Note: Descriptions are shown in the official language in which they were submitted.
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ABSORBENT ARTICLE COMPRISING AN ACTIVATED REGION
FIELD OF THE INVENTION
This invention relates to disposable absorbent articles such as disposable
diapers and other
articles intended for use on incontinent persons.
BACKGROUND OF THE INVENTION
Disposable absorbent articles are designed to absorb and contain bodily waste
in order to
prevent soiling of the body and clothing of the wearer, as well as bedding or
other objects with
which the wearer comes into contact. As the usage of disposable absorbent
articles has
expanded, their complexity has increased with the incorporation of additional
features serving to
enhance their performance and appearance. The costs of the materials and the
costs of the
manufacturing processes have also increased in conjunction with the increase
in complexity. As
a result, the prices at which these articles are sold have risen to levels
that many potential
purchasers around the world cannot afford to pay. Thus, a need exists for a
simple disposable
absorbent article.
SUMMARY OF THE INVENTION
An absorbent article comprising a chassis formed by a web comprising at least
one
continuous layer that forms a portion of a backsheet and a portion of
laterally opposing side
flaps. The web may be folded laterally inward to form the side flaps and side
edges of the
chassis. A portion of the chassis at or immediately adjacent the side edges
may comprise
laterally oriented alternating ridges and valleys while other portions of the
chassis may comprise
longitudinally oriented alternating ridges and valleys.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawing figures, like reference numerals identify like
elements, which
may or may not be identical in the several exemplary embodiments that are
depicted. Some of
the figures may have been simplified by the omission of selected elements for
the purpose of
more clearly showing other elements. Such omissions of elements in some
figures are not
necessarily indicative of the presence or absence of particular elements in
any of the exemplary
embodiments, except as may be explicitly delineated in the corresponding
written description.
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In the drawing figures and in the written description, lowercase letters
appended to
reference numerals indicate generally symmetric elements, e.g., left and right
symmetric
elements may be respectively identified by the reference numerals la and lb. A
reference
numeral without an appended lowercase letter identifies all of the elements to
which that
particular reference numeral applies, e.g., the same elements as a group may
be designated 1.
The edges of various components are shown offset from each other for clarity;
the depiction
of parallel edges immediately adjacent to each other is intended to represent
that these edges are
disposed either collinearly or in close proximity to each other.
Figure 1 is a plan view of an exemplary disposable absorbent article in the
form of a diaper
20, which is shown in its flat, uncontracted state, i.e., without the
contraction induced by elastic
members. In Figure 1, the interior of the diaper is shown facing the viewer.
Figure 2 is a plan view of the diaper 20 of Figure 1 with the exterior portion
of the diaper 20
shown facing the viewer.
Figure 3 is a section view of the diaper 20 of Figure 1 taken at the section
line 3-3.
Figure 4 is a section view of the diaper 20 of Figure 1 taken at the section
line 4-4.
Figure 5 is a section view of the diaper 20 of Figure 1 taken at the section
line 5-5.
Figure 6 is a section view of the diaper 20 of Figure 1 taken at the section
line 6-6.
Figure 7 is a simplified side elevation view of an exemplary diaper 20 of
Figure 1 being
worn about a lower torso of a wearer.
Figure 8 is a front elevation view of the diaper 20 of Figure 7.
Figure 9 is a back elevation view of the diaper 20 of Figure 7.
Figure 10 is an elevation view of a laminate stretch panel.
Figure 11 is a view of the laminate stretch panel of Figure 10 in a stretched
condition.
Figure 12 is a plan view of an exemplary absorbent assembly 200 with the
interior portion
of the absorbent assembly 200 shown facing the viewer.
Figure 13 is a section view of the absorbent assembly of Figure 12 taken at
the section line
13-13.
Figure 14 is a section view of the absorbent assembly of Figure 12 taken at
the section line
14-14.
Figure 15 is a section view of an alternative embodiment of the absorbent
assembly 200 of
Figure 12.
Figure 16 is a section view of an exemplary storage component 272.
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Figure 17 is a section view of an alternative embodiment of the storage
component 272 of
Figure 16.
Figure 18 is a section view of an alternative embodiment of the side flaps 147
of Figure 1
taken at the section line 4-4.
Figure 19 is a section view of an alternative embodiment of the side flaps 147-
19 of Figure
1 taken at the section line 4-4.
Figure 20 is a section view of an alternative embodiment of the side flaps 147
of Figure 1
taken at the section line 4-4.
Figure 21 is a section view of an alternative embodiment of diaper 20 of
Figure 1
comprising an inner liner taken at the section line 3-3.
Figure 22 is a section view of an alternative embodiment of diaper 20 of
Figure 1
comprising an inner liner taken at the section line 6-6.
Figure 23 is a plan view of an alternative embodiment of exemplary chassis web
149, which
is shown in its flat, uncontracted state, i.e., without the contraction
induced by elastic members,
and prior to formation of the side flaps. In Figure 23, the exterior of the
diaper is shown facing
the viewer.
Figure 24 is a cross section view of the diaper 20 of Figure 23.
Figure 25 is a plan view of an alternative embodiment of the chassis web 149
of Figure 23.
Figure 26 is a cross section view of the chassis web 149 of Figure 25.
Figure 27 is a plan view of an alternative embodiment of the chassis web 149
of Figure 23.
Figure 28 is a cross section view of the chassis web 149 of Figure 27.
Figure 29 is a plan view of an alternative embodiment of an activation and
attachment
pattern 675 and 210 of Figure 1, which is shown in its flat, uncontracted
state, i.e., without the
contraction induced by elastic members. In Figure 29, the exterior of the
diaper is shown facing
the viewer.
Figure 30 is a plan view of an alternative embodiment of an attachment pattern
210 of
Figure 1, which is shown in its flat, uncontracted state, i.e., without the
contraction induced by
elastic members. In Figure 30, the exterior of the diaper is shown facing the
viewer.
Figure 31 is a section view of an alternative embodiment of the side flaps 147
of Figure 1
comprising attached side flaps taken at the section line 4-4.
Figure 32 is a section view of the abdominal stretch panel 370 of Figure 1
taken along the
longitudinal axis 42.
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Figure 33 is a section view of an alternative embodiment of the diaper 20 of
Figure 1 taken
along the longitudinal axis 42 comprising an inner liner.
Figure 34 is a simplified section view of an alternative embodiment of the
interior surface
102 of Figure 1 taken at the section line 3-3.
Figure 35 is a plan view of an alternative embodiment of waist regions 36 and
38 of Figure
1, wherein the waist regions 36 and 38 comprise apertures 622.
Figure 36 is a plan view of an exemplary disposable absorbent article in the
form of a diaper
20, which is shown in its flat, uncontracted state, i.e., without the
contraction induced by elastic
members. In Figure 36, the interior of the diaper is shown facing the viewer.
Figure 37 is a section view of the diaper 20 of Figure 36 taken at the section
line 37-37.
Figure 38 is a section view of the diaper 20 of Figure 36 taken at the section
line 38-38.
Figure 39 is a section view of the diaper 20 of Figure 36 taken at the section
line 39-39.
Figure 40 is a section view of the diaper 20 of Figure 36 taken at the section
line 40-40.
Figure 41 is a section view of an alternative embodiment of the diaper 20 of
Figure 36 taken
at the section line 38-38.
Figure 42 is a section view of an alternative embodiment of the diaper 20 of
Figure 36 taken
at the section line 38-38.
Figure 43 is a section view of an alternative embodiment of the diaper 20 of
Figure 36 taken
at the section line 38-38.
Figure 44 is a plan view of an exemplary disposable absorbent article in the
form of a diaper
20, which is shown in its flat, uncontracted state, i.e., without the
contraction induced by elastic
members. In Figure 44, the interior of the diaper is shown facing the viewer.
Figure 45 is a section view of the diaper 20 of Figure 44 taken at the section
line 45-45.
Figure 46 is a section view of the diaper 20 of Figure 44 taken at the section
line 46-46.
Figure 47 is a section view of the diaper 20 of Figure 44 taken at the section
line 47-47.
Figure 48 is a section view of the diaper 20 of Figure 44 taken at the section
line 48-48.
Figure 49 is a plan view of an exemplary disposable absorbent article in the
form of a diaper
20, which is shown in its flat, uncontracted state, i.e., without the
contraction induced by elastic
members. In Figure 49, the interior of the diaper is shown facing the viewer.
Figure 50 is a plan view of an alternative embodiment of exemplary chassis web
149, which
is shown in its flat, uncontracted state, i.e., without the contraction
induced by elastic members,
and prior to formation of the side flaps. In Figure 50, the exterior of the
diaper is shown facing
the viewer.
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Figure 51 is a plan view of an alternative embodiment of exemplary chassis web
149, which
is shown in its flat, uncontracted state, i.e., without the contraction
induced by elastic members,
and prior to formation of the side flaps. In Figure 51, the exterior of the
diaper is shown facing
the viewer.
Figure 52 is a plan view of an exemplary fragment of a formed web material.
DETAILED DESCRIPTION OF THE INVENTION
In this description, the following terms have the following meanings:
The term "absorbent article" refers to a device that absorbs and contains
liquid, and more
specifically, refers to a device that is placed against or in proximity to the
body of the wearer to
absorb and contain the various exudates discharged from the body.
The term "diaper" refers to an absorbent article that is generally worn by
infants and
incontinent persons about the lower torso and that is specifically adapted to
receive and contain
urinary and fecal waste. A diaper may be in the form of a taped diaper or a
pull-on (pant style)
diaper.
The term "disposable" refers to the nature of absorbent articles that
generally are not
intended to be laundered or otherwise restored or reused as an absorbent
article, i.e., they are
intended to be discarded after a single use and, may be recycled, composted or
otherwise
disposed of in an environmentally compatible manner.
The term "longitudinal" refers to a direction running from a waist edge to an
opposing waist
edge of the article and generally parallel to the maximum linear dimension of
the article.
Directions within 45 of the longitudinal direction are considered to be
"longitudinal".
The term "lateral" refers to a direction running from a side edge to an
opposing side edge of
the article and generally at a right angle to the longitudinal direction.
Directions within 45 of
the lateral direction are considered to be "lateral".
The term "circumferential" refers to a direction encircling the waist of the
wearer generally
parallel to the lateral direction.
The term "disposed" refers to an element being attached and positioned in a
particular place
or position in a unitary structure with other elements.
The term "attach" refers to elements being connected or united by adhering,
bonding,
fastening etc., by any method suitable for the elements being attached
together and their
constituent materials. Many suitable means for attaching or joining elements
together are well-
known, including adhesive, pressure, thermal, mechanical, etc. Such attachment
methods may
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be used to attach elements together over a particular area either continuously
or intermittently.
Unless indicated otherwise, elements that are described as being attached to
each other are
attached directly together, with either nothing or via one or more closure
members 700, e.g., an
adhesive or fastener, between them. Elements that are described as being
attached to each other
are attached together either permanently or temporarily, i.e., permanent
attachment means that
one or both of the elements and/or any closure members 700 that are present
must be
functionally damaged in order to separate them such that they are not
reattachable or refastenable
and temporary attachment, means that one or both of the elements and/or any
closure members
700 that are present may be separated and reattached or refastened (i.e.,
opened and closed)
multiple times while substantially maintaining functionality of the closure
member.
The term "laminate" refers to elements being attached together in a layered
arrangement.
The terms "water-permeable" and "water-impermeable" refer to the penetrability
of
materials in the context of the intended usage of disposable absorbent
articles. Specifically, the
term "water-permeable" refers to a layer or a layered structure having pores,
openings, and/or
interconnected void spaces that permit liquid water to pass through its
thickness in the absence of
a forcing pressure. Conversely, the term "water-impermeable" refers to a layer
or a layered
structure through the thickness of which liquid water cannot pass in the
absence of a forcing
pressure. A layer or a layered structure that is water-impermeable according
to this definition
may be permeable to water vapor, i.e., may be "water vapor-permeable". Such a
water vapor-
permeable layer or layered structure is commonly known in the art as
"breathable". As is well
known in the art, a common method for measuring the permeability to water of
the materials
typically used in absorbent articles is a hydrostatic pressure test, also
called a hydrostatic head
test or simply a "hydrohead" test. Suitable well known compendial methods for
hydrohead
testing are approved by INDA (formerly the International Nonwovens and
Disposables
Association, now The Association of the Nonwoven Fabrics Industry) and EDANA
(European
Disposables and Nonwovens Association).
The terms "proximal" and "distal" refer respectively to the location of an
element near to or
far from the center of a structure, e.g., the proximal edge of a
longitudinally extending element is
located nearer to the longitudinal axis than the distal edge of the same
element is located relative
to the same longitudinal axis.
The terms "interior" and "exterior" refer respectively to the location of an
element that is
intended to be placed against or toward the body of a wearer when an absorbent
article is worn
and the location of an element that is intended to be placed against or toward
any clothing that is
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worn over the absorbent article. Synonyms for "interior" and "exterior"
include, respectively,
"inner" and "outer", as well as "inside" and "outside". Also, when the
absorbent article is
oriented such that its interior faces upward, e.g., when it is laid out in
preparation for setting the
wearer on top of it, synonyms include "upper" and "lower", "above" and
"below", "over" and
"under", and "top" and "bottom", respectively.
The term "nonwoven" refers to a sheet, web, or batt of directionally or
randomly oriented
fibers, made by bonding or entangling the fibers through mechanical, thermal,
or chemical
means. Nonwoven materials exclude paper and products which are woven, knitted,
tufted, or
felted by wet milling. The fibers may be man-made synthetics.
The term "abdominal stretch panel" refers to a structural component that
resists elongation
by providing a circumferential contractive force around the waist opening of a
diaper when it is
stretched in the circumferential direction.
The term "application force" is the force required to extend the waist region
of the diaper in
order to apply the diaper onto the wearer.
The term "sustained fit force" is the force delivered by the diaper at the
waist that provides
the requisite body contact post application in order to deliver proper fit,
gasketing, and sustained
position (i.e., sustained fit).
Description of Exemplary Diaper Embodiments
In Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6, the
exemplary diaper 20 is
shown in its flat uncontracted state prior to being formed into a pant. The
finished pant product
is shown in Figure 7, Figure 8, and Figure 9.
One end portion of the exemplary diaper 20 may be configured as a front waist
region 36.
The longitudinally opposing end portion may be configured as a back waist
region 38. An
intermediate portion of the diaper 20 extending longitudinally between the
front waist region 36
and the back waist region 38 may be configured as a crotch region 37.
The basic structure of the diaper 20 may include a chassis 100. The chassis
100 has a
laterally extending front waist edge 136 in the front waist region 36 and a
longitudinally
opposing and laterally extending back waist edge 138 in the back waist region
38. The chassis
100 has a longitudinally extending left side edge 137a and a laterally
opposing and longitudinally
extending right side edge 137b, both chassis side edges extending
longitudinally between the
front waist edge 136 and the back waist edge 138. The chassis 100 has an
interior surface 102
and an exterior surface 104. The chassis 100 also has a longitudinal axis 42
and a lateral axis 44.
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The longitudinal axis 42 extends through the midpoint of the front waist edge
136 and through
the midpoint of the back waist edge 138. The lateral axis 44 extends through
the midpoint of the
left side edge 137a and through the midpoint of the right side edge 137b. The
exemplary chassis
100 shown in Figure I additionally has longitudinally extending and laterally
opposing side flaps
147a and 147b that are described in more detail below. The portion of the
chassis forming the
backsheet and side flaps (including the side barriers and cuff flaps) may be
formed by a web
(herein, the "chassis web") comprising one or more layers. One or more of the
layers forming the
chassis web 149 may be water impervious. The layers forming the chassis web
149 may have
different lateral extents or may be coterminus in width. And, the chassis web
149, as well as the
layer or layers forming the chassis web 149, may be laterally and/or
longitudinally continuous.
A portion or the whole of the chassis 100 may be made extensible to a degree
greater
than the inherent extensibility of the material or materials from which the
chassis is made, e.g.,
the backsheet 26. The additional extensibility may be desirable in order to
allow the chassis 100
to conform to the body of a wearer during movement by the wearer. The
additional extensibility
may also be desirable, for example, in order to allow the user of a diaper 20
including a chassis
100 having a particular size before extension to extend the front waist region
36, the back waist
region 38, or both waist regions of the chassis 100 to provide additional body
coverage for
wearers of differing size, i.e., to tailor the diaper to the individual
wearer. Such extension of the
waist region or regions may give the diaper a generally hourglass shape, so
long as the crotch
region 37 is extended to a relatively lesser degree than the waist region or
regions, and may
impart a tailored appearance to the diaper 20 when it is worn. In addition,
the additional
extensibility may be desirable in order to minimize the cost of the diaper.
For example, an
amount of material that would otherwise be sufficient only to make a
relatively smaller diaper
lacking this extensibility can be used to make a diaper capable of being
extended to adequately
cover a wearer that is larger than the non-extended, smaller, diaper would
fit.
A portion of the chassis 100 in the front and/or back waist regions 36 and 38
may be
made laterally extensible to a maximum extensibility greater than a maximum
extensibility of
another portion of the chassis 100 in the crotch region 37 such that a lateral
extension of each of
the portions in the front, back, and crotch regions 36, 38, and 37 to its
maximum extensibility
imparts an hourglass shape to the chassis 100. As disclosed in U.S. Patent
Publication No. 2009-
0264844, published filed on October 22, 2009, titled, Extrusion Bonded
Laminates for Absorbent
Articles, one or more layers of the chassis web may comprise an elastomeric
film which may
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provide the desired amount of extension and recovery forces during use of the
laminate. As
mentioned above, lateral extensibility may be achieved by incorporating an
elastomeric film into
one or more layers of the chassis web. Many suitable elastic materials that
may be used for one
or more layers of the chassis web include synthetic or natural rubbers (e.g.,
crosslinked
polyisoprene, polybutadiene and their saturated versions (after
hydrogenation), and
polyisobutylene), thermoplastic elastomers based on multi-block copolymers,
such as those
comprising copolymerized rubber elastomeric blocks with polystyrene blocks
(e.g., styrene-
isoprene-styrene, styrene-butadiene-styrene, styrene-ethylene/butylene-
styrene, styrene-
ethylene/propylene-styrene, and styrene-butadiene/isoprene-styrene, including
their
hydrogenated and non-hydrogenated forms), thermoplastic elastomers based on
polyurethanes,
polyesters, polyether amides, elastomeric polyolefins including polyethylenes
and
polypropylenes, elastomeric polyolefin blends, and combinations thereof.
For instance, one useful group of elastomeric polymers that may be used in the
chassis
web are the block copolymers of vinyl arylene and conjugated diene monomers,
such as AB,
ABA, ABC, or ABCA block copolymers where the A segments may comprise arylenes
such as
polystyrene and the B and C segments (for those embodiments comprising B
and/or C segments)
may comprise dienes such as butadiene or isoprene. A similar, newer group of
elastomeric
polymers are the block copolymers of vinyl arylene and hydrogenated olefin
monomers, such as
AB, ABA, ABC, or ABCA block copolymers where the A segments may comprise
arylenes such
as polystyrene and the B and C segments (for those embodiments comprising B
and/or C
segments) may comprise saturated olefins such as ethylene, propylene, or
butylene. Suitable
block copolymer resins are readily available from KRATON Polymers of Houston,
Texas,
DexcoTM Polymers LP of Planquemine, Louisiana, or SeptonTM Company of America,
Pasadena,
Texas.
Another useful group of elastomeric polymers that may be used in the chassis
web are
olefin-based elastomers. In one embodiment, the elastomeric film comprises a
polyolefinic
elastomer (POE). Examples of POEs include olefin block copolymers (OBCs) which
are
elastomeric copolymers of polyethylene, sold under the trade name INFUSETM by
The Dow
Chemical Company of Midland, Michigan. Other examples of POEs include
copolymers of
polypropylene and polyethylene, sold under the trade name VISTAMAXX by
ExxonMobil
Chemical Company of Houston, Texas and/or VERSIFY by Dow Chemical, Midland,
MI.
For the elastomeric film portion of the chassis web, other polymers may be
blended into
the compositions to enhance desired properties. For example, a linear low-
density polyethylene
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may be added to the film composition to lower the viscosity of the polymer
melt and enhance the
processability of the extruded film. High-density polyethylene may be added to
prevent age-
related degradation of the other polymers. Polypropylene has been found to
improve the
robustness of the elastomer and improve the films' resistance to pinholing and
tearing.
Additionally, polypropylene-based thermoplastic elastomer reactor blends
(e.g., ADFLEX,
available from LyondellBasell Industries, Laporte, TX) may be used to increase
the toughness
the film, as disclosed in WO 2007/146149.
The basic structure of the diaper 20 also may include an absorbent assembly
200 that may
be attached to the chassis 100. The absorbent assembly 200 has a laterally
extending front edge
236 in the front waist region 36 and a longitudinally opposing and laterally
extending back edge
238 in the back waist region 38. The absorbent assembly 200 has a
longitudinally extending left
side edge 237a and a laterally opposing and longitudinally extending right
side edge 237b, both
absorbent assembly side edges extending longitudinally between the front edge
236 and the back
edge 238. The absorbent assembly 200 has an interior surface 202 and an
exterior surface 204.
The absorbent assembly 200 may be disposed symmetrically with respect to
either or both of the
longitudinal axis 42 and the lateral axis 44. Alternatively, the absorbent
assembly 200 may be
disposed asymmetrically with respect to either or both of the longitudinal
axis 42 and the lateral
axis 44. For example, the absorbent assembly 200 shown in Figure 1 is disposed
symmetrically
with respect to the longitudinal axis 42 and asymmetrically with respect to
the lateral axis 44. In
particular, the absorbent assembly 200 shown in Figure 1 is disposed
asymmetrically toward the
front waist region 36.
The respective front edge 236, back edge 238, left side edge 237a, and right
side edge 237b
of the absorbent assembly 200 may lie inward of the respective front waist
edge 136, back waist
edge 138, left side edge 137a, and right side edge 137b of the chassis 100, as
in the exemplary
diaper 20 shown in Figure 1. In certain embodiments, the front edge 236 and
back edge 238 of
the absorbent assembly 200 may lie inward of the front and back interior
abdominal stretch
panels 370 and 390, e.g., between the proximal edges 372 and 392 of the
interior abdominal
stretch panels 370 and 390 and the lateral axis 44. Alternatively, one or more
of the edges of the
absorbent assembly 200 may coincide with the corresponding edge(s) of the
chassis 100. In yet
another alternative embodiment, as shown in Figures 1 and 32, the interior
front and back
abdominal stretch panels 370 and 390 may overlap a portion of the absorbent
assembly 200. In
such an overlapping configuration, it may be advantageous for the interior
abdominal stretch
panels 370 and/or 390 to remain unattached to the absorbent assembly 200 over
a portion of the
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longitudinal extent of the abdominal stretch panel 370 and/or 390,
particularly in the laterally
central portions of the chassis, i.e., area between the laterally opposing
side flaps 147, for
example 117 and 118, to provide an abdominal stretch panel waist cap or stand
up waist feature
forming a pocket 650 which helps to prevent leakage of urine and/or feces at
the waist.
The chassis 100 and 100 may additionally include an inner liner 22 attached to
the
backsheet 26 and/or the absorbent assembly 200 as illustrated in Figures 21
and 22. The inner
liner 22 may form a portion of the interior surface 102 of the chassis 100
that is intended to be
placed against the body of the wearer. The inner liner 22 may be formed of a
soft material that
will not irritate the skin of the wearer. Such an inner liner 22 may serve to
isolate the skin of the
wearer from a portion of the backsheet 26 as may be desirable, for example,
when the diaper 20
is worn under conditions in which contact between the skin and a backsheet 26
could be
uncomfortable. Many suitable materials for the inner liner 22 are well-known
in the art,
including rayon and synthetic nonwovens such as spunbonded or carded
polypropylene or
polyester. The inner liner 22 may extend to the same width and the same length
as the backsheet
26.
Alternatively, one or more of the edges of the inner liner 22 may lie inward
of the edges (i.e.,
side edges 137a and b, and waist end edges 136 and 138) of the chassis 100.
For example, with
reference to the exemplary diaper 20 shown in Figure lonly the portions of the
inner liner 22
(see Figures 21 and 22) lying in a front gap 606 between the front edge 236 of
the absorbent
assembly 200 and the front waist edge 136 of the chassis 100 and a back gap
607 between the
back edge 238 of the absorbent assembly 200 and the back waist edge 138 of the
chassis 100 are
exposed, while the remainder of the inner liner 22 is covered by the absorbent
assembly 200 and
the side flaps 147a and b. Therefore, a laterally extending strip of the inner
liner 22 disposed in
the front gap 606 in the front waist region 36 and a similar laterally
extending strip of the inner
liner 22 disposed in the back gap 607 in the back waist region 38 may suffice
to isolate the skin
of the wearer from the backsheet 26 in these two gaps. The inner liner 22 may
be partially
disposed under the side flaps 147 or alternatively the inner liner 22 may be
disposed on top of the
side flaps 147 in one or both of the waist regions 36 and 38. In certain
embodiments, as shown
in Figure 33, the inner liner 22 may overlap a portion of the absorbent
assembly 200. In such an
overlapping configuration, it may be advantageous for the inner liner 22 to
remain unattached to
the absorbent assembly 200 over a portion of the longitudinal extent of the
inner liner 22
particularly in the laterally central portions, area between the laterally
opposing side flaps 147,
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for example 117 and 118, to provide an inner liner waist cap or stand up waist
feature forming a
pocket 650 which helps to prevent leakage of urine and/or feces at the waist.
The basic structure of the diaper 20 also may include at least one abdominal
stretch panel
that may be attached to the chassis 100 in a waist region. When the chassis
100 is stretched in
the circumferential direction, the abdominal stretch panel resists by
providing a circumferential
contractive force around the waist opening of the diaper 20. In Figure 1,
Figure 2, Figure 3,
Figure 4, Figure 5, and Figure 6, the diaper 20 is shown as having four
abdominal stretch panels.
In particular, in Figure 1 and Figure 3, a front interior abdominal stretch
panel 370 is shown
attached interiorly to the chassis 100 in the front waist region 36 of the
diaper 20. Similarly, in
Figure 1 and Figure 6, a back interior abdominal stretch panel 390 is shown
attached interiorly to
the chassis 100 in the back waist region 38 of the diaper 20. In Figure 2 and
Figure 3, a front
exterior abdominal stretch panel 360 is shown attached exteriorly to the
chassis 100 in the front
waist region 36. Finally, in Figure 2 and Figure 6, a back exterior abdominal
stretch panel 380 is
shown attached exteriorly to the chassis 100 in the back waist region 38 of
the diaper 20. The
abdominal stretch panel may be applied to the surface of the absorbent article
in an untensioned
state, i.e. the abdominal stretch panel applies little or no contractive force
on the article until the
waist region of the article is extended laterally, e.g. during application.
Alternatively, the
abdominal stretch panel may be applied to the surface of the absorbent article
under tension and
therefore applies some contractive force to the waist region of the article
prior to use.
Alternatively, the diaper 20 may have four abdominal stretch panels as
described above, or
may have only one, two, or three abdominal stretch panels, as desired for
providing an
appropriate level of circumferential contractive forces around the waist of a
wearer. For
example, in some embodiments, the diaper 20 may have only a front exterior
abdominal stretch
panel 360, while in other exemplary embodiments, the diaper 20 may have both a
front exterior
abdominal stretch panel 360 and a back exterior abdominal stretch panel 380.
In some
exemplary embodiments, the diaper 20 may have only a front interior abdominal
stretch panel
370, while in other exemplary embodiments, the diaper 20 may have both a front
interior
abdominal stretch panel 370 and a back interior abdominal stretch panel 390.
In some exemplary
embodiments, the diaper 20 may have an exterior abdominal stretch panel and an
interior
abdominal stretch panel in either the front waist region 36 or the back waist
region 38, and only
either an exterior abdominal stretch panel or an interior abdominal stretch
panel in the opposing
waist region. The exterior abdominal stretch panels 360 and 380 may be
attached to the exterior
surface of the backsheet 26. The interior abdominal stretch panels 370 and 390
may be attached
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to the interior surface of the chassis 102 and/or the interior surface of the
absorbent assembly 202
and/or the upper surfaces 613a and b of the side flaps 147a and b.
During application of the diaper 20, particularly a diaper configured as a
pull-on pant, the
diaper 20 may be pulled upward along the legs and over the hips of the wearer
to the waist.
Several factors impact ease of application for pull-on style diapers. First,
the wearer or caregiver
should be able to get the wearer's legs through the leg openings easily.
Second, the abdominal
stretch panels 360, 370, 380, and 390 should have an acceptable application
force (i.e., the force
that allows a wearer or caregiver of the wearer to extend the abdominal
stretch panels 360, 370,
380, and 390 and pull the diaper upward over the wearer's buttocks and hips
without excessive
effort). Excessive application force makes application of the diaper 20 more
difficult for both
the caregiver and/or the wearer, for example a potty training child who pulls
the pant up and
down on their own. Finally, the abdominal stretch panels 360, 370, 380, and
390 should provide
an adequate level of wearing force or sustained fit force (i.e., the force
that the abdominal stretch
panels 360, 370, 380, and 390 apply to the waist of the wearer during wear
providing the
requisite sustained fit, including maintaining the position, fit, and
gasketing of the diaper 20 at
the waist, without marking the skin).
As shown in Figure 7, Figure 8, and Figure 9, when the diaper 20 is worn on
the lower torso
of a wearer, the front waist edge 136 and the back waist edge 138 of the
chassis 100 encircle the
waist of the wearer, while at the same time the chassis side edges 137a and
137b encircle the legs
of the wearer. At the same time, the crotch region 37 may be positioned
between the legs of the
wearer and the absorbent assembly 200 extends from the front waist region 36
through the crotch
region 37 to the back waist region 38.
Description of the Chassis
The chassis 100 may include a water-impermeable backsheet 26. The backsheet 26
forms
an exterior surface that is intended to be placed toward any clothing that is
worn over the diaper
20. Many suitable materials for use as the backsheet 26 are well-known,
including films of
polyethylene and other polyolefins. Multi-layer backsheets, such as a laminate
of a film 30 and a
nonwoven material 31 or a laminate of multiple nonwoven layers, may also be
suitable for use as
the backsheet 26. Such a backsheet may be oriented with the nonwoven 31
disposed exteriorly
of the film, as shown in Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and
Figure 6, to provide
the feel and appearance of a more cloth-like outermost layer than would be
provided by using the
film 30 as the outermost layer. A multi-layer backsheet 26, such as a laminate
of a film 30 and a
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nonwoven 31, may also be suitable for use with the nonwoven 31 disposed
interiorly to separate
the film 30 from the skin of the wearer, or with nonwoven 31 disposed both
exteriorly and
interiorly, such that the film 30 is sandwiched. In addition, the nonwoven 31
and film 30 layers
of the multi-layer laminate may have different widths, for example the film 30
may be wider
than the nonwoven 31 or alternatively the nonwoven 31 may be wider than the
film 30.
As shown in Figures 36-43, the chassis web 149 may be formed from multiple
pieces,
including a center sheet 726 and laterally opposing side sheets 60. The center
sheet 726 and the
side sheets may be formed from the same or different material types. For
example, the center
sheet 726 may comprise a water vapor impermeable material and the side sheets
may comprise a
water vapor permeable material. Exemplary materials suitable for use in the
side sheets 60
include polyolefinic films, microporous or other breathable formed films,
breathable monolithic
films, and hydrophobic nonwovens. Suitable hydrophobic nonwovens include SM
(spunbond
meltblown), SMS (spunbond meltblown spunbond), and SMMS (spunbond meltblown
meltblown spunbond) composites. The materials of the water vapor-permeable
side sheets 60
may be selected to balance overall product economics and function. For
example, a relatively
more expensive nonwoven material having a relatively high basis weight may
provide an
acceptable level of water-impermeability for use in a single layer side flap
construction.
Alternatively, a relatively less expensive nonwoven having a relatively lower
basis weight may
provide the requisite level of water-impermeability only if it is doubled,
thereby requiring a
relatively greater area of material. As another example, a microporous film
may provide a
relatively optimal combination of water-impermeability and material cost. In a
multi-layer
chassis web 149 configuration one of the layers may comprise the center sheet
726 and side
sheets forming a first multi-piece layer. The first multi-piece layer may be
attached to a separate
layer which may comprise a single continuous material or may be in the form of
a second multi-
piece web. One such embodiment comprises a multi-piece film layer having a
water vapor
impermeable center sheet 726 and water vapor permeable side sheets. The multi-
piece film layer
may be laminated to a one piece nonwoven to form a multi-layer chassis web
149.
As shown in Figures 36-43, the exemplary chassis 100 has longitudinally
extending and
laterally opposing breathable side flaps 147a and 147b that are disposed on
the interior portion of
the diaper 20 that faces inwardly toward the wearer and contacts the wearer.
The side flaps are
formed by folding portions of the chassis 100 including the water vapor-
permeable side sheets 60
laterally inward, i.e., toward the longitudinal axis 42, to form both the
respective side flaps 147a
and 147b and the side edges 137a and 137b of the chassis 100. The side sheets
60 of the chassis
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100 may be folded laterally inward to form the side flaps. Alternatively, the
chassis may be
folded such that each side flap may include the respective side sheet 60 and a
portion of the
center sheet 726. In either configuration, at least a portion of each side
flap is breathable due to
its inclusion of at least a portion of the respective water vapor-permeable
side sheet.
Alternatively, the side sheet may be water vapor impermeable and the center
sheet 726 may be
water vapor permeable.
As shown in Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6,
the exemplary
chassis 100 has longitudinally extending and laterally opposing side flaps 147
that are disposed
on the interior portion of the diaper 20 that faces inwardly toward the wearer
and contacts the
wearer. The side flaps 147 may be formed by folding portions of the chassis
100 laterally
inward, i.e., toward the longitudinal axis 42, to form both the respective
side flaps 147 and the
side edges 137 of the chassis 100. Alternatively, as shown in Figure 31, the
side flaps 147 may
be formed by attaching an additional layer or layers to the chassis 100 at or
adjacent to each of
the respective side edges 137 of the chassis 100.
Each side flap 147 has a proximal edge 157. In the exemplary diaper 20 shown
in Figure 1,
the side flaps 147 overlap the absorbent assembly 200, i.e., the proximal
edges 157 lie laterally
inward of the respective side edges 237 of the absorbent assembly 200. Such an
overlapped
configuration may be desirable in order to impart a more finished appearance
to the diaper 20
than that imparted by a non-overlapped configuration. Alternatively, the side
flaps 147 may not
overlap the absorbent assembly 200.
Each of the side flaps 147 may be attached to the interior surface 102 of the
chassis 100 in
longitudinally oriented side flap attachment zones 151 in the front waist
region 36 and
longitudinally oriented side flap attachment zones 152 in the back waist
region 38.
In the exemplary chassis 100 shown in Figure 1, the side flaps 147 may also be
attached to
the interior surface 102 of the chassis 100 in laterally oriented side flap
attachment zones 153
adjacent to the front waist edge 136 and in a longitudinally opposing
laterally oriented side flap
attachment zones 154 adjacent to the back waist edge 138.
In embodiments in which the front edge 236 or the back edge 238 of the
absorbent assembly
200 coincides with the respective front waist edge 136 or back waist edge 138
of the chassis 100
and the side flaps 147 overlap the absorbent assembly 200, the side flaps 147
may be attached to
the absorbent assembly 200 instead of, or in addition to, being attached to
the interior surface
102 of the chassis 100.
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In embodiments in which the chassis 100 comprises a multi-layer chassis web
149, such as
a laminate of a film 30 and a nonwoven 31, the nonwoven 31 may extend
laterally to the full
extent, width of the film 30 or alternatively the nonwoven 31 may have a width
that is less than
or greater than that of the film 30 layer. In an embodiment where the nonwoven
31 has a width,
lateral extent, that is less than that of the film 30, the portion of the
chassis web 149 that is folded
to form the side flap 147 may consist solely of the film 30 layer, or may
consist substantially of
the film 30 layer (in other words, for a multilayered chassis web 149, the
nonwoven 31 may
extend across the exterior surface 104 from one chassis side edge 137a to the
opposing side edge
137b; or alternatively, the nonwoven 31 may wrap the chassis side edges 137a
and b and cover a
portion of the side flaps 147a and b). In an embodiment where the nonwoven 31
has a width,
lateral extent, that is greater than that of the film 30, the portion of the
chassis web 149 that is
folded to form the side flap 147 may consist solely of the nonwoven 31 layer,
or may consist
substantially of the nonwoven 31 layer. Furthermore, the nonwoven 31 of a
multi-layer chassis
web 149 may extend longitudinally to the full extent, length, of the film 30
or alternatively the
nonwoven 31 may have a longitudinal extent that is less than that of the film
30 layer. In an
embodiment where the nonwoven 31 has a length, longitudinal extent, that is
less than that of the
film 30, the portion of the chassis 100 uncovered by the nonwoven 31 in the
front and/or back
waist regions 36 and 38 may be covered by the abdominal stretch panels 360,
370, 380, and 390.
As illustrated in Figures 23-28, 50 and 51, one or more of the layers (e.g.,
the film 30 and
nonwoven 31) of the chassis web 149 may comprise one or more design fields for
example 615
and 618a and 618b. A first design field 615 may be in contrast to other design
fields (i.e., it
exhibits a difference when compared with another design field, for example, a
second design
field 618a and third design field 618b) or to other portions of backsheet 26
or other portions of
the viewable surfaces (of an intact diaper viewed with the naked eye) of the
diaper 20, for
example, the abdominal stretch panels 360 comprising fourth design field 660
and 380
comprising fifth design field 680. The design fields 615, 618a, 618b, 660 and
680 may comprise
one or a combination of individual graphic elements (e.g., the hair of a human
image may be a
first graphic element and the eyes of the same image may be a second graphic
element), patterns
of graphic elements, and solid or interrupted colored regions. For example,
the various design
fields may be comprised of a continuously repeating pattern formed in a
longitudinally extending
direction. Alternatively, the design fields 615, 660 and 680 may be comprised
of graphic
elements (not shown) designed for a specific size diaper 20 or to provide
specific design
language associated with a specific region (e.g., front waist region 36, back
waist region 38, or
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crotch region 37 of the diaper 20. Such graphic elements are often referred to
as pitched
graphics meaning the design is linked or associated with the pitch (i.e.,
length) of the diaper 20
or portions of the diaper 20 linked to the diaper's pitch. Further, two or
more design fields can
be partially overlapped with one another to form a mixed design field.
In certain embodiments of the present invention, particularly those
embodiments where a
portion of the chassis web 149 is folded to form longitudinally extending
laterally opposing side
flaps 147a and b, the design field 615 may extend to cover (or be viewable
over) the entirety of
the exterior surface 104 of the absorbent article, as well as cover (or be
viewable on) a portion of
the upper surfaces 613a and b of the side flaps 147a and b. To be clear, the
design fields may be
viewable through the nonwoven 31 that forms the exterior surface 104 of the
backsheet 26 or the
upper surfaces 613a and b of the side flaps 147a and b when printed on the
film 30 that the
nonwoven 31 may be exteriorly bonded to. In such a case, the design fields 615
and 618 would
be viewable due to the properties of the nonwoven 31 (e.g., thinness,
transparency, opacity, etc.).
In one embodiment, a first design field 615 extends laterally from one side
edge 137a to the
laterally opposing side edge 137b of the chassis 100. In addition to covering
the exterior surface
104 of the chassis 100 it may be desired to have the first design field 615
wrap over the side
edge(s) 137a and b of the chassis 100 and extend laterally inward to cover at
least a portion of
the side flaps 147a and b. Alternatively, the side flaps 147a and b may
comprise a second and
third design fields 618 a and b respectively. In certain embodiments, the
design fields 615, 618 a
and b, 660 and 680 may provide not only a pleasing aesthetic visual appearance
to the viewable
portions of the absorbent article, but it may also distinguish the side flaps
147a and b from the
backsheet 26, or portions of the side flaps 147a and b from itself (e.g.
distinguishing the cuff
flaps 631 from the side barriers 633) such that the wearer or caregiver is
assisted with proper
placement of the side flaps 147a and b during application of the diaper 20.
See Figures 23 and
24, for example, the backsheet 26 has a first design field 615 undulating
along a left fold line
608a of the chassis web 149 and terminating at a right fold line 608b of the
chassis web 149.
The fold lines 608a and b are the lines that the chassis web 149 is folded
along to form backsheet
26 side flaps 147a and b and side edges 137a and b. A second design field 618
may extend from
the right side edge 619 of the first design field 615 to the unfolded right
side edge 155b (which
becomes the proximal edge 157b of the side flap 147b when the chassis 100 is
folded to form the
side flaps 147a and b). Alternatively, as shown in Figures 25 and 26, the
first design field 615
may extend from a point at or adjacent the left side edge 137a to a point at
or adjacent 137b of
the chassis 100 such that the side flaps 147a and b become visually distinct
elements. Both the
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18
first design field 615, second design field 618 a, and third design field 618
b, when present, can
make portions of the side flaps 147a and b (e.g. the cuff flaps 631 and side
barriers 633) more
visually distinct, especially when a second elastic strand 168a and b is used,
such that the double
cuff feature (i.e., incorporation of a first and second elastic strands 167a
and b and 168a and b,
wherein the first elastic strands 167a and b is immediately adjacent the
proximal edges 157a and
b of the side flaps 147a and b and the second elastic strand 168a and b is
oriented immediately
adjacent the side edge 137a and b of the chassis 100) is visually highlighted.
It should be
understood that, as shown in Figures 27 and 28, the double cuff feature may
also be highlighted
by the first design field 615 being contrasted against side flaps 147a and b
which do not
comprise graphic elements in the second or third design field 618a and b, and
therefore comprise
a solid color (single color) and texture of the backsheet 26 making it up. In
a muli-piece chassis
web 149 construction as described above, design field 615 may be disposed on
the center sheet
726 and design field 618 may be disposed on the side sheets 60.
As shown in Figures 50 and 51, the abdominal stretch panels 360, 370, 380, and
390
comprise design fields 660, 670, 680 and 690, fourth, sixth, fifth and seventh
design fields
respectively. In one embodiment, the design field 660 and/or 680 may comprise
the only graphic
elements visible on the exterior of the absorbent article (when being worn),
i.e., the remainder of
the viewable exterior of the article (when being worn) has no additional
graphic elements. In an
alternative embodiment, design field 660 and/or 680 on the viewable exterior
of the abdominal
stretch panel (when being worn) may comprise a multi-color graphic element or
design field and
the remainder of the viewable exterior of the absorbent article (when being
worn) may comprise
a single color design field. In yet another alternative embodiment, the design
field 660 and/or
680 of the abdominal stretch panel may comprise a single color design field
and design fields
615 or 618 may comprise a multi-color design field. Alternatively, design
field 660 and/or 680
may comprise a single color design field, or multicolor design field and/or
multi-color graphic
elements and may be combined with a backsheet comprising no graphic elements,
a single color
design field or single or multicolor graphic elements.
Furthermore the design field 660 of the abdominal stretch panel disposed in
the front waist
region may comprise a graphic element or elements intended to indicate the
front of the
absorbent article while the design field 680 of the abdominal stretch panel
disposed in the back
waist region may comprise a graphic element or elements intended to indicate
the back of the
absorbent article thereby helping the caregiver or wearer to orient the
product accurately for
application. Likewise, the backsheet comprising design field 615 disposed in
the front waist
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region may comprise a graphic element or elements intended to indicate the
front of the
absorbent article while the design field 615 of the backsheet disposed in the
back waist region
may comprise a graphic element or elements intended to indicate the back of
the absorbent
article.
Between the longitudinally opposing side flap attachment zones, the proximal
edges 157 of
the side flaps 147 remain free, i.e., are not attached to the interior surface
102 of the chassis 100
or to the absorbent assembly 200. Also between the longitudinally opposing
side flap attachment
zones, each side flap may include one or more (specifically including one,
two, three, or four
strands per side flap) longitudinally extensible flap elastic gathering
members that may be
attached adjacent to the proximal edge of the side flap by any of many well-
known means. Each
of such flap elastic gathering members may be attached over its entire length
or over only a
portion of its length. For example, such flap elastic gathering members may be
attached only at
or near its longitudinally opposing ends and may be unattached at the middle
of its length. Such
flap elastic gathering members may be disposed in the crotch region 37 and may
extend into one
or both of the front waist region 36 and the back waist region 38. For
example, in the exemplary
chassis 100 shown in Figure 1, an elastic strand 167 may be attached adjacent
to the proximal
edge 157 of each of the side flaps 147 and extends into both the front waist
region 36 and the
back waist region 38.
Each flap elastic gathering member may be enclosed inside a folded hem. For
example, in
the exemplary chassis 100 shown in Figure 4 and Figure 5, each of the elastic
strands 167 may
be enclosed inside a hem 170 formed adjacent to the proximal edge 157 of the
respective side
flap 147. Alternatively, the flap elastic gathering member(s) may be
sandwiched between two
layers of the chassis or may be attached on a surface of the chassis 100 and
remain exposed.
When stretched, the flap elastic gathering member disposed adjacent to each
side flap
proximal edge allows the side flap edge to extend to the flat uncontracted
length of the chassis,
e.g., the length of the chassis 100, as shown in Figure 1. When allowed to
relax, the flap elastic
gathering member contracts to pull the front waist region 36 and the back
waist region 38 toward
each other and thereby bend the diaper 20 into a "U" shape in which the
interior of the "U" shape
may be formed by the portions of the diaper 20 that are intended to be placed
toward the body of
the wearer. Because each of the proximal edges 157 remains free between the
longitudinally
oriented side flap attachment zones 151 and 152, the contractive force of the
elastic strand 167
lifts the proximal edge 157 of the side flap 147 away from the interior
surface 102 of the chassis
100. This lifting of the proximal edges 157 when the diaper 20 is in the
relaxed condition lifts
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the side flaps 147 into position to serve as side barriers adjacent to the
side edges 237 of the
absorbent assembly 200.
As shown in Figures 1, 2, 4, 5, 18, 19, and 20, one or more (specifically
including one, two,
three, or four strands per side flap) second elastic strands 168a and b may be
attached at or
adjacent the chassis side edges 137a and b of the chassis 100 where it is
folded to form the side
flaps 147a and b. When allowed to relax, the second elastic strands 168a and b
may gather the
side edges 137a and b of the chassis 100 to form side barriers 633a and b and
function as a
barrier to leakage of urine and fecal waste. A channel 621a and b may be
formed adjacent the
side edge 137a and b of the chassis 100 where it is folded to form the side
flap 147a and b such
that the portion of the chassis web 149 forming the channel 621a and b remains
largely non-
adhered to itself or to the second elastic strands 168a or b, particularly in
each of the opposing
waist regions 36 and 38, such that the second elastic strands 168a and b
floats in the hollow of
the channels 621a and b to enable the second elastic strands 168a and b to
snap back to its glued-
in length once the diaper 20 is cut to length during manufacture.
As shown in Figures 2, 4, 5, 18, 19 and 20 the side flaps 147 may be formed
into cuff flaps
631 and side barriers 633. Particularly, side barrier attachments 630 may be
oriented between
the first and second elastic strands 167 and 168. The placement of side
barrier attachments 630
relative to the longitudinal axis 42 has a direct and coupled effect on the
depth of cuff flaps 631
and the size of the side barriers 633. For example, when the side barrier
attachments 630 are
moved laterally inward, the depth of the cuff flaps 631 decreases and the size
of the side barriers
633 increases. Conversely, as shown in Figure 18, when the side barrier
attachments 630 are
moved laterally outward, the depth of the cuff flaps 631 increases and the
size of the side barriers
633 decreases. The depth and/or size of the cuff flaps 631 and side barriers
633 may be adjusted
for various applications to provide enhanced functionality. In one such
embodiment, as shown in
Figure 19, it has been found that reduced depth cuff flaps 631 and larger side
barriers 633
provides better application ease with regard to a pull-on pant style
application. This
configuration increases the size of the leg opening (not shown in Figure 19)
enabling the wearer
to step into the diaper 20 more easily. In yet another embodiment, it has been
found that
increasing the depth of the cuff flaps 631 and reducing the size of the side
barriers 633 provides
improved leakage protection and increased perception of capacity.
The depth of the cuff flaps 631 as measured from the proximal edge 157 of the
side flap 147
to the side barrier attachment 630 may be from about 2 cm to about 7 cm, from
about 2.5 cm to
about 6.5 cm, or from about 3 cm to about 6 cm. The length of the side flap
147, as measured
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from the proximal edge 157 of the side flap 147 to the side edge 137 of the
chassis 100 may be
from about 4.5 cm to about 9.5 cm, from about 5 cm to about 8.5 cm, or from
about 5.5 cm to
about 7.5 cm. Alternatively, as shown in Figure 20, a second pair of side
barrier attachments
630c and d may be used such that one can adjust the height of the cuff flaps
631 of the side flaps
147 without impacting the height of the side barriers 633. A channel 634a and
b may be formed
between side barrier attachments 630a and c and/or 630b and d and may comprise
one or more
additional elastic gathering members/strands 635a and b disposed therein.
For embodiments wherein the side flaps 147 are formed by attaching additional
layers (e.g.,
film 30 and/or nonwoven 31) to the chassis 100 at or adjacent to each of the
respective side
edges 137a and b of the chassis 100, the second elastic strand 168a and b may
be oriented and
attached between the layers (e.g., film 30 and nonwoven 31) see Figure 32. The
layers (e.g., film
30 and nonwoven 31) may also form a channel (e.g., 621a and b) and provide the
functionality
associated with it as described above.
As shown in Figures 44-49, the basic structure of the diaper 20 may include a
chassis 100.
The chassis 100 has a laterally extending front waist edge 136 in the front
waist region 36 and a
longitudinally opposing and laterally extending back waist edge 138 in the
back waist region 38.
The finished chassis 100 has longitudinally extending front folded side edge
segments 133a and
133b in the front waist regions, longitudinally opposing longitudinally
extending back folded
side edge segments 133c and 133d in the back waist region, and longitudinally
extending cut side
edge segments 135 in at least the crotch region, each of the cut side edge
segments 135
connecting the respective front and back folded side edge segments 133. In
combination, the
respective folded side edge segments 133 and cut side edge segments 135 form
the composite
side edges 137, which connect the front waist edge and the back waist edge.
The chassis 100 has
an interior surface 102 and an exterior surface 104. The chassis 100 also has
a longitudinal axis
42 and a lateral axis 44. The longitudinal axis 42 extends through the
midpoint of the front waist
edge 136 and through the midpoint of the back waist edge 138. The lateral axis
44 extends
through the midpoint of the left side edge 137a and through the midpoint of
the right side edge
137b. The exemplary chassis 100 shown in Figure 44 additionally has
longitudinally extending
and laterally opposing side flaps 147a and 147b that are described in more
detail below.
In the finished diaper, the chassis has a generally "hourglass" shape, as in
the exemplary
diaper 20 shown in Figure 44. Such a non-rectangular shape may be desirable in
order to impart
a tailored appearance to the diaper 20 when it is worn. Such a non-rectangular
shape may also
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be desirable in order to impart an impression that the diaper 20 will fit
comfortably between the
legs of a wearer.
The chassis 100 is given the hourglass shape by the removal of laterally
opposing portions
of the chassis 100 from at least the crotch region 137, to form laterally
opposing side notches
139. This formation of the side notches 139 in the chassis makes its lateral
dimension at and
adjacent to the lateral axis 44 smaller than its lateral dimension at and
adjacent to the front waist
edge 136 and smaller than its lateral dimension at and adjacent to the back
waist edge 138, i.e.,
makes the chassis narrower in the crotch region 37 than at the waist edges 136
and 138.
The contour of the side notch 139 that is formed by the removal folded
material along the
cut side edge segment 135 is defined by the contour of that cut side edge
segment. The contour
may be continuously arcuate. Alternatively, the contour may be a composite
formed by two
longitudinally opposing arcuate portions 140 and a generally straight
intermediate portion 141
connecting the arcuate portions, and thus not continuously arcuate, as in the
exemplary diapers
20 shown in Figure 44. The side notches 139 may be disposed symmetrically with
respect to
either or both of the longitudinal axis 42 and the lateral axis 44 of the
chassis 100. For example,
the side notches 139 are shown disposed symmetrically with respect to both the
longitudinal axis
42 and the lateral axis 44 in Figure 44. Alternatively, the side notches 139
may be disposed
asymmetrically with respect to either or both of the longitudinal axis 42 and
the lateral axis 44.
For example, the side notches 139 may be disposed symmetrically with respect
to the
longitudinal axis 42 and asymmetrically with respect to the lateral axis 44,
for example where the
side notches are offset toward the front waist edge 136.
The formation of the side notches 139 by the removal of the laterally opposing
portions of
the chassis leaves only longitudinally separated segments of the folded side
edges 133 intact to
prevent any bodily waste material from migrating laterally and escaping from
the diaper 20. In
particular, only the front folded side edge segments 133a and 133b and the
back folded side edge
segments 133c and 133d remain intact. The removal of the side portion 142 to
form each side
notch 139 detaches the respective side flap 147 from the underlying layer of
the chassis along the
contour of each cut side edge segment 135, thus creating an opening through
which bodily waste
material could escape. Therefore, the chassis 100 may include at least one
longitudinally
extending continuous barrier attachment 630 disposed laterally proximally of
each cut side edge
segment 135. Each side flap 147 is attached to the underlying layer of the
chassis 100 at the
barrier attachment 630. Each barrier attachment 630 is water-impermeable at
least laterally and
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23
thereby preferably acts as a dam to prevent the lateral escape of bodily waste
material in the gap
between the longitudinally separated front and back folded side edge segments.
A single barrier attachment 630 may be used to attach each side flap 147 or,
alternatively,
two or more barrier attachments 630 may be used to attach each side flap 147.
One or more
barrier attachments 630 used to attach each side flap can be described as
forming a barrier
attachment zone (that is, each side flap having its own barrier attachment
zone). For example, in
the exemplary diaper 20 shown in Figure 44, two laterally spaced barrier
attachments 630 may
be used to attach each side flap 147. As another example, a single barrier
attachment 630 may be
used to attach each side flap 147 in the exemplary diapers 20. As yet another
example, four
laterally spaced barrier attachments 630 may be used to attach each side flap
147 in the
exemplary diaper 20. The use of a single barrier attachment 630 for each side
panel 147 may
help to minimize the cost of the diaper 20. On the other hand, the use of more
than one barrier
attachment 630 for each side panel 147 may help to prevent the lateral escape
of bodily waste
materials in the event that one side seal is not perfectly continuous and
thereby allows flow past
itself.
The barrier attachments 630 may be oriented generally parallel to the
longitudinal axis 42
and to each other, as shown in Figure 44. The barrier attachments 630 may be
configured as
mirror images of each other.
The barrier attachments 630 may be formed by heat bonding, pressure bonding, a
combination of heat bonding and pressure bonding, ultrasonic bonding, adhesive
bonding, or in
any other way or combination of ways known in the art for forming laterally
water-impermeable
bonds. Each barrier attachment 630 may extend from the front waist edge 136 to
the back waist
edge 138, as shown in Figure 44. Alternatively, a barrier attachment 630 may
extend less far in
the longitudinal direction. For example, a barrier attachment 630 may extend
longitudinally only
as far as the respective cut side edge segment 135 extends.
The barrier attachment 630 may initially extend through the side portion of
the chassis 100
that is eventually removed to form the side notch 139. Exemplary barrier
attachments 630
remaining longitudinally continuous after the formation of the side notches
139 are also shown in
the finished exemplary diaper 20 of Figure 44 and Figure 49.
The barrier attachments 630 may be substantially linear in form as shown in
Figure 44.
Alternatively, a barrier attachment 630 may be curvilinear in form. For
example, a barrier
attachment 630 may have a contour generally concentric to the contour of the
cut side edge
segment 135 and thereby "follow" the contour of the cut side edge segment from
a point at or
CA 02760584 2011-10-31
24
adjacent to a respective front folded side edge segment 133a or 133b to the
respective
corresponding back folded side edge segment 133c or 133d. In such a
configuration, the
combination of the front folded side edge segment, the side seal, and the back
folded side edge
segment may form a longitudinally continuous barrier to the lateral flow of
bodily waste material
between the front and back waist edges. As another alternative in which a
combination of the
front folded side edge segment, the side seal, and the back folded side edge
segment may form a
longitudinally continuous barrier to the lateral flow of bodily waste
material, a barrier attachment
630 may be sufficiently wide to extend from laterally inward of the cut side
edge segment 135 to
the folded side edge segments 133, such as the exemplary side seals shown in
Figure 49.
Each barrier attachment 630 may be formed as a relatively narrow stripe being
at least ten
times as long as it is wide, such as the exemplary side seals shown in Figure
44. Alternatively,
each barrier attachment 630 may be formed as a relatively wide band being less
than ten times as
long as it is wide, such as the exemplary side seals shown in Figure 49.
At and/or adjacent to each of the side edges 137 of the chassis, the front
waist region 36
and the back waist region 38 are attached together to form the finished pant
product having a
waist opening 10 and two leg openings 12. This attachment may have the form of
side seams
115. Such a side seam may be formed where the waist regions are overlapped
such that the
interior surface of one lies against the exterior surface of the other. In
another form, a side seam
may be formed where the side edges in the waist regions are abutted. In
another form, a side
seam may be formed where either the interior surfaces or the exterior surfaces
of the waist
regions are in face-to-face contact, i.e., in' a so-called flanged attachment.
Such flanged
attachments are shown in Figure 7, Figure 8, and Figure 9.
Referring to Fig. 7, side seam 115 may comprise primary closure members 700
which are
refastenable. The primary closure members 700 may comprise any refastenable
fastening
components known in the art. For example, the primary closure members 700 may
comprise
mechanical fasteners, e.g. hook and loop fasteners, hook and hook fasteners,
macrofasteners,
buttons, snaps, tab and slot fasteners, tape fasteners, adhesive fasteners,
cohesive fasteners,
magnetic fasteners, hermaphrodidic fasteners and the like. Some suitable
examples of fastening
systems and/or fastening elements are discussed in U.S. Patent Nos. 3,848,594;
4,662,875;
4,846,815; 4,894,060; 4,946,527; 5,151,092; 5,221,274; 6,251,097; 6,669,618;
and 6,432,098;
U.S. Patent Publication No. 2007-0078427, entitled, "Anti-Pop Open
Macrofasteners" published
on April 5, 2007; and U.S. Patent No. 7,799,006, entitled, "A Fastening System
Having Multiple
Engagement Orientations". Additionally, various suitable pant
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configurations are disclosed in U.S. Patent Nos. 5,246,433; 5,569,234;
6,120,487; 6,120,489;
4,940,464; 5,092,861; 5,897,545; 5,957,908; and U.S. Patent Publication Nos.
2003/0233082;
2005/0234419A1; 2003/0088220; 2005/0130821; 2003/0233082; 2005/0215971;
2005/0215970;
2007/0078427; 2007/0093769; 2007/0074381; 2007/0078426A1; and 2008-0107861.
A side seam may be formed where the waist regions are overlapped such that the
interior surface of one lies against the exterior surface of the other. In
such an embodiment, one
closure member 700 may be disposed on the interior surface of the side flap
while the other
closure member 700 is disposed on the exterior surface of the backsheet. In an
alternative
embodiment, a side seam may be formed where the side edges in the waist
regions are abutted.
In such an embodiment, the closure member 700 may be disposed on the outer
surface of the
backsheet in both the front and back waist regions and/or on the inner surface
of the side flaps in
the front and back waist regions such that it spans from one waist region to
the opposing waist
region. In yet another embodiment, a side seam may be formed where either the
interior surfaces
or the exterior surfaces of the waist regions are in face-to-face contact,
i.e., in a so-called flanged
attachment. Such flanged attachments are shown in Figure 7, Figure 8, and
Figure 9.
In other embodiments, closure members 700 may be employed to enable adjustment
of the
article once the article has been applied to a wearer. Secondary closure
members (not shown)
serve to increase the tension (i.e., "cinch") in the waist hoop subsequent to
application in order to
provide enhanced sustained fit of the article. Secondary closure members (not
shown) may
include any type of fastener as known in the art and may be associated with a
stretch element that
aids in increasing the tension in the waist hoop. A secondary closure member
(not shown) may
be disposed adjacent one of the primary closure members 700 or may be made
unitarily with one
of the primary closure members 700, The purpose of a secondary closure member
(not shown) is
to allow the user to adjust the fit of the article. It should be understood
that multiple closure
members, i.e. primary, secondary, tertiary, etc. may be incorporated into one
or all of the
components forming the refastenable side seam 115.
Further, it should be appreciated that closure members 700 need not have an
infinite life
span, but it is sufficient that the closure members 700 attached in a
refastenable manner can be
separated and re-attached successively several times over the typical use life
span of the
absorbent article. It will also be appreciated that the aggressiveness of
actual fastening may be
reduced significantly from fastening to refastening in absolute terms, but
that such reduction is
not "substantial degradation" of fastener performance if the resulting
refastened strength is
sufficient for the fastening system's purpose of use.
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26
A portion or the whole of the chassis 100 may be made extensible to a degree
greater than
the inherent extensibility of the material or materials from which the chassis
is made, e.g., the
backsheet 26. The additional extensibility may be desirable in order to allow
the chassis 100 to
conform to the body of a wearer during movement by the wearer. The additional
extensibility
may also be desirable, for example, in order to allow the user of a diaper 20
including a chassis
100 having a particular size before extension to extend the front waist region
36, the back waist
region 38, or both waist regions of the chassis 100 to provide additional body
coverage for
wearers of differing size, i.e., to tailor the diaper to the individual
wearer. Such extension of the
waist region or regions may give the diaper a generally hourglass shape, so
long as the crotch
region 37 is extended to a relatively lesser degree than the waist region or
regions, and may
impart a tailored appearance to the diaper 20 when it is worn. In addition,
the additional
extensibility may be desirable in order to minimize the cost of the diaper.
For example, an
amount of material that would otherwise be sufficient only to make a
relatively smaller diaper
lacking this extensibility can be used to make a diaper capable of being
extended to adequately
cover a wearer that is larger than the unextended smaller diaper would fit.
A portion of the chassis 100 in the front and/or back waist regions 36 and 38
may be made
laterally extensible to a maximum extensibility greater than a maximum
extensibility of another
portion of the chassis 100 in the crotch region 37 such that a lateral
extension of each of the
portions in the front, back, and crotch regions 36, 38, and 37 to its maximum
extensibility
imparts an hourglass shape to the chassis 100. In one embodiment, the portion
of the chassis 100
underlying and/or immediately adjacent an abdominal stretch panel (e.g.,
back/front
interior/exterior abdominal stretch panels 360, 370, 380, and 390) may be made
laterally
extensible to a maximum extensibility greater than a maximum extensibility of
another portion
of the chassis 100, for example the crotch region 37, such that a lateral
extension of each of the
portions to its maximum extensibility facilitates application of the diaper 20
onto the body of a
wearer by enabling the waist opening 10 to be extended to fit over the
wearer's hips and in
addition, opening and orienting the leg openings 12 enabling the wearer to
place the legs through
the leg openings 12 more effectively.
Additional lateral extensibility in the chassis 100 may be provided in a
variety of ways. For
example, a material or materials from which the chassis 100 is made may be
pleated by any of
many known methods. Alternatively, all or a portion of the chassis may be
intermittently
activated to create a structured elastic-like formed web material or a formed
laminate of web
materials like those described in U.S. Patent No. 5,518,801 issued on 21 May
1996 in the name
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27
of Chappell et al. In another preferred embodiment, the web material of the
present invention
exhibits at least two significantly different stages of resistive force to an
applied elongation along
at least one axis when subjected to an applied elongation in a direction
substantially parallel to
the axis. The web material may include a strainable network having at least
two distinct regions.
One of the regions is configured such that it will exhibit resistive forces in
response to an applied
axial elongation in a direction substantially parallel to the axis before a
substantial portion of the
other region develops any significant resistive force to the applied
elongation. At least one of the
regions has a surface-pathlength which is greater than that of the other
region as measured
substantially parallel to the axis while the material is in an untensioned
condition. The region
exhibiting the longer surface-pathlength may include one or more rib-like
elements, forming
ridges and valleys, which extend beyond the plane of the other region. The web
material exhibits
first resistive forces to the applied elongation until the elongation of the
web material is
sufficient to cause a substantial portion of the region having the longer
surface-pathlength to
enter the axis of applied elongation, whereupon the web of material exhibits
second resistive
forces to further elongation. (i.e., become essentially coplanar with the axis
of applied
elongation). The total resistive force to elongation is higher than the first
resistive force to
elongation provided by the first region.
This formed web material may include distinct laterally extending regions in
which the
original material has been altered by embossing or another method of
deformation to create a
pattern of generally longitudinally oriented alternating ridges and valleys
and also may include
laterally extending unaltered regions between the laterally extending altered
regions. The
formed web material can be extended in a direction perpendicular to the ridges
up to the point
where the ridges and valleys flatten with substantially less force than is
required to extend
beyond that point. In addition to lateral extensibility, the creation of a
formed laminate web as
described above provides the backsheet 26 with improved texture and cloth-like
appearance and
feel. The deformation creates a cloth-like pattern in the film and increases
the loft of the
nonwoven 31 in multi-layer film 30 and nonwoven 31 laminate backsheets 26.
An exemplary fragment 300 of such a formed web material 305 is shown in Figure
52. This
formed web material 305 may include distinct laterally extending regions 310
in which the
original material has been altered by embossing or another method of
deformation to create a
pattern of generally longitudinally oriented alternating ridges 312 and
valleys 314. The formed
web material 305 also may include laterally extending unaltered regions 316
located between the
laterally extending altered regions 310.
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28
Such a formed web material 305 can be laterally extended beyond its original
dimension
with the application of relatively less force than that required to extend the
same material to the
same extent when undeformed. In particular, the effects of an application of
opposing divergent
forces directed generally perpendicular to the ridges 312 and valleys 314
include an extension of
such a formed web material along an axis between the opposing forces and the
generation of a
resistive contractive force, primarily in the unaltered regions 316. This
resistive force is
relatively smaller than the resistive force that is generated by the same
material in its unaltered
form when extended to the same extent, at least up to an extension at which
the ridges and
valleys in the altered regions flatten and begin to contribute to the
resistive force. Thus, such
formed web materials exhibit an extensible behavior resembling that of
traditional elastic
materials in the range of extensibility that is useful for the type of lateral
extension desired for
use in absorbent articles. However, such formed web materials may be made of
relatively less
expensive materials that are not inherently elastic and, thus, their use may
provide an advantage
in terms of the cost of manufacturing the absorbent articles.
Alternatively, a portion of the chassis can be continuously activated (e.g.,
ring-rolled and
thus rendered highly extensible as described in U.S. Pat. No. 5,366,782
(issued Nov. 22, 1994 to
Curro, et al)). Specifically, a ring-rolling apparatus (not shown), which
comprises opposing rolls
(not shown) having intermeshing teeth (not shown) that incrementally stretch
and thereby
plastically deform the chassis (or a portion thereof) thereby rendering the
chassis extensible in
the ring-rolled regions. In one embodiment, the backsheet 26 can be ring-
rolled in a portion of at
least one of the front or back waist regions 36 and 38, for example the
portion of the chassis 100
underlying and/or immediately adjacent the back/front interior/exterior
abdominal stretch panels
360, 370, 380, and 390, while other regions may comprise a structured elastic-
like formed web
material.
The activation approaches described above are achieved by using a set of
opposing rolls
comprising a staggered orientation of teeth such that when a material such as
the chassis web 149
or backsheet passes through the intermeshing rolls, the material is deformed
to create the desired
activation pattern in the web. Alternatively, the teeth of one of the rolls
may be continuous
around the circumference of the roll while the teeth on the opposing roll may
be discontinuous
forming intermittent activation (e.g. a structured elastic-like formed web) or
a pitched continuous
activation (e.g. continuously activated in the opposing waist regions and not
the crotch region).
The depth to which the teeth intermesh, i.e. depth of engagement, will
determine to what degree
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29
the web is incrementally stretched and/or plastically deformed and therefore
the degree of
extensibility imparted to the web.
In some embodiments, the chassis web 149 can be activated in a portion of side
barriers
or cuff flaps to a greater extent, for example, length of the
activated/deformed region or the depth
of engagement. For example, in these embodiments, one or both of the waist
regions of the
chassis immediately adjacent the side edges may comprise longer longitudinally
oriented ridges
and valleys while other portions of the waist region may comprise relatively
shorted
longitudinally oriented ridges and valleys. Alternatively, one or both of the
waist regions of the
chassis immediately adjacent the side edges and or end edges may comprise a
material that has
been deformed to a greater extent forming larger (i.e. deeper) longitudinally
oriented ridges and
valleys while other portions of the absorbent article may comprise relatively
smaller (i.e.
shallower) longitudinally oriented ridges and valleys.
In certain embodiments, the activated portion of the chassis web 149 disposed
in one of the
front or back waist region may comprise a continuous activation pattern (e.g.,
via ring rolling)
and an intermittent activation pattern (i.e., a structured elastic-like formed
web material). These
two activation patterns may be disposed in an overlapping or side-by-side
relationship. For
example, as a more particular embodiment, the entire chassis web 149 may be
intermittently
activated to form a structured elastic-like formed web material and the
portion of the chassis web
149 disposed in one or both of the waist regions may be continuously
activated, such that the
continuously activated region overlaps the intermittently activated region.
As illustrated in Figure 34, when exterior abdominal stretch panels 360 and
380 are used,
but not interior abdominal stretch panels 370 and 390, ring-roll type (e.g.
continuous) activation
may create corrugations 636 in the interior of the waist regions 36 and 38.
Specifically, the
chassis 100 (including the backsheet 26, side flaps 147, and inner liner 22
(when present)), may
be corrugated to provide an undulating inner surface 102, forming the
corrugations 636. These
corrugations 636 are believed to promote breathability and, overall, a
healthier environment for
the wearer's skin, particularly in the waist region.
Alternatively, when interior abdominal stretch panels 370 and 390 are used,
but not
exterior abdominal stretch panels 360 and 380, ring-roll type (e.g.
continuous) activation may
create corrugations 636 on the exterior of the waist regions 36 and 38.
Specifically, the chassis
100 (including the backsheet 26, side flaps 147, and inner liner 22 (when
present)), may be
corrugated to provide an undulating outer surface 104, forming the
corrugations 636. These
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corrugations 636 are believed to provide an impression of extensibility as the
waist region of the
article is extended during application.
The chassis 100 may be ring-rolled across the entire width in one or both of
the front/back
waist regions 36 and 38 or alternatively may be ring-rolled over only a
portion of the chassis 100
width. In yet another embodiment the portion of the chassis 100 may be ring-
rolled where the
side flaps 147a and b overlap and are joined to the chassis 100 in the side
flap attachment zones
151, 152, 153, and 154. The ring-rolling may take place prior to folding
portions of the chassis
100 to form the side flaps 147a and b or alternatively after the side flaps
147a and b have been
formed and/or attached. Further, ring-rolling may take place after the
back/front interior/exterior
abdominal stretch panels 360, 370, 380, and 390 are attached.
The front laterally central portion 117 and the back laterally central portion
118 of the
chassis 100 may have a different range of extensibility from the portions of
the chassis in the
side flap attachment zones 151, 152, 153, and 154 where the side flaps 147a
and 147b may be
attached to the interior surface 102 of the chassis. Additionally or
alternatively, the laterally
central portions 117 and 118 may be extensible to a greater or lesser degree
when subjected to a
given level of opposing tensile forces, i.e., may be more easily or less
easily extensible, than the
portions of the chassis in the side flap attachment zones. For example, if the
chassis is made
uniformly extensible across its entire width prior to the formation of the
side flaps, the double
layering in the areas of the side flap attachment zones after the formation of
the side flaps may
have an effect of decreasing the degree of lateral extensibility of those
areas under a given level
of opposing tensile forces, such as by the side flaps acting as parallel
"springs" that may be
extended in order to extend the underlying attached portion of the chassis. As
another example,
the altered regions in the laterally central portions of the chassis may be
deformed to a greater or
a lesser degree than the altered regions in the side flap attachment zones to
render the laterally
central portions more easily or less easily extensible than the respective
portions in the side flap
attachment zones.
Additionally, as shown in Figures 29 and 30, a portion of one or a combination
of the
backsheet, side barriers, and cuff flaps may be activated as described above
to provide a greater
level of longitudinal extensibility. In such an embodiment, at least one of
the opposing rolls may
include a staggered orientation of teeth such that when engaged with the
opposing roll, a curved
or shaped activation pattern is formed in the web. This curved pattern may be
useful for
activating the side barriers of a shaped diaper (e.g., a side notched diaper)
or useful for activating
around particular diaper elements (e.g., graphic elements). Alternatively, the
teeth of the rolls
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31
may be oriented in a substantially non-staggered pattern thereby creating a
longitudinally
extending area of extensibility that comprises a substantially straight
pattern formed in the web.
The depth to which the teeth intermesh, i.e. depth of engagement, will
determine to what degree
the web is incrementally stretched and/or plastically deformed and therefore
the degree of
extensibility imparted to the web.
In some embodiments, the chassis web 149 can be activated in a portion of side
barriers
or cuff flaps. For example, in these embodiments, as shown in Figures 29 and
30, the portion of
the chassis immediately adjacent the side edges can comprise laterally
oriented alternating ridges
712 and valleys 714 while other regions may comprise longitudinally oriented
alternating ridges
312 and valleys 314.
In certain embodiments, the activated portion of the chassis web 149 disposed
in the front or
back waist region comprises a longitudinally continuously activation pattern
(e.g., via ring
rolling) and a longitudinally intermittent activation pattern (i.e., a
structured elastic-like formed
web material). These two activation patterns may be disposed in an overlapping
or side-by-side
relationship.
In certain embodiments, the activated portion of the chassis web 149 disposed
adjacent the
side edges, for example, the side barriers and/or cuff flaps may comprise a
laterally continuous
activation pattern comprising laterally oriented ridges 712 and valleys 714
(e.g., via ring rolling)
and a longitudinally intermittent activation pattern (i.e., a structured
elastic-like formed web
material). These two activation patterns may be disposed in an overlapping or
side-by-side
relationship. In other words, the overlapping orientation of the two distinct
types of activation
may be performed sequentially on the same region of the diaper. For example,
as a more
particular embodiment, the entire chassis web 149 may be longitudinally
intermittently activated
in the machine direction to form a structured elastic-like formed web material
and the portion of
the chassis web 149 forming the side barriers and/or cuff flaps may be
continuously activated to
form laterally oriented ridges712 and valleys 714, such that the side barriers
and/or cuff flaps are
activated in both the longitudinal and lateral directions.
Description of the abdominal stretch panel(s)
As shown in the figures, each abdominal stretch panel has a circumferentially
extending
longitudinally distal edge that is disposed at or adjacent to the respective
waist edge of the
chassis 100 and a longitudinally opposing circumferentially extending
longitudinally proximal
edge that is disposed relatively nearer to the lateral axis 44 than the
longitudinally distal edge of
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the same abdominal stretch panel is disposed. Each abdominal stretch panel
also has laterally
opposing longitudinally extending side edges, an interior surface, and an
exterior surface.
In particular, the front interior abdominal stretch panel 370, when present,
has a
circumferentially extending longitudinally distal edge 371 and a
longitudinally opposing
circumferentially extending longitudinally proximal edge 372. The front
interior abdominal
stretch panel 370, when present, also has laterally opposing longitudinally
extending side edges
373, an interior surface 374, and an exterior surface 375. Similarly, when
present, the back
interior abdominal stretch panel 390 has a distal edge 391, a proximal edge
392, side edges 393,
an interior surface 394, and an exterior surface 395. Similarly, when present,
the front exterior
abdominal stretch panel 360 has a distal edge 361, a proximal edge 362, side
edges 363, an
interior surface 364, and an exterior surface 365. Similarly, when present,
the back exterior
abdominal stretch panel 380 has a distal edge 381, a proximal edge 382, side
edges 383, an
interior surface 384, and an exterior surface 385.
Each of the abdominal stretch panels shown in Figure 1, Figure 2, Figure 3,
and Figure 6
has a circumferential extent that is substantially equivalent to the lateral
extent of the chassis 100
in the respective waist region. In such embodiments, each abdominal stretch
panel may be
attached to the chassis 100 where the front waist region 36 and the back waist
region 38 are
attached together. For example, if a side seam 115 is formed by means of
pressure bonding or
thermal bonding in any of their forms, including ultrasonic bonding, an
abdominal stretch panel
may be attached to the chassis in the same side seam, such that the side seam
effectively extends
through the thicknesses of the chassis 100 and the abdominal stretch panel. An
ability to bond
all of the layers together in one side seam may have advantages in terms of
manufacturing
simplicity and cost, because the side seam can be formed in a single bonding
process.
Alternatively, any of the abdominal stretch panels may have a circumferential
extent that is
less than the lateral extent of the chassis 100 in a particular waist region.
For example, an
interior abdominal stretch panel 370 and/or 390 may have a lateral extent only
approximately as
great as the distance between the proximal edges 157 of the side flaps 147. As
another example,
an interior abdominal stretch panel 370 and/or 390 may have a lateral extent
greater than the
distance between the proximal edges 157 of the side flaps 147 but less than
the distance between
the side edges 137 of the chassis 100. The portions of such an interior
abdominal stretch panel
that lie laterally outboard of the proximal edges 157 of the side flaps 147
may be sandwiched
between the side flaps 147 and the interior surface 102 of the chassis 100.
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The interior surface of each interior abdominal stretch panel contacts the
skin of the wearer
when the diaper 20 is worn. Therefore, the layer forming the interior surface
may be formed of a
soft material that will not irritate the skin of the wearer. Many suitable
materials are known in
the art, including rayon and synthetic nonwovens, such as spunbonded or carded
polypropylene,
polyethylene, or polyester or other olefinic materials.
An abdominal stretch panel may have a laminate structure. In particular, an
abdominal
stretch panel may include an interior layer and an additional layer or layers
disposed exteriorly of
the interior layer. An elastic version of one of the aforementioned suitable
materials, may
comprise a nonwoven exhibiting substantial elastic properties, such a material
may be used for
any of the layers. For example, a front interior abdominal stretch panel 370
having a laminate
structure in shown in Figure 10. This abdominal stretch panel may include both
an interior skin-
contacting layer 82 and one or more elastic layers 83 laminated to the
interior layer 82. Suitable
materials for the elastic layer 83 are well-known in the art, including
natural rubber strands,
synthetic rubber strands, elastomeric films, etc. The material chosen for the
elastic layer 83 may
exhibit a force response proportional to its elongation. As shown in Figure
10, an abdominal
stretch panel may also include an exterior cover layer 84 laminated to the
elastic layer 83 on its
surface opposite the interior layer 82, thereby forming a trilaminate in which
the elastic layer 83
is sandwiched between the interior layer 82 and the exterior cover layer 84.
The layers of an abdominal stretch panel may be laminated by any method
suitable for the
elements being attached together and their constituent materials. For example,
the elastic layer
83 may be maintained in a stretched condition while being attached to a
relaxed interior layer 82
(and/or a relaxed exterior cover layer 84 if present) and then allowed to
relax. The resultant
contraction of the elastic layer 83 may gather the interior layer 82 in such a
way as to create
rugosities and the laminate thus formed may be extended in the direction of
the original stretch
up to the original dimension of the interior layer 82 (and/or the exterior
cover layer 84 if present)
with only the elastic layer 83 resisting the extension. A similar result may
be achieved by, for
example, first gathering the interior layer 82 (and/or the exterior cover
layer 84 if present), such
as by pleating it, and then attaching the elastic layer 83 in a relaxed
condition. The resultant
laminate may be extended in a direction perpendicular to the pleat ridges up
to the original
dimension of the interior layer 82 (and/or the exterior cover layer 84 if
present) with only the
elastic layer 83 resisting the extension.
In some exemplary methods, the lamination may be performed with both the
elastic layer 83
and the interior layer 82 (and/or the exterior cover layer 84 if present)
relaxed. All or a portion
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34
of the resultant laminate abdominal stretch panel may subsequently be
"activated" by subjecting
it to elongation to create localized ruptures or regions of deformation in a
portion 85a of the
interior layer 82 (and/or a portion 85c of the exterior cover layer 84 if
present). In Figure 11, a
stretched abdominal stretch panel having an activated portion 85 is shown,
with the
ruptured/deformed portion 85a of the interior layer 82 and the
ruptured/deformed portion 85c of
the exterior cover layer 84 shown in dashed lines representing exemplary
deformation of, breaks
in and/or separation of the fibers in nonwoven materials. The
ruptured/deformed portion 85a of
the interior layer 82 (and/or the ruptured/deformed portion 85c of the
exterior cover layer 84 if
present) in the resultant activated portion 85 of the laminate provides little
or no resistance to
extension in the direction of the original elongation. For example, when a
nonwoven is used for
the interior layer 82 (and/or the exterior cover layer 84 if present), the
ruptured/deformed
portion(s) typically include(s) areas of deformation, breaks in and/or
separation of the fibers that
render the ruptured/deformed portion(s) substantially incapable of
transmitting tensile forces in
the plane of the nonwoven. Some suitable activation methods are known in the
art as "ring-
rolling" processes.
A combination of lamination methods may be used, if desired, so long as they
are suitable
for the elements being attached together and their constituent materials. For
abdominal stretch
panel embodiments comprising an elastic film and a nonwoven, the film and
nonwoven may
differ in size both laterally and longitudinally. For example, an abdominal
stretch panel may
comprise a laminate of film and nonwoven wherein the film extends laterally
only partially
across the width of the nonwoven of the abdominal stretch panel. In yet
another embodiment,
the film layer of the abdominal stretch panel may extend longitudinally only
partially across the
longitudinal length of the nonwoven of the abdominal stretch panel. Such
designs minimize the
amount of active stretch material and help minimize overall cost of the
structure.
An abdominal stretch panel may have uniform extension characteristics
throughout its area
or may have different extension characteristics in different portions. For
example, a portion of
an abdominal stretch panel may be made laterally extensible to a maximum
extensibility greater
than a maximum extensibility of an adjacent portion, such that a desired fit
on a wearer can be
achieved. The difference in extensibility may be provided by varying the
lamination and/or
activation process, for example by varying the localized elongation in an
activation process.
Some users may desire to tear open the diaper 20 in order to remove it from
the body of the
wearer. In order to provide guidance regarding where the product may be torn
open, a visible
tear locator line may be printed on an abdominal stretch panel and the
adjacent portion of the
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chassis 100. For example, a pair of laterally opposing tear locator lines 72a,
72b may be printed
exteriorly on a front exterior abdominal stretch panel 360 as shown in Figure
8. Tearing an
exterior abdominal stretch panel and the underlying portion of the chassis 100
(and the
underlying interior abdominal stretch panel, if present) at both of two
laterally opposing tear
locator lines will release the diaper 20 from the waist and both legs of the
wearer.
Such a tear locator line 72 may be printed on any abdominal stretch panel(s).
For some
users, locating the tear locator lines 72 on a front exterior abdominal
stretch panel may be
preferable, because they may prefer to lay their infants down on their backs
while removing the
diaper, and tear locator lines 72 disposed on a front abdominal stretch panel
are likely to be more
easily visible than tear locator lines 72 disposed on a back abdominal stretch
panel.
In order to minimize the level of tensile force required to tear open the
diaper 20 for
removal from the wearer, frangible tear lines may be provided. Such a
frangible tear line may be
formed in a layer or a laminate of layers by perforation, by the formation of
a brittle area or areas
at which the material will preferentially fracture when stressed, by the
formation of a weaker
area or areas at which the material will preferentially tear when stressed, by
the formation of a
friable area or areas at which the material will preferentially crumble when
stressed and/or bent,
or by any other method of providing frangibility that is suitable for the
materials involved.
For example, a pair of laterally opposing frangible tear lines 80a, 80b may be
formed in a
back exterior abdominal stretch panel 380 as well as the portion of the
chassis 100 overlain by
the back abdominal stretch panel, as shown in Figure 9. In this embodiment,
the frangible tear
lines 80 intersect the distal edge 381 of the back exterior abdominal stretch
panel 380 laterally
inboard of its side edges 383 and intersect its proximal edge 382 at the
intersection of the
proximal edge 382 and the side edge 137 of the chassis 100 at the margin of
each leg opening.
The frangible tear lines 80 may be disposed elsewhere, but the depicted
configuration may be
preferred in some embodiments. For example, if the frangible tear lines 80
continued generally
linearly toward the lateral axis 44, continuous portions of the diaper 20
would remain in place
around the legs of the wearer. When the frangible tear lines 80 are shaped to
intersect the
margins of the respective leg openings as described above, tearing the diaper
20 at both of the
laterally opposing frangible tear lines 80 will release the diaper 20 from the
waist and both legs
of the wearer.
Such frangible tear lines 80 may be disposed in any abdominal stretch
panel(s). For some
users, locating the frangible tear lines 80 in a front abdominal stretch panel
may be preferable,
because they may prefer to lay their infants down on their backs while
removing the diapers, and
CA 02760584 2011-10-31
36
frangible tear lines 80 in a front abdominal stretch panel are likely to be
more easily visible and
more easily usable than frangible tear lines 80 disposed in a back abdominal
stretch panel. If both
an exterior abdominal stretch panel and an interior abdominal stretch panel
are present in a waist
region, the frangible tear lines may be formed in both of the abdominal
stretch panels as well as
the portion of the chassis 100 sandwiched between them.
In some embodiments, both frangible tear lines and tear locator lines may be
provided.
For example, tear locator lines may be printed at or adjacent to frangible
tear lines. In such an
embodiment, the presence of the visible tear locator lines may prove helpful
to the user in
locating the frangible tear lines for use in removal of the diaper 20.
The diaper 20 may comprise apertures 622 as illustrated in Figure 35 disposed
through
one or both of the front and back waist regions 36 and 38. For example, the
apertures 622 may
extend through the back interior abdominal stretch panel 390, the backsheet
26, including the
nonwoven 31, and the back exterior abdominal stretch panel 380 to provide air
passages for
breathability. The apertures 622 may be formed by any suitable means known in
the art including
hot needle aperturing, laser cutting, die cutting, slitting, etc. One such
method achieves apertures
622 using an apparatus (not shown) comprising a pair of counter-rotating,
intermeshing rollers,
wherein a first roller comprises circumferentially-extending ridges and
grooves, and a second
roller comprises teeth being tapered from a base and a tip, the teeth being
joined to the second
roller at the base, the base of the tooth having a cross-sectional length
dimension greater than a
cross-sectional width dimension; and moving the back interior abdominal
stretch panel 390, the
backsheet 26, (which may comprise a film layer 30, a nonwoven 31 or both), and
the back
exterior abdominal stretch panel 380 through a nip of the counter-rotating,
intermeshing rollers;
wherein apertures 622 are formed in the back interior abdominal stretch panel
390, the backsheet
26, (which may comprise a film layer 30, a nonwoven 31 or both), and the back
exterior
abdominal stretch panel 380 as the teeth on one of the rollers intermesh with
grooves on the other
of the rollers. An exemplary method of forming the apertures 622 is disclosed
in U.S. Publication
No. 2006-0087053.
The number of apertures 622 per unit area of apertured web (i.e., the area
density of
apertures 622) can be varied from about 1 aperture 622 per square centimeter
to as high as 60
apertures 622 per square centimeter. There can be at least 10 or at least 20
apertures 622 per
square centimeter, depending on the end use. In general, the area density need
not be uniform
across the entire area of web, but apertures 622 may be oriented in only
certain regions (e.g., the
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37
front or back waist regions 36 and 38) of the chassis 100, and can be disposed
in a variety of
shapes, including lines, stripes, bands, circles, and the like.
The abdominal stretch panels attached to the chassis as described herein are
desirable from
the standpoints of comfort and appearance. For example, unlike typical stretch
waistbands, each
abdominal stretch panel covers some portion of a waist region of the diaper
20, i.e., is disposed
on one or both of the interior and exterior surfaces rather than being hidden
between layers of the
chassis 100. Therefore, if the abdominal stretch panel is formed from soft and
attractive
materials, such as one of the aforementioned nonwovens, the exposed abdominal
stretch panel
can provide a finished appearance resembling that of cloth underwear and
thereby convey an
impression of softness and comfort to the user.
Description of the Absorbent Assembly(ies)
As shown in Figures 12, 13, 14, and 15, the absorbent assembly 200 includes an
absorbent
core 250 that serves to absorb and retain liquid bodily waste materials. The
absorbent core 250
has a laterally extending front edge 256 and a longitudinally opposing and
laterally extending
back edge 258. The absorbent core 250 also has a longitudinally extending left
side edge 257a
and a laterally opposing and longitudinally extending right side edge 257b,
both absorbent core
side edges extending longitudinally between the front edge 256 and the back
edge 258. The
absorbent core 250 also has an interior surface 252 and an exterior surface
254.
The absorbent assembly 200 may be attached to the interior surface 102 of the
chassis 100
over any part or the whole of the area of the absorbent assembly 200. The
absorbent assembly
200 may be attached on its exterior surface 204 to the chassis 100 in a shaped
attachment pattern,
for example a cruciform attachment pattern, i.e., an attachment pattern that
forms or is arranged
in a cross or "+" shape.
Suitable configurations of cruciform attachment patterns are disclosed in U.S.
Patent No.
6,962,578 to La Von issued on 8 November 2005.
Alternatively, the absorbent assembly 200 may be attached to the interior
surface 102 of the
chassis 100 in a convexly-shaped attachment pattern 210', which may be in the
shape of an oval
or may be egg-shaped. The convexly-shaped attachment pattern 210' may be
contiguous, i.e., all
of its portions may be touching or connected throughout the pattern in an
unbroken sequence.
Alternatively, it may include detached portions and thereby lack contiguity
but still be arranged
such that the shape of the overall pattern is in the form of, for example, an
oval. For example, a
discontiguous convexly-shaped attachment pattern 210' may include a
longitudinally extending
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38
portion disposed along the longitudinal axis 42 and separate left and right
laterally spaced
portions disposed along or adjacent to the lateral axis 44, the laterally
spaced portions having
extending longitudinally to different lengths thereby forming an oval shaped
pattern. In one
embodiment, shown in Figure 29, the oval-like attachment pattern 210 comprises
5 laterally
spaced stripes of adhesive 624-628 attaching the absorbent assembly 200 to the
interior surface
102 of the chassis 100. The central stripe 626 may be disposed at or adjacent
the longitudinal
axis 42 and is shown as having the greatest longitudinal extent. The most
distal of the adhesive
stripes 624 and 628 are shown as having the least longitudinal extent and the
intermediate stripes
625 and 627, those located between the distal stripes 624 and 628 and the
central stripe 626 are
shown having a longitudinal extent between that of the central stripe 626 and
the distal stripes
624 and 628.
The portions of the chassis 100 that lie outside such a convexly-shaped
attachment pattern
210 or oval-like attachment pattern 210 are not restrained by attachment to
the absorbent
assembly 200 and therefore remain extensible. Thus, in embodiments where the
absorbent
assembly 200 is attached to the backsheet 26 in the convexly-shaped attachment
pattern 210, the
backsheet 26 substantially loses its extensibility in the area of attachment.
The portion of the
backsheet 26 disposed outside of the convexly-shaped attachment pattern 210
may remain
extensible. Thus, it may be desirable to activate the backsheet 26 in a
pattern complimentary
with a given attachment pattern (e.g., a concave activation pattern 675 to
compliment a
convexly-shaped or oval-like attachment patterns 210).
Within the extent of the shaped attachment patterns (e.g., the cruciform,
convexly-shaped,
and oval-like attachment patterns 210), the absorbent assembly 200 may be
attached to the
chassis 100 continuously or intermittently as shown in Figures 29 and 30. For
example, a film of
adhesive (not shown) may be applied continuously over the entire area of the
cruciform
attachment pattern 210 and then used to continuously attach the absorbent
assembly 200 to the
chassis 100. As an alternative example, an adhesive may be applied
discontinuously at and
inside the boundaries of the convexly shaped attachment pattern 210", such as
in the form of
dots, stripes (e.g., stripes 624-628), beads, spirals, etc., and then used to
attach the absorbent
assembly 200 to the chassis 100.
The shaped attachment patterns (e.g., the cruciform, convexly-shaped, and oval-
like
attachment patterns 210) may be disposed symmetrically or asymmetrically with
respect to either
or both of the longitudinal axis 42 and the lateral axis 44 of the chassis
100. In addition, the
shaped attachment patterns (e.g., the cruciform, convexly-shaped, and oval-
like attachment
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39
patterns 210) may be disposed symmetrically or asymmetrically with respect to
either or both of
the side edges 237a and b and the front and back edges 236 and 238 of the
absorbent assembly
200. Other suitable configurations of cruciform attachment patterns 210 are
disclosed in U.S.
Patent No. 6,962,578 issued on 8 November 2005.
The absorbent core 250 may be disposed between a lower covering sheet that is
disposed on
the exterior face of the absorbent core 250 and an upper covering sheet that
is disposed on the
interior face of the absorbent core 250. Such an upper covering sheet and
lower covering sheet
may be attached together to contain the absorbent core 250 between them and
thereby form the
absorbent assembly 200. For example, in the exemplary absorbent assembly 200
shown in
Figures 12, 13, 14 and 15, an upper covering sheet 24 and a lower covering
sheet 25 are attached
together at or adjacent to the side edges 237 of the absorbent assembly 200 in
longitudinally
extending adhesive attachment zones 29. Alternatively, the upper covering
sheet 24 and the
lower covering sheet 25 may be attached together in places other than the side
edges 237, e.g., at
or adjacent to the end edges 236 and 238 of the absorbent assembly 200, or at
or adjacent to both
the end edges 236 and 238 and the side edges 237. Both the upper covering
sheet and the lower
covering sheet are water vapor-permeable, i.e., breathable.
The upper covering sheet 24 may be water-permeable and may allow liquid waste
to pass
through to the absorbent core 250, where the liquid waste may be absorbed. The
lower covering
sheet 25 may be water-impermeable. However, alternatively, the lower covering
sheet 25 may
be water-permeable.
In the exemplary absorbent assembly 200 shown in Figures 12, 13, 14 and 15,
the upper
covering sheet 24 and the lower covering sheet 25 are of the same size, i.e.,
both the upper
covering sheet 24 and the lower covering sheet 25 extend to the front edge 236
and back edge
238, as well as to the side edges 237 of the absorbent assembly 200.
Alternatively, the upper
covering sheet 24 and the lower covering sheet 25 may differ in size.
As another example, the upper covering sheet 24 may be larger than the lower
covering
sheet 25 and may be wrapped over the side edges 257 of the absorbent core 250
onto the interior
surface of the absorbent core 250, where the upper covering sheet 24 and the
lower covering
sheet 25 may be attached together. Alternatively, in place of a separate upper
covering sheet 24
and a separate lower covering sheet 25, a single covering sheet may be wrapped
around the
absorbent core 250 and attached to itself to contain the absorbent core 250.
The absorbent core 250 includes a storage component 272 that serves to absorb
and retain
liquid bodily waste materials. Suitable known materials for the absorbent core
storage
CA 02760584 2011-10-31
component include cellulose fibers in the form of comminuted wood pulp,
commonly known as
"airfelt", natural or synthetic fibrous materials, and superabsorbent
polymers, used either singly
or in mixtures and commonly formed into layers or sheets, etc.
The absorbent core may include an acquisition component in addition to one or
more
storage components. The absorbent core acquisition component serves to acquire
deposited liquid
bodily waste material and transfer it to the absorbent core storage component.
Any porous
absorbent material which will imbibe and partition liquid bodily waste
material to the storage
component or components may be used to form the acquisition component.
Examples of such
acquisition materials are more fully described in U.S. Patent No. 4,950,264
issued to Osborn on
August 21, 1990.
Such an absorbent core acquisition component 290 is shown overlying the
absorbent core
storage component 272 in Figure 15. A separation sheet 292 of, e.g., a tissue
or a non woven
material, may be disposed between the absorbent core storage component 272 and
the absorbent
core acquisition component 290 to help ensure that none of the gel formed by a
superabsorbent
polymer that may be included in the absorbent core storage component reaches
the skin of the
wearer.
In some exemplary embodiments, an absorbent core storage component may include
the
discrete form of an absorbent material that is immobilized in pockets formed
by a layer of a
thermoplastic material, such as a hot melt adhesive material, that
intermittently contacts and
adheres to a substrate sheet, while diverging away from the substrate sheet at
the pockets.
Absorbent core components having such structures and being suitable for the
storage of liquid
bodily wastes are described in U.S. Patent Application Publication Nos.
2004/0162536 dated 19
August 2004 and 2004/0167486 dated 26 August 2004, as well as U.S. Application
Nos. 2008-
0312617, to Hundorf, 2008-0312618, to Hundorf, 2008-0312628, to Hundorf, 2008-
0312621, to
Hundorf, 2008-0312622, to Hundorf, 2008-0312625, to Hundorf, 2008-0312619, to
Ashton,
2008-0312620, to Ashton, and U.S. Patent No. 8,017,827, to Ashton.
An exemplary absorbent core storage component 272 having such a structure is
shown in
Figure 16. In this absorbent core storage component 272, particles 270 of a
superabsorbent
polymer are contained inside pockets 280 formed by a layer 275 of a
thermoplastic material. The
layer 275 of the thermoplastic material intermittently contacts and adheres to
a substrate sheet
274 at the areas of attachment 282. Between the areas of attachment 282, the
layer 275 diverges
away from the substrate sheet 274 to form the pockets 280. The layer 275 may
have the form of a
CA 02760584 2011-10-31
41
sheet of fibers of the thermoplastic material through which the liquid waste
may pass to the
particles to be absorbed by the particles 270 of the superabsorbent polymer.
In Figure 16, a separate thermoplastic layer covering sheet 276 is shown
overlying the
layer 275 of the thermoplastic material. Alternatively, the separate
thermoplastic layer covering
sheet 276 may be omitted.
As another alternative, as shown in Figure 17, two absorbent core storage
components
272 may be superposed with one absorbent core storage component 272 inverted
such that its
pockets 280 nest into the recesses at the areas of attachment 282 of the other
absorbent core
storage component 272 and the respective single substrate sheets 274 distally
oppose each other.
In such an absorbent core 250, the distally opposing single substrate sheets
274 may serve
respectively as the upper covering sheet 24 and the lower covering sheet 25.
Intended Scope of Claims
It is expressly not admitted that any of the documents or any combination of
the
documents, patents, patent applications and any patents which issue thereon,
as well as any
corresponding published foreign patent applications, and all publications
listed and/or referenced
in this description, teaches or discloses the present invention. To the extent
that any meaning or
definition of a term in this document conflicts with any meaning or definition
of the same term in
a document cited herein, the meaning or definition assigned to that term in
this document shall
govern.
The dimensions and values disclosed herein are not to be understood as being
strictly
limited to the exact numerical values recited. Instead, unless otherwise
specified, each such
dimension is intended to mean both the recited value and a functionally
equivalent range
surrounding that value. For example, a dimension disclosed as "40 mm" is
intended to mean
"about 40 mm".
The citation of any document, including any cross referenced or related patent
or
application, is not an admission that it is prior art with respect to any
invention disclosed or
claimed herein or that it alone, or in any combination with any other
reference or references,
teaches, suggests or discloses any such invention. Further, to the extent that
any meaning or
definition of a term in this document conflicts with any meaning or definition
of the same term in
a document cited herein, the meaning or definition assigned to that term in
this document shall
govern.
While particular embodiments of the present invention have been illustrated
and
described, it would be obvious to those skilled in the art that various other
changes and
CA 02760584 2011-10-31
42
modifications can be made without departing from the spirit and scope of the
invention. It is
therefore intended to cover in the appended claims all such changes and
modifications that are
within the scope of this invention.
