section 80 may also be composed of the soft, resilient, woven or
nonwoven fabric.
A selected fastening mechanism is operatively joined to each flip tab section 60.
10 With reference to Fig. 1, the selected fastening mechanism is attached to theoutward surface 54 of the flip tab section. The fastening mechanism between the
landing zone and the flip tab section 60 may be adhesive, cohesive, mechanical or
combinations thereof. A configuration which employs a releasable, in~terengagingmechanical fastening system can, for example, locate a first element of the
mechanical fastener on the flip tab section 60. For example, with a hook-and-loop
fastener, the hook material can be operably connected to the flip tab section 60 and
the loop material can be operably connected to the landing zone 50. Alternatively,
the loop material can be operably connected to the flip tab section 60 and the hook
material can be operably connected to the landing zone.
In the shown configuration of Figs. 1, 2 and 3, a member of primary hook
material can be laminated, or otherwise connected and affixed, to the longitudinally
outboard region of the flip tab section with an operable construction attachment to
provide the first fastening component 52. In particular, the shown hook member is
laminated to a outward-side surface 54 of the flip tab section with the hook elements
extending generally outwardly of the article. The outboard, longitudinally distal edge
of the hook material may be coterminous with the outboard, laterally distal edge of
the flip tab section. Alternatively, the outboard, longitudinally distal edge of the flip
tab section may be spaced longitudinally inboard from the terminal, longitudinally
distal edge of the flip tab section. In either configuration, the longitudinally distal
edge of the flip tab section 60 provides a longitudinally terminal edge of the article.
Further aspects of the invention can include a supplemental fastening system, such
as provided by a supplemental fastener component 100 and a cooperating
supplemental landing zone 102. With reference to Fig. 2, a second, supplemental
- 25 -
CA 02240032 l998-07-02
fastening component 100 can be provided on the inward surface 92 of the second
waistband portion 14 of the article at a lateral side or end region 88 of the second
waistband portion 14. Desirably, a supplemental fastening component 100 is
provided on the inward surface at each of a pair of laterally opposed end or side
regions 88 of the second waistband portion.
A second, supplemental landing zone component 102 can be provided on the
outward surface 92 of the article along a selected region of the first waistbandportion 12, and is configured to operatively attach to the second fastening
component 100. Desirably, the supplemental landing zone component 102 is
configured to include spaced-apart portions which engage or otherwise attach to
each of the supplemental fastening components 100 disposed on the opposite
ends 88 of the second waistband portion 14.
In a particular aspect of the invention, the supplemental landing zone component102 can be provided on an outer surface of either or both of the base panel
sections 80. For example, the outward surface 108 of the base panel section 80 can
be composed of a fabric which is mechanically engageable with the supplemental
fastening component 100. Alternatively, the supplemental landing zone 102 may beprovided by one or more separately provided packages of suitable landing zone
material which are attached to the outward surface 108 of the base panel 80.
With reference to Fig. 8, the supplemental fastener component 100 can alternatively
be provided on the inward surface 90 of the first waistband portion 12 of the article.
A second, supplemental landing zone component 102 is provided on an outward
surface 92 of the second waistband portion 14 of the article, and can be disposed
along at least an operative part of the second waistband portion. A section of the
second fastening component 100 can be disposed on the inward surface of the
article at each lateral end region 86 of the first waistband portion 12, and the second
fastening component 102 is configured to operatively attach to the second fastening
component 100. The supplemental landing zone component 102 can be positioned
on an outward surface 92 of the second waistband portion 14 of the article, and can
be disposed along at least an operative part of the second waistband portion.
In particular aspects, the supplemental landing zone component 102 may be
provided by a fabric loop material disposed on the inward surface 106 of the base
- 26 -
CA 02240032 1998-07-02
,
panel sections 80. The loop component may be separately provided and operativelyattached to the base panel section 80, or may be integrally formed from the materiai
of the base panel section. With this arrangement, the cooperating supplemental
fastening component 100 can be positioned on an outward surface 92 of the secondwaistband portion 14 of the article, and can be disposed along at least an operative
part of the second waistband portion. The supplemental fastening component 100
can be configured such that appointed, spaced-apart portions of the supplementalfastening component can engage or otherwise attach to the regions of the landingzone, loop material for operatively holding the article on a wearer.
In the various configurations of the invention, the first and/or second fastening
component may include an adhesive, a cohesive, a complementary element of an
interengaging mechanical fastening system, or the like, as well as combinations
thereof. The mechanical fastener components can be provided by m~echanical-type
fasteners such as hooks, buckles, snaps, buttons and the like, which include
cooperating and complementary, mechanically interlocking components. For
example, the mechanical fastening system may be a hook-and-loop type of fastening
system. Such fastening systems generally comprise a "hook" or hook-like, male
component, and a cooperating "loop" or loop-like, female component which engagesand releasably interconnects with the hook component. Desirably, the
interconnection is selectively releasable and re-attachable. Conventional systems
are, for example, available under the VELCRO'trademark. The hook element may
be provided by a single or multiple hook configuration, such as provided by a
mushroom-head type of hook element. The loop element may be provided by a
woven fabric, a nonwoven fabric, a knitted fabric, a perforated or ape~tured layer,
and the like, as well as combinations thereof. The many arrangements and variations
of such fastener systems have been collectively referred to as hook-and-loopfasteners.
In desired arrangements of the invention, the first fastening component 52 and/or the
second fastening component 100 may include a hook type of mechanical fastening
element. Accordingly, the corresponding first landing zone component 52 and/or
second landing zone component 102 can include a complementary loop element.
!t should also be readily apparent that, in the various configurations of the invention,
the relative positions and/or materials of the fastening component and its
* denotes trademark 27
.
CA 02240032 1998-07-02
corresponding landing zone component can be transposed. For example, in a hook-
and-loop fastening system, the first and/or second fastening component may
optionally be composed of a loop element and the first and/or second landing zone
components may be provided by a hook-type element.
s
Examples of suitable hook-and-loop fastening systems are described in
U.S.P. 5,019,073 issued May 28, 1991 to T. Roessler et al.
Other examples of hook-and-loop fastening systems are described in U.S. Patent
Application Serial No. 366,080 entitled HIGH-PEEL TAB FASTENER, hled
December 28,1994 by G. Zehner et al. (attorney docket No. 11,571) which issued
as U.S. Patent No. 5,605,735.
- In a typical configuration of a hook-and-loop fastening system, the hook material
member is operably connected to the fastening tab 36, and the loop materiaNs
employed to construct at least one cooperating landing zone 50. The landing zonecan, for example, be suitably positioned on the exposed, outward-side surface of the
backsheet 30. As previously mentioned, an alternative configuration of the hook-and-loop fastening system may have the loop material secured to the fastener tab 36
and may have the hook material employed to form the landing zone 50.
In the various aspects and configurations of the invention, the hook element material
can be of the type referred to as micro-hook material. A suitable micro-hook
material is distributed under the designation CS200 and is available from 3M
Company, a business having offices in St. Paul, Minnesota. The micro-hook
materia! can have hcoks in ~he shape of mushroom "caps", and can be configured
with a hook density of about 1600 hooks per square inch; a hook height which is
-28-
CA 02240032 l998-07-02
within the range of about 0.033 - 0.097 cm (about 0.013 to 0.038 inch); and a cap
width which is within the range of about 0.025 - 0.033 cm (about 0.01 to 0.013
inch). The hooks are attached to a base film substrate having a thickness of about
0.0076- 0.01 cm (about 0.003-0.004 inch) and a Gurley stiffness of about 15 mgf.
Another suitable micro-hook material is distributed under the designation VELCROCFM-29 1058, and is available from VELCRO U.S.A., Inc., a business having offfices
in Manchester, New Hampshire. The micro-hook material can have hooks in the
shape of angled hook elements, and can be configured with a hook density of about
264 hooks per square centimeter (about 1700 hooks per square inch); a hook height
which is within the range of about 0.030 - 0.063 cm (about 0.012 - 0.025 inch);
and a hook width which is within the range of about 0.007 to 0.022 cm (about 0.003
to 0.009 inch). The hook elements are coextruded with a base layer substrate
having a thickness of about 0.0076 - 0.008 cm (about 0.003 - 0.0035 inch),
and the member of hook material has a Gurley stiffness of about 12 mgf (about
12 Gurley units).
For the purposes of the present invention, the various stiffness values are
determined with respect to a bending moment produced by a force which is directed
perpendicular to the plane substantially defined by the length and width of the
component being tested. A suitable technique for determining the stiffness values
described herein is a Gurley Stiffness test, a description of which is set forth in
TAPPI Standard Test T 543 om-94 (Bending Resistance of Paper (Gurley type
tester)). A suitable testing apparatus is a Gurley Digital Stiffness Tester;
Model 4171-D manufactured by Teledyne Gurley, a business having offfices in Troy,
New York. This instrument allows the testing of a wide variety of materials through
the use of various lengths and widths in combination with the use of a 5, 25, 50, or
200 gram weight placed in one of three positions on the pointer of the apparatus.
For purposes of the present description, the stated Gurley stiffness values are
intended to correspond to the values that would be generated by a "standard" sized
sample. Accordingly, the scale readings from the Gurley stiffness tester are
appropriately converted to the stiffness of a standard size sample, and are
traditionally reported in terms of milligrams of force (mgf). Currently, a standard
"Gurley unit" is equal to a stiffness value of 1 mgf, and may equivalently be
employed to report the Gurley stiffness. The standard size sample has a width of 1"
- 29 -
CA 02240032 1998-07-02
and a nominal length of 3" (actual length of 3.5"). The actual length of the sample is
the nominal length, plus an additional 0.25" of length for holding in the clamp and
another 0.25" of length for overlapping the vane. Tables of factors for taking scale
readings generated with non-standard sized test samples and converting the
readings to the stiffness of the standard size sample are given in the Instruction
Manual for the Gurley Stiffness Tester provided by Teledyne Gurley. Accordingly,other designated dimensions for the test sample may also be conveniently
employed, so long as the appropriate conversion factor is employed to determine the
appropriate value which corresponds to the standard size sample.
In the various aspects and configurations of the invention, the loop material can be
provided by a nonwoven, woven or knit fabric. For example, a suitable loop material
fabric can be composed of a 2 bar, warp knit fabric of the type availa~ble from
Guilford Mills, Inc., Greensborough, North Carolina under the trade designation
15 #34285, as well other of knit fabrics. Suitable loop materials are also available from
the 3M Company, which has distributed a nylon woven loop under their
SCOTCHMATI~ brand. The 3M Company has also distributed a linerless loop web
with adhesive on the backside of the web, and 3M knitted loop tape.
In particular aspects of the invention, the loop material need not be limited to a
discrete landing zone patch. Instead the loop material can, for example, be provided
~ by a substantially continuous, outer hbrous layer which is integrated to extend over
substantially the total exposed surface area of a cloth-like outer cover employed with
the diaper 10. The resultant, cloth-like backsheet 30 can thereby provide the loop
2s material for an operative "fasten anywhere" mechanical fastening system.
In the various configurations of the invention, the engagement force between theparticular fastening component and its appointed landing zone component should be
large enough and durable enough to provide an adequate securement of the articleon the wearer during use. In desired configurations, the engagement force can
provide a peel force value of not less than about 75 grams-force (gmf).
Alternatively, the peel force is not less than about 100 gmf, and optionally is not less
than about 400 gmf. In particular aspects, the peel force is not more than about1,200 gmf. Alternatively. the peel force is not more than about 800 gmf, and
optionally is not more than about 600 gmf. The engagement force can additionally
* denotes trademark
- 30 -
CA 02240032 l998-07-02
provide a shear force value of not less than about 1,000 gmf. Alternatively, theshear force is not less than about 2,000 gmf, and optionally, is not less than about
3,000 gmf . In further aspects, the shear force is not more than about 10,000 gmf.
Alternatively, the shear force is not more than about 9,000 gmf, and optionally is not
5 more than about 8,000 gmf.
The peel force can be determined in accordance with standard procedure
ASTM D5170, approved Sept. 15, 1991 and published Nov. 1991. The shearforce
value can be determined in accordance with the standard procedure ASTM D-5169,
o approved September 15, 1991 and published Nov. 1991.
Each of the fastening components and elements in the various constructions of the
invention may be operably attached to its supporting substrate by ernploying any one
or more of the attachment mechanisms employed to construct and hold together thevarious other components of the article of the invention. The fastening elements in
the various fastening regions, may be integral!y formed, such as by molding, co-extrusion or the like, along with the associated substrate layer. The substrate layer
and its associated mechanical fastening elements may be formed from substantially
the same polymer material, and there need not be a discrete step of attaching the
fastening elements to an initially separate substrate layer. For example, the
individual hook elements may be integrally formed simultaneously with a hook base-
layer by coextruding the base layer and hook elements from substantially the same
polymer material.
It should be readily appreciated that the strength of the attachment or other
interconnection between the substrate layer and the attached fastening componentshould be greater than the peak force required to remove the fastener tab 36 from its
releasable securement to the appointed landing zone of the article.
Figs. 4 through 7 illustrate the operation of the fastening system provided by adesired configuration of the invention. Fig. 4 shows a representative perspective
view of a diaper generally positioned for use on a wearer. With reference to Fig. 5,
the diaper can be initially placed and mounted on the wearer by first positioning and
wrapping the first, back waistband portion 12 and the two fastener base panel
sections 80, around the wearer's back and side torso areas (not shown). Fig. 5 also
- 31 -
CA 02240032 l998-07-02
illustrates (with dashed outlines) optional enlargements 100a of the supplemental
fasteners 100 and optional enlargements 102a of the supplemental landing
zones 102 which may be operatively incorporated into any of the various
arrangements of the invention. Such configurations can provide additional
supplemental fastening areas which extend to more laterally inboard locations of the
article. The additional supplemental fastening area of each supplemental
fastener 100 or supplemental landing zone 102 can be provided by a contiguous
enlargement of the fastener or landing zone component. Alternatively, such
additional fastening area can be provided by one or more, spaced-apart or otherwise
10 noncontiguous segments of the selected fastener component and/or landing zonecomponent which are operatively and cooperatively located within one or more of the
regions representatively shown by the dotted outlines.
With reference to Fig. 6, the intermediate region 16 of the diaper can then be brought
15 through the wearer's crotch region, and the second, front waistband portion 14 of the
article can be placed into an operatively aligned, mating correspondence with the
back waistband portion 12. When appropriately mated, the supplemental fasteners
100, if present, can then be secured to the supplemental landing zones 102, with the
assembled front and back waistband portions thereby encircling the wearer's body.
20 The flip tab sections 60 can then be pivoted about their individual folding lines 59 to
wrap outwardly and downwardly around the laterally extending, longitudinally
terminal edge region 84 of the front waistband portion 14 (Fig. 7). The primary
fastener components 52 on the designated outward surfaces 54 of the folded flip tab
sections 60 can then be secured to the one or more appointed primary landing zone
25 regions 50 affixed to the outermost surface 92 of the front waistband portion 14. In
the shown arrangement, a single primary landing zone strip region can be provided
by or otherwise attached to the outer surface of the backsheet layer 30.
Figs.11 through 14 illustrate the operation of the fastening system provided by an
30 alternative configuration of the invention. Fig.11 representatively shows a
perspective view of the diaper generally arranged for use. The diaper can be initially
placed on the wearer by first positioning and wrapping the first, back waistband 12
and the fastener base panel sections 80, if any, behind the wearer's back (Fig.12).
The intermediate region 16 of the diaper can then be brought through the wearer's
35 crotch region, and the second, front waistband portion 14 of the article can be placed
- 32 -
CA 02240032 l998-07-02
in an operative position against the wearer's front and side torso areas (Fig.13).
The placement of the diaper is adjusted to provide an operative alignment and
mating correspondence between the back and front waistband portions 12 and 14,
respectively. When appropriately mated, the supplemental fasteners 100, if present,
can then be secured to the supplemental landing zone or zones 102, with the
assembled front and back waistband portions thereby encircling the wearer's body.
With reference to Fig.14, the flip tab sections 60 can then be pivoted about their
individual folding lines 59 to wrap inwardly and downwardly around the laterallyextending, longitudinally terminal edge region 84 of the front waistband portion 14.
10 The primary fastener components 52 on the designated inward surfaces 56 of the
folded flip tab sections 60 can then be secured to the one or more appointed primary
landing zone regions 50 affixed to or otherwise provided on the innermost, bodyside
surface 90 of the front waistband portion 14. In the shown arrangement, for
example, the primary landing zone region can be a separately provided member
which is assembled and attached to the inner surface of the topsheet layer 28.
Alternatively, the landing zone region 50 may be integrally formed with one or more
of the components which provide the inner, bodyside surface of the diaper. For
example, the landing zone region may be provided by a selected region of the
topsheet layer which has been operatively configured to provide sufficient high levels
of peel and shear force engagement for the desired fastening operation.
Having described the invention in rather full detail, it will be readily apparent that
various changes and modifications can be made without departing from the spirit of
the invention. All of such changes and modifications are contemplated as being
within the scope of the invention as defined by the subjoined claims.
-33-
