Note: Descriptions are shown in the official language in which they were submitted.
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ARTICLE OF COMMERCE INCLUDING
TWO-PIECE WEARABLE ABSORBENT ARTICLE
FIELD OF THE INVENTION
The present invention relates generally to the field of diapers and other
wearable
absorbent articles having features for the containment and absorption of
bodily exudates, and
more particularly, to such articles having disposable absorbent inserts and
reusable outer covers.
BACKGROUND OF THE INVENTION
It is likely that reusable diapers made of cloth have been in use since the
invention of
cloth. Reusable cloth diapers, however, present difficulties relating to
sanitation needs, in
handling, laundering and effectively sanitizing soiled diapers for re-use.
Reusable cloth diapers
also may be relatively unreliable with respect to containing bodily exudates
(i.e., they may tend
to leak). Because a wet cloth diaper may be in direct contact with the skin,
unless wetness is
quickly detected and the wet diaper removed, it may promote over-hydration of
the wearer's
skin, which makes the skin vulnerable to diaper rash.
The introduction of disposable diapers in relatively recent times has
mitigated these
disadvantages for many. Generally, upon removal from a wearer, a soiled
disposable diaper need
not be emptied, laundered or handled to any significant extent, but rather,
may be discarded as is.
Any soiled areas of the wearer's body may then be cleaned, and a clean new
disposable diaper
may be placed on the wearer as necessary. Many current disposable diapers have
structures that
make them relatively more effective at containing exudates than traditional
cloth diapers. Many
have structures and materials that make them relatively more effective at
conveying and storing
liquid exudates away from the wearer's skin. Some have features that enable
them to "breathe",
thereby reducing humidity inside the diaper, and some even include skin care
compositions that
are transferred to the skin when the diaper is worn. Such features may reduce
the likelihood
and/or extent of skin over-hydration and otherwise promote or help maintain
skin health.
For economic reasons, currently most disposable diapers are made of
substantial
proportions of materials derived from petroleum, such as polypropylene and/or
polyethylene.
These materials often appear in the form of spun fibers forming cloth-like
nonwoven web
materials, or alternatively or in addition, films.
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In recent years concerns have arisen concerning the "environmental footprint"
of human
activities of all kinds. The manufacture and use of diapers is no exception,
particularly in view
of the growing human population, i.e., the growing number of babies. One view
seems to be that
use of disposable diapers is detrimental to the environment because the
materials of which they
are typically made may be derived from non-renewable resources and require
substantial
amounts of energy in their manufacture. Additionally, because disposable
diapers typically are
not re-used or recycled, their use may be deemed by some to be
unsatisfactorily taxing upon
disposal facilities such as landfills. If the alternative is reusable cloth
diapers, however, another
view seems to be that the increased use of energy (e.g., for operating
equipment, heating laundry
water, and treating wastewater) and chemicals (e.g., detergents and water
treatment agents),
necessary for laundering soiled diapers at the rate they are typically used,
and treating the
associated wastewater, present their own set of stresses on the environment.
As may be
appreciated, analysis concerning which alternative is more "environmentally
friendly" is
complicated, and undisputed conclusions either way do not yet appear to exist.
Regardless of which alternative one may believe is more environmentally
friendly,
however, it appears that in developed nations, today's disposable diapers are
generally favored
over reusable cloth diapers among caregivers of babies and young children.
This is probably
attributable to the advantages of reducing or eliminating the unpleasantness,
sanitary concerns,
and extra work and/or expense associated with handling and laundering soiled
reusable cloth
diapers, better containment of exudates, and effectiveness at promoting and/or
helping maintain
skin health.
Manufacture of wholly disposable diapers is generally considered a capital-
intensive
business. This is a consequence of the complex machinery required to produce
product from
incoming material streams at economically-feasible production rates, which
often exceed 450 or
more articles per manufacturing line, per minute. Any innovation which has the
potential to
simplify the process or the equipment required, or reduce material costs, has
the corresponding
potential to reduce per-article costs for the manufacturer and the consumer.
Several designs of diapers that include a reusable cloth outer cover and
either a reusable
or a disposable absorbent insert have been manufactured and marketed. However,
for the user,
these designs have still presented at least some of the disadvantages of
traditional cloth diapers,
while not providing some of the advantages available from current disposable
diaper designs.
In view of the concerns set forth above, it would be advantageous if a
wearable absorbent
article were available that provides advantages afforded by both disposable
and reusable diapers,
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while reducing the respective disadvantages of these alternatives. It also
would be advantageous
if a construction were provided that could simplify manufacturing processes
and/or reduce costs.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a wearable absorbent article as it might
appear being worn
by a wearer about the lower torso;
Fig. 2A is a plan view of an outer cover opened and laid flat, outer surface
facing the
viewer;
Fig. 2B is a plan view of an outer cover opened and laid flat, inner surface
facing the
viewer;
Fig. 2C is a plan view of an outer cover opened and laid flat, inner surface
facing the
viewer;
Fig. 2D is a plan view of an outer cover opened and laid flat, inner surface
facing the
viewer;
Fig. 2E is a plan view of an outer cover opened and laid flat, inner surface
facing the
viewer; next to a plan view of an insert opened and laid flat, outer (garment-
facing) surface
facing the viewer;
Fig. 2F is a plan view of an outer cover opened and laid flat, inner surface
facing the
viewer; next to a plan view of an insert opened and laid flat, outer (garment-
facing) surface
facing the viewer;
Fig. 2G is a plan view of an outer cover opened and laid flat, inner surface
facing the
viewer; next to a plan view of an insert opened and laid flat, outer (garment-
facing) surface
facing the viewer;
Fig. 2H is a plan view of an outer cover opened and laid flat, inner surface
facing the
viewer; next to a plan view of an insert opened and laid flat, outer (garment-
facing) surface
facing the viewer;
Fig. 21 is a plan view of an outer cover opened and laid flat, inner surface
facing the
viewer; next to a plan view of an insert opened and laid flat, outer (garment-
facing) surface
facing the viewer;
Fig. 3 is a perspective view of a disposable absorbent insert shown apart from
an outer
cover, as it might appear in a free-standing, relaxed state;
Fig. 4 is a plan view of a disposable absorbent insert shown stretched out and
laid flat,
body-facing surfaces facing the viewer;
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Fig. 5A is a cross sectional view of an example of an insert such as shown in
Fig. 4, taken
at line 5A-5A in Fig. 4;
Fig. 5B is a cross sectional view of an example of an insert such as shown in
Fig. 4, taken
along line 5B-5B in Fig. 4;
Fig. 5C is a cross sectional view of another example of an insert such as
shown in Fig. 4,
taken along line 5C-5C in Fig. 4;
Fig. 5D is a cross sectional view of another example of an insert such as
shown in Fig. 4,
taken along line 5D-5D in Fig. 4;
Fig. 5E is a cross sectional view of another example of an insert such as
shown in Fig. 4,
taken along line 5E-5E in Fig. 4;
Fig. 5F is a cross sectional view of another example of an insert such as
shown in Fig. 4,
taken along line 5F-5F in Fig. 4;
Fig. 6a is a front view of fixtures used on a constant rate of extension
tensile tester for use
in the Edge Deflection Force Measurement Method herein, with an included test
sample;
Fig. 6b is a side view of a lower fixture used on a constant rate of extension
tensile tester
for use in the Edge Deflection Force Measurement Method herein;
Fig. 7 illustrates preparation of a test sample of an insert including an end
support
stiffener, for testing in the Edge Deflection Force Measurement Method herein;
Fig. 8 is a front view of a lower fixture used on a constant rate of extension
tensile tester
for use in the Bending Stiffness Measurement Method herein;
Fig. 9 is a side view of an upper fixture used on a constant rate of extension
tensile tester
for use in the Bending Stiffness Measurement Method herein;
Fig. 10 is a front view of an upper fixture used on a constant rate of
extension tensile
tester for use in the Bending Stiffness Measurement Method herein; and
Fig. 11 is a graph showing Peak Bending Force and slope calculation areas on a
bending
curve.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
For purposes of this description, the following terms have the meanings set
forth:
"Absorbent insert" and "insert" mean a component of a wearable absorbent
article that is
adapted to contain and/or absorb urine, feces, menses or any combination
thereof, and is adapted
to be installable and removable as a modular unit, from an outer cover.
Herein, an absorbent
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insert may also be referred to as an "absorbent assembly". The terms
"absorbent insert," "insert"
and "absorbent assembly" may be used interchangeably herein.
"Chassis" means a component of a wearable absorbent article that is adapted to
be worn
about the lower torso of a wearer, and is adapted to support an absorbent
insert and hold the
insert next to the wearer's body. Herein, a chassis may also be referred to as
an "outer cover".
The terms "outer cover" and "chassis" are interchangeable for purposes herein.
"Disposable", when referring to an absorbent insert, means that the absorbent
insert is not
adapted or intended to be effectively sanitarily laundered in an ordinary
household laundering
process and ordinary household equipment, and thereby is ordinarily unsuitable
for sanitary and
effective reuse so as to provide as-new intended functions and performance,
following soiling by
exudates and removal from an outer cover. By way of non-limiting examples,
effective
laundering may be frustrated or prevented, causing the insert to be
disposable, by inclusion of
materials and/or construction: that do not retain their substantial as-new
physical shape or
structure through ordinary household laundering and drying so as to be
effective as-new in reuse;
that absorb aqueous liquids and cannot be sufficiently dried/dehydrated in
ordinary household
drying equipment and ordinary drying cycles so as to be effective as-new in
reuse; that dissolve
or substantially degrade in ordinary household laundering or drying, causing
the insert to be
substantially damaged or rendered useless; and/or that cannot be effectively
cleaned of exudate
material through ordinary laundering, so as to be sanitary and otherwise
acceptable for re-use.
"Fastener component" means any component of a system that effects removable
fastening, attachment or holding of a first structure to a second structure.
The system may have a
single fastener component, for example, an adhesive patch on the first
structure adapted to adhere
to one or more types of surfaces on the second structure, or a hook, or patch
of hooks on the first
structure, adapted to catch on one or more types of surfaces on the second
structure. By way of
further example, any structure such as a pocket, strap, hook, buckle, etc. on
a first structure
adapted to capture and retain, in whole or in part, the second structure, is a
"fastener component"
as used herein. The system also may comprise two or more fastener components,
for example,
respective components of a hook-and-loop fastening system (such as VELCRO),
respective
surfaces having a cohesive material applied thereto; male and female snap
fastener components, a
button and button hole, slot or loop, other fastenably cooperating elements,
etc. Other examples
of fastener components include zipper components, "zip lock" engaging
components, loops,
posts, pockets, bands or straps, microfasteners, macrofasteners, and fastener
components such as
described in U.S. Patents Nos. 6,936,039; 6,893,388; 6,669,618; 6,432,098; and
6,251,097, and
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U.S. Published Applications, Pub. Nos. 2005/0234419; 2005/0215971;
2005/0215970;
2005/0130821; 2004/0023771; 2003/0233082; 2003/0119641; 2003/0088220; and
2002/0169431.
"Lateral" (and forms thereof), with respect to a wearer, means along a
direction generally
transverse or across the direction extending from the front to the rear of the
wearer, or vice versa.
With respect to a component of a wearable absorbent article, "lateral" (and
forms thereof), means
along a direction generally transverse or across the direction extending along
the component as it
would be properly situated on a wearer, from the front to the rear of the
wearer, or vice versa.
"Longitudinal" (and forms thereof), with respect to a wearer, means along a
direction
generally extending from the front to the rear of the wearer, or vice versa.
With respect to a
component of a wearable absorbent article, "longitudinal" (and forms thereof),
means along a
direction generally extending along the component as it would be properly
situated on a wearer,
from the front to the rear of the wearer, or vice versa.
"Outer cover" means a component of a wearable absorbent article that is
adapted to be
worn about the lower torso of a wearer, and is adapted to support an absorbent
insert and hold the
insert next to the wearer's body. Herein, an outer cover may also be referred
to as a "chassis".
The terms "outer cover" and "chassis" are interchangeable for purposes herein.
"Reusable", when referring to an outer cover, means an outer cover that is
adapted to
permit removal of at least a first insert, and replacement thereof with at
least a second insert,
without substantial destruction of any components of the outer cover that are
necessary to
provide the substantial as-new functionality of the outer cover, and without
the necessity of any
repair or reconstruction following such insert replacement.
"Use," with respect to an outer cover, means one event of the wearing of the
outer cover
until the time an absorbent insert is replaced.
"User" means a caregiver or other person who may apply a wearable absorbent
article to
a wearer. Where the wearer is capable of donning the wearable absorbent
article him/herself, the
wearer is also a "user".
"Wearer" means a person who may wear a wearable absorbent article as described
herein.
"Wearable absorbent article" means any article designed to be worn about the
lower torso
and to contain and/or absorb urine, feces, menses or any combination thereof.
"Wearable
absorbent article" includes but is not limited to baby or children's diapers
(of the "tape"-
fastenable, otherwise fastenable, "pull-up" or any other variety), training
pants and adult
incontinence pants, briefs and the like.
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Two-Piece Wearable Absorbent Articles
Fig. 1 depicts an example of a wearable absorbent article 10 having certain
features, as it
might appear while being worn by a wearer. Wearable absorbent article 10 may
include an outer
cover 20, having front waist edge 21, rear waist edge 22, and a pair of leg
opening edges 23.
Figs. 2A, 2B and 2C depict an outer cover 20 as it may appear opened and laid
flat. In
Fig. 2A, the outer, i.e., garment-facing, surfaces of outer cover 20 face the
viewer; in Figs. 2B
and 2C, the inner, i.e., wearer-facing, surfaces of outer cover 20 face the
viewer. Front and rear
waist edges 21, 22 are depicted at the top and bottom of the drawings,
respectively. Outer cover
20 may have crotch region 26, front region 27, rear region 28 and a pair of
fastening ears 29
laterally extending from rear region 28. Outer cover 20 will have a length LC
from the
forwardmost portion of front waist edge 21 to the rearwardmost portion of rear
waist edge 22,
and an outer cover lateral axis 45 equally dividing this length. Thus, front
region 27 is forward
of outer cover lateral axis 45, and rear region 28 is rearward of outer cover
lateral axis 45. Outer
cover 20 may have disposed thereon one or more insert fastener components such
as front and
rear insert fastener components 33, 32.
Fig. 3 depicts a disposable absorbent insert 50 that may form an inner
component of the
wearable absorbent article 10, shown in perspective view as it might appear in
a free-standing,
relaxed state, apart from outer cover 20. Insert 50 may be designed to contain
and/or absorb
body exudates, and may be made of pliable materials as will be described
further below. Insert
has forward region 54 and rearward region 55, and may include front fastener
component 56
and rear fastener component 57. Insert 10 may include a body-facing liner or
topsheet 51, outer
liner or backsheet 52, and a pair of standing cuffs 53. Referring to Fig. 4,
insert 50 will have a
length L from the forwardmost portion of forward region 54 to the rearwardmost
portion of
rearward region 55, and an insert lateral axis 70 equally dividing this
length. Thus, forward
region 54 is forward of insert lateral axis 70, and rearward region 55 is
rearward of insert lateral
axis 70.
Referring to Figs. 2B and 3, insert 50 may have rear fastener component 57
disposed
thereon. Alternatively, or in addition, outer cover 20 may have rear insert
fastener component 32
disposed thereon. Similarly, insert 50 may have front fastener component 56
disposed thereon.
Alternatively, or in addition, outer cover 20 may have front insert fastener
component 32
disposed thereon. If a two-component fastening system is used, fastener
component pairs 57, 32
and 56, 33 may be cooperating components that effect fastening therebetween
when these
respective components are brought together. Thus, in the example depicted, in
order to install
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absorbent insert 50 into outer cover 20, a user may lay outer cover 20 flat,
inner surface 25 facing
up, stretch and orient insert 50 such that rear fastener component 57 faces
rear insert fastener
component 32 and front fastener component 56 faces front insert fastener
component 33, and
bring these respective fastener component pairs 57, 32 and 56, 33 together to
effect fastening
therebetween.
If it is desired that outer cover 20 be reusable, for outer cover 20 to remain
substantially
sanitary and useful (without requiring laundering or disposal) after removal
and replacement of
an insert, it may be desired that all parts of outer cover 20 remain
substantially unsoiled after an
exudation of waste (especially fecal matter) by the wearer. Thus, it may be
desired that when
insert 50 is installed within an outer cover 20, there is no non-removable
portion or component of
outer cover 20 that lies over or covers a substantial portion of wearer-facing
surfaces of insert 50
(expressed differently, no non-removable portion or component of outer cover
20 is situated
between a substantial portion of insert 50 and the wearer when the wearable
absorbent article is
worn), at least in the areas proximate to wearer body features that discharge
exudates. Thus, it
may be desired that outer cover 20 include no non-removable cover sheet or the
like that covers
or contains substantial portions of wearer-facing surfaces of insert 50 within
outer cover 20, nor
any overlying structures such as pockets, straps or flaps that substantially
wrap or cover the insert
proximate to exudate discharge points, or lie substantially between insert 50
and the wearer's
anus and/or genitals, when the wearable absorbent article is worn. If outer
cover 20 lacks such
overlying structures, this may increase the likelihood that the wearer's
exudates will contact only
insert 50, and not portions of outer cover 20.
Referring to Figs. 1, 2A and 2B, it can be seen that wearable absorbent
article 10 may be
placed on a wearer by wrapping outer cover 20 between the wearer's legs and
under the buttocks
such that crotch region 26 is between the wearer's legs, bringing front waist
edge 21 and rear
waist edge 22 into the positions approximately as shown in Fig. 1, and then
securing fastening
ears 29 to front region 27, thereby forming a pant-like garment about the
wearer as suggested in
Fig. 1. When insert 50 has been installed into outer cover 20, insert 50 will
then be disposed
within outer cover 20, next to the wearer, with the standing cuffs 53 oriented
and extending
longitudinally adjacent the inner portions of leg edges 23 (i.e.,
longitudinally between the
wearer's legs).
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Examples of Possible Outer Cover Details
Fastening System
Referring to Figs. 2A and 2B, to enable fastening of fastening ears 29 to
front region 27,
fastening ears 29 may have outer cover fastener components 30 disposed
thereon. Alternatively,
or in addition, front region 27 may have disposed thereon one or more
receiving fastener
components 31 disposed thereon. Fastener components 30, 31 may be selected so
as to be
cooperative to effect fastening of ears 29 to front region 27.
In one example, outer cover fastener components 30 may include a patch of
hooks, and
receiving fastener component 31 may include a patch of loops. An example of a
suitable hook-
and-loop fastening system is a VELCRO system (a product of Velcro Industries
B.V.) A hook-
and-loop fastening system provides certain advantages. Because the respective
hook and loop
components are supplied in sheet form, they may be cut into suitably shaped
patches that can be
affixed to a cloth or nonwoven substrate by various mechanisms, including
adhesive bonding,
mechanical bonding, ultrasonic bonding, sewing, stitching, serging, edging,
and the like. If
patches of hooks or loops are affixed to fastening ears 29 to form outer cover
fastener
components 30, as suggested by Fig. 2B, a laterally extended patch of
cooperating hook or loop
material can be affixed to outer cover front region 27 to form a receiving
fastener component 31,
as suggested by Fig. 2A. By providing for fastening of ears 29 to front region
27 at laterally
varying locations thereon, this arrangement provides for easy and simple
adjustability of waist
opening size of the wearable absorbent article.
In another example, as noted above, the outer cover fastening system may
include other
types of fastener components. To provide for waist opening size adjustability,
fastener
components disposed on fastening ears 29 that cooperate with extended surfaces
or multiple
cooperating fastener components disposed on front region 27 may be used.
Receiving fastener
components may be multiply disposed on front region 27 in laterally arranged,
varying locations,
allowing for fastenability of respective ears 29 to front region 27 at
laterally varying locations.
Referring to Fig. 2B, outer cover 20 also may have one or more respective
fastener
protectors 39 disposed thereon. This feature may prevent fastener components
having features
likely to randomly and unintentionally engage and catch on portions of the
outer cover, or other
articles, during storage, carrying, laundering and similar/related activities,
from doing so, thereby
avoiding potential bunching, entangling and/or damage to either outer cover 20
or other articles
during such activities. For example, if fastener components 30 are patches of
hooks,
appropriately placed fastener protectors 39 may include patches of
corresponding loops. This
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will enable the user to fold ears 29 over to engage them with fastener
protectors 39, thereby
holding them in the folded-over position such that hooks thereon will be
concealed and prevented
from snagging other articles when outer cover 20 is not being worn.
Materials
Outer cover 20 and/or layers or portions thereof may be made of any knitted,
woven or
nonwoven textile or textile-like material that is appropriately compatible
with skin of the
intended wearer(s). Outer cover 20 may be constructed of durable and/or semi-
durable materials.
Generally, only for purposes of reference in this description, "durable"
refers to a woven or
knitted textile material of any kind that may be used as a component of a
washable clothing
article. As used herein, "durable" includes materials which are "launderable"
as defined and
described in co-pending U.S. Publication Nos. 2010-0179495, 2010-0179503 and
entitled, respectively, "REUSABLE OUTER COVER FOR AN ABSORBENT ARTICLE,"
"REUSABLE OUTER COVER FOR AN ABSORBENT ARTICLE HAVING ZONES OF
VARYING PROPERTIES," and "LEG AND WAISTBAND STRUCTURES FOR AN
ABSORBENT ARTICLE," by Donald C. Roe (Procter & Gamble Attorney Docket Nos.
11557,
11558 and 11559), filed on the same day hereof. Generally, only for purposes
of this description,
"semi-durable" refers to a nonwoven material or laminate thereof that when
used as an outer
cover material can withstand more than one use with an insert without losing
its structural
integrity to an extent that renders it unserviceable. As used herein, "semi-
durable" includes
materials which are "laundering resistant" as defined and described in the co-
pending U.S.
applications identified immediately above. Thus, outer cover 20 may be
constructed of materials
and construction that make it reusable and/or washable.
Durable materials of which outer cover 20 may be constructed may include any
natural or
synthetic textile materials known in the diaper, pant, underwear, performance
clothing, sport
clothing, or general clothing or textile arts. Durable materials may include
woven or knitted
textiles made of natural fibers such as cotton, linen, wool, bamboo, hemp,
silk, rayon, and the
like, as well as blends of any of these fibers with any other(s), or with
synthetic fibers. Examples
of synthetic fibers suitable for use as components of durable materials
include polyester, nylon,
spandex and/or other elastomer fibers. Durable outer cover materials also may
include
breathable water repellent materials such as GORE-TEX (a product of W. L. Gore
& Associates,
Inc., Elkton, MD), fabrics comprising microencapsulated phase-change polymer
materials such
as OUTLAST COMFORTEMP fabrics (products of Outlast Technologies, Boulder, CO -
see
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U.S. Patent Nos. 6,514,362 and US 6,207,738, for example), COOLMAX (a product
of Invista,
Wichita, KS), and the like.
Suitable durable materials may be formed in any weave or knit fabric form,
including
birdseye fabric, terry, fleece, flannel, knits, stretch knits, sherpa,
suedecloth, microfleece, satin,
velour, Burley knits, etc. Suitable examples include POLARTECH POWER DRY,
POWER
STRETCH and WIND PRO (products of Polartec, LLC, Lawrence, MA). Knitted
textiles, which
may be more inherently stretchable and elastic than woven or nonwoven
materials, may impart
better fit, comfort and/or appearance to the outer cover. Incorporation of
fibers of spandex or
other elastomer also may also enhance stretchability and elasticity, and
thereby impart better fit,
comfort and/or appearance to the outer cover, than textiles not including such
elastomeric fibers.
Specific suitable examples for durable outer cover materials include jersey
knits of blends
of: rayon (93%) and spandex (7%) fibers; modal (94%) and spandex (6%) fibers;
cotton and
spandex fibers; and bamboo and spandex fibers. Materials that have stretch
capability of equal to
or greater than about 2X may be desired. Suitable examples of materials may
have basis weights
of about 0.09-0.15 gram/in.2 per layer, or other basis weights.
Durable outer cover materials may be selected to impart desired comfort,
appearance and
performance to outer cover 20. In some circumstances it may be desired to
select durable outer
cover materials which are sufficiently inexpensive to allow for disposal, if
soiled extensively or
damaged, with minimized issues of cost or conscience.
Semi-durable outer cover materials may include any natural or synthetic
nonwoven web
and/or film materials known in the diaper or pant arts. Semi-durable materials
of which outer
cover 20 may be constructed may include non-woven web materials of
polypropylene and/or
polyethylene fibers, polyester fibers, and any other synthetic fibers used to
form nonwoven web
materials used as components of disposable diapers, and blends thereof.
Natural fibers such as
cotton, linen, wool, bamboo, hemp, silk, rayon, and the like may be blended
with synthetic fibers
to form such a nonwoven web suitable as a component layer of outer cover 20.
Non-limiting examples of fibers, nonwovens and laminates of nonwovens and
films that
might be considered for use as semi-durable outer cover materials may be found
in U.S. Patents
Nos. 7,223,818; 7,211,531; 7,060,149; 6,964,720; 6,905,987; 6,890,872;
6,884,494; 6,878,647;
and 5,518,801; and U.S. Published Applications Nos. 2008/0319407;
2008/0045917;
2007/0293111; 2007/0287983; 2007/0287348; 2007/0249254; 2007/0203301; and
2005/0164587.
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Semi-durable outer cover materials also may be selected to impart desired
comfort,
appearance and performance to outer cover 20. In some circumstances it also
may be desired to
select semi-durable outer cover materials which are sufficiently inexpensive
to allow for
disposal, if soiled extensively or damaged, with minimized issues of cost or
conscience.
The outer cover also, or additionally, may include a laminated or
substantially separate
film layer, which may be elastic, to provide enhanced liquid penetration
resistance and/or elastic
properties. Elastic properties also can be added or enhanced via the addition
of other materials to
the outer cover in layer, band or strip fashion, including elastic strands,
bands, scrims, and the
like. A film layer may be laminated with a durable material or semi-durable
material. A film
layer may include an elastomer based on KRATON (a product of Kraton Polymers
U.S., LLC,
Houston, Texas), or by way of further example, VISTAMAXX available from
ExxonMobil
Chemical Company, Houston, TX; FLEXAIRE, EXTRAFLEX or FABRIFLEX (products of
Tredegar Film Products Corporation, Richmond, VA), and various latex-free
elastomeric sheets
available from Fulflex Elastomerics Worldwide (Greenville, TN).
Inclusion of an elastomeric material, either as a fibrous component of a cloth
or
nonwoven layer, or as a film layer, provides for improved stretchability and
elasticity where it
may be deemed useful to accommodate the wearer's anatomy and movements, such
as over the
wearer's buttocks and/or around the waist areas, and improved fit and comfort.
Additionally,
where a film layer may be included, it may impart additional liquid
containment capability to the
outer cover. A film layer may include a film that is substantially liquid
impermeable, but vapor
permeable, so as to provide breathability and reduce humidity within the outer
cover while it is
being worn, reducing chances for over-hydration of the skin where liquid
containment capability
is desired. A breathable film also may be provided by mechanically perforating
or aperturing a
film by various processes. Examples of such processes are described in U.S.
Patent No.
8,158,043 and U.S. Publication No. 2011-0024940.
Referring to Fig. 2A, in one example outer surface 24 may be formed by a first
layer of a
durable or semi-durable material. The material selected may include fibers
having hydrophobic
properties, providing enhanced liquid containment attributes to such first
layer. In another
example, however, it may be desirable in some circumstances for the selected
material to include
hydrophilic fibers, or fibers treated to be hydrophilic, so as will cause the
material to more
readily absorb and/or transmit liquid therethrough. This may serve to provide
supplemental
absorbency within the outer cover for the event in which liquid exudates
escape the insert, or to
provide one way of communicating to the user that liquid exudates have escaped
the insert.
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Additionally, in some circumstances it may be desirable that the material
selected have soft
tactile properties so as to have a pleasant feel that the user and/or wearer
find attractive. The
material also may be selected so as to have a desired appearance, including
but not limited to
coloration, sheen, texture, etc.
Outer cover 20 may be formed of a single layer of a durable or semi-durable
material, or
may have two or more layers in the front region 27 and/or rear region 28.
Accordingly, referring
to Fig. 2B, in another example inner surfaces 25 may be formed by a second
layer of a durable or
semi-durable material. The material selected may include fibers having
hydrophobic properties,
providing enhanced liquid containment attributes to the second layer. In
another example,
however, it may be desirable in some circumstances for the selected material
to include
hydrophilic fibers, or fibers treated to be hydrophilic. This may be desired
in some
circumstances to cause the material forming inner surfaces 25 to more readily
absorb liquid, or
transmit liquid therethrough. This may serve to provide supplemental
absorbency within the
outer cover for an event in which liquid exudates escape the insert, reducing
the likelihood that
the outer cover will leak. Alternatively, it may provide one way of
communicating to the user
that liquid exudates have escaped the insert, by causing wetness to be
transmitted through to the
outer cover outer layer such that wetness is visible on outer surfaces.
Alternatively, it may serve
to provide a layer that tends to draw moisture away from the skin, for a
drier, more comfortable
feel.
Additionally, in some circumstances it may be desirable that the material(s)
selected for
inner surfaces 25 have soft tactile properties so as to have a pleasant feel
against the skin,
particularly in areas where no portion of an insert is expected to be present
between the outer
cover and the wearer's skin.
In another example, the second layer of material may be formed of a textile
material
having enhanced elasticity, such as by inclusion of fibers of an elastomeric
material (such as
spandex). In another example, an intermediate film layer may be included,
laminated or not
laminated with another layer.
Forming the outer cover 20 of more than one layer, for example, two, or more,
layers, as
described above, may provide various benefits. A second layer (and any
additional layers) may
provide supplemental tensile strength in both the lateral and longitudinal
directions across the
outer cover 20. Additionally, a first layer may be selected for a first set of
properties, and a
second layer may be selected for a second set of properties. For example,
material forming a first
layer may be selected for having comparatively greater elasticity and a
particular texture, color
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and/or other appearance-related properties, and material forming a second
layer may be selected
for having comparatively greater hydrophobicity, hydrophilicity and/or
softness to the skin for
purposes of an inner layer, the two layers in combination imparting a
combination of desirable
attributes to the outer cover. For example, the inner layer may be formed of
material(s) and/or
treated to be more hydrophilic so as to provide for absorbency and reduced
chances of fluid
runoff (leakage), while the outer layer may be formed of material(s) that are
more hydrophobic,
so as to, e.g., resist environmental soiling, or resist liquid transmission
from the inner layer to the
outer layer. Additionally, a plurality of layers may better serve to conceal
bumps, corners, seams
or other features of an insert, as compared with a single layer, for a
smoother, more attractive
appearance.
In addition to forming differing layers of differing materials, it may be
desirable to form a
single layer of differing materials, for example, differing materials in the
respective front, crotch
and/or rear regions of the outer cover. Such differing materials may be joined
at a seam such as
inner seam 40 and/or outer seam 41. For example, the material predominately
forming the inner
surface of rear region 28 may be selected primarily for its elasticity
features, which may better
serve to provide snug fit about wearer body contours and accommodate wearer
movement (i.e.,
about the buttocks and hips). By comparison, the material predominately
forming the inner
surface of front region 27 and/or crotch region 26 might be selected primarily
for its
hydrophobicity or hydrophilicity, which may better serve to contain liquid
exudates.
Layers or other elements of the outer cover may be joined to each other via
any suitable
mechanism, including, for example, adhesives, mechanical bonding, ultrasonic
bonding, sewing,
stitching, serging, edging, and the like.
Additionally or alternatively to the constructions and materials described
above, the outer
cover may be constructed and may include materials and features as described
in U.S.
Publication Nos. 2010-0179495, 2010-0179503 and entitled, respectively,
"REUSABLE OUTER COVER FOR AN ABSORBENT ARTICLE," "REUSABLE OUTER
COVER FOR AN ABSORBENT ARTICLE HAVING ZONES OF VARYING PROPERTIES,"
and "LEG AND WAISTBAND STRUCTURES FOR AN ABSORBENT ARTICLE," by Donald
C. Roe, filed on the same day hereof.
Elasticized Waistbands. Leg Bands
Referring again to Figs. 1, 2A and 2B, front waist band portion 34, rear waist
band
portion 35, and leg band portions 36 are depicted. One or more of these band
portions 34, 35, 36
may be formed of one or more strands or strips including an elastomeric
material such as spandex
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or a blend of spandex and other fibers, enveloped by a nonwoven or textile
material, which may
include the edges of the material forming the inner and/or outer layers of
outer cover 20, to form
and elasticize the respective band portions. The elastic material may be
affixed to or within an
outer cover layer in a strained condition, or at zero applied strain. Textile
material(s) enveloping
the elastic strand(s) or strip(s) may be sewn around elastic strand(s) or
strip(s) to hold them in
place within the respective band portions. If the elastic material is strained
prior to, and while,
being enveloped and affixed to form these band portions during the
manufacturing process, upon
relaxation the enveloping material and adjacent outer cover material may be
caused to gather and
form ruffles 37 therealong, which constitute gathered outer cover material.
This can serve to
promote snug fit, wearer comfort and appearance. The band portion may be
disposed along the
edge of the outer cover, and in some circumstances it may be desired to have
the band portion
situated along substantially the entire length of the leg and/or waist
openings so as to form bands
that substantially or completely encircle the wearer's legs and/or waist while
outer cover 20 is
worn. The gathered material within ruffles 37 can serve to accommodate
stretching of waist
band portions 34, 35 and leg band portions 36. This arrangement including
elasticized leg band
portions 36 as described, not only may provide for better fit about the
wearer's legs, but also may
enable the outer cover 20, when formed of appropriately sized and shaped
material, to form a
pouch-like structure 75 in the crotch region (see Fig. 1) when worn, which may
serve to provide
space within the outer cover to accommodate the insert 50 (Fig. 3) and help
hold it in place
within outer cover 20, in a substantially laterally centered position within
the crotch region. This
may be deemed advantageous in examples in which an insert 50 is attached
within outer cover 20
by fastener components only located proximate to the respective ends of insert
50, and not at any
longitudinally intermediate locations, as described further below.
Alternatively, or additionally,
the elastic strands or strips in waist band portions 34, 35 and leg band
portions 36 may be affixed
within the outer cover only at or near their respective ends, e.g., within a
pouch, tube or envelope
structure formed of outer cover material -referred to herein as a "drawstring
elastic". This will
allow the elastic material and associated outer cover material to stretch and
move freely and
independently of each other, which may promote fit and comfort. A snug fit
about the wearer's
legs provided by such elasticized leg band portions 36 may serve to enhance
containment
capability of the wearable absorbent article.
One or more of waist band portions 34, 35 and leg band portions 36 may be
elasticized in
the manner described above, or by other mechanisms. For example, elasticized
band/strip
material such as that used to form elastic waistbands and leg bands or other
banding features of
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conventional cloth underwear, briefs or other articles of clothing may be
separately produced,
and affixed to the materials forming outer cover 20 in any suitable manner,
during the
manufacture thereof.
In another example, one or more of waist band portions 34, 35 and leg band
portions 36
may be formed of elastic material simply affixed about the leg opening and/or
waist opening
edges by use of adhesive and/or compression bonding. In another example, an
elastic strip
material may formed by affixing a plurality of strained elastomeric strands or
strips to one or
more strips of unstrained nonwoven web material, or film. When the resulting
elastic strip
material is allowed to relax, the unstrained material forms transverse
rugosities that comprise
gathered unstrained material, which will accommodate stretching of the elastic
strip material. By
affixing the elastic strip material at one or more of waist band portions 34,
35 and/or leg band
portions 36, the elastic strip material may be used to form one or more of
elasticized waist band
portions 34, 35 and/or leg band portions 36.
Anchoring Bands
Outer cover 20 also may include an anchoring supplement such as anchoring band
38
disposed on or in the outer cover rear region 28 as indicated in Figs. 2A, 2B.
As suggested in
Figs. 2A and 2B, anchoring band 38 may be affixed along a layer, or disposed
between layers,
forming inner surfaces 25 and outer surfaces 24 of outer cover 20. Anchoring
band 38 may
include an elastomeric or elasticized strip or band of material, affixed to
outer cover 20 at
locations proximate to its rearward corners or proximate to fastening ears 29.
Thus, anchoring
band 38 may be partially or substantially force-decoupled from the other
layer(s) of the outer
cover along its lateral length from the layer(s) forming the inner and outer
surfaces of outer cover
20, via attachment to the outer cover only by the ends of anchoring band 38,
or only at a limited
number of selected intermediate lateral locations along anchoring band 38. For
example,
anchoring band 38 might be attached to outer cover 20 only at the ends of
anchoring band 38. In
another example, anchoring band 38 might be attached to outer cover 20 only at
the ends and at
the lateral center of anchoring band 38. This substantially force-decoupled
arrangement allows
anchoring band 38 and surrounding portions of outer cover 20 to stretch and
move substantially
independently of one another, which may promote better fit and comfort. In
another example,
however, anchoring band 38 may be an elastic band, strip or strap laminated
with or otherwise
affixed to a layer of stretchable material forming either of or both the inner
and outer surfaces of
the outer cover, along substantially the entire length of anchoring band 38.
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When strained laterally by application to the wearer, anchoring band 38 may
serve to
provide, or supplement, lateral tensile forces in the article about the
wearer's waist, thereby
tending to draw the waist opening snug, enhancing fit and enhancing securement
of the wearable
absorbent article about the wearer's waist. The elastic modulus of the
anchoring band may be
higher than the elastic modulus of the surrounding, adjacent, or coextensive
outer cover
materials.
An anchoring band, or system of one or more anchoring band members, may have
any
additional features described in, for example, co-pending U. S. Publication
Nos. 2008-0004591;
2008-0004589; 2008-0188822; 2008-0125739; 2008-0004593; 2008-0004592; 2008-
0004586;
2008-0004587; 2008-0004590; 2008-0004582; 2008-0004583; 2008-0004584; and 2007-
0287983; 2008-0015537 and 2007-0287982; 2009-0069779; 2009-0069772; 2009-
0069782;
2009-0069773; 2009-0069774; and 2009-0069775; 2009-0069778; 2009-0069777; and
2009-
0069781; 2009-0069779; 2009-0069772; 2009-0069782; 2009-0069773; 2009-0069774;
and
2009-0069775; and co-pending U.S. Publication Nos. 2010-0179498; 2010-0179502;
and 2010-
0179499 ; entitled, respectively, "REUSABLE WEARABLE ABSORBENT ARTICLES WITH
ANCHORING SYSTEMS," "REUSABLE WEARABLE ABSORBENT ARTICLES WITH
ANCHORING SUBSYSTEMS," and "REUSABLE OUTER COVERS FOR WEARABLE
ABSORBENT ARTICLES," by Donald C. Roe (Procter & Gamble Attorney Docket Nos.
11225M, 11565 and 11566), filed on the same day hereof..
In another example, instead of, or in addition to, being oriented
substantially laterally as
suggested by the depicted location of anchoring band 38 in Figs. 2A and 2B,
one or more
members forming anchoring bands may be oriented diagonally between the
longitudinal and
lateral directions. For example, as suggested in Fig. 2A, a pair of diagonal
anchoring bands 38a
may have respective waist ends thereof affixed at a location area proximate to
corners of the
outer cover and/or fastening ears 29, and respectively extend toward both the
lateral and
longitudinal center of outer cover 20, as suggested in Fig. 2A. The respective
center ends of
bands 38a may be affixed to the outer cover at locations proximate the lateral
center of the outer
cover as suggested in Fig. 2A, and bands 38a may be either force-decoupled or
force-coupled to
the outer cover along the lengths of bands 38a, as described above. In an
example where an
insert is connected to an anchoring band for additional longitudinal support
as described further
below, diagonal anchoring bands such as diagonal anchoring bands 38a may serve
to provide
supplementary longitudinal tension along outer cover 20, providing
supplemental longitudinal
support therewithin.
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Outer Cover Asymmetry
In order to enhance and/or maximize fit, wearer comfort and appearance of the
outer
cover 20, it may be desirable to fashion outer cover 20 so as to accommodate
anatomical
contours and body movements of the intended wearer. For example, as suggested
by Figs. 2A
and 2B, outer cover 20 may have differing shape and/or greater material
surface area in the rear
region 28 than in the front region 27. Human anatomy in the lower
torso/hip/thigh region is
asymmetric about the lateral plane of the body, i.e., the geometry of the
front of the human body
is different than that of the back. To provide for better fit and comfort, the
outer cover geometry
and functionality, including stretch properties, may be adapted accordingly.
Differing shape
and/or greater material surface area in the rear region may serve to better
cover the buttocks
through movements of the wearer (including sitting and/or bending forward at
the hips), while
lesser material surface area in the front region may serve to avoid material
bunching and/or an ill-
fitting appearance, particularly when the wearer is in positions including
sitting and/or bending
forward at the hips. As a result, the outer cover may be asymmetric in shape
or surface area
across outer cover lateral axis 45.
For purposes of this description, when used with respect to an outer cover,
"asymmetric"
and "asymmetry" mean that features, geometry (e.g., shape), materials and/or
construction on
one side of outer cover lateral axis 45 differ substantially in some respect
from those on the other
side of outer cover lateral axis 45. Such asymmetric construction results from
having various
features of outer cover 20 designed to accommodate the body features and
functions of the
intended wearer as they differ front-to-rear, to enhance
containment/absorbency performance,
comfort, fit and/or appearance of the wearable absorbent article, and/or to
economize on use of
materials. "Asymmetric" and "asymmetry" do not refer to differences across the
outer cover
lateral axis that are attributable to features that may be included on an
outer cover only for
purposes of: purely cosmetic coloration or surface decoration; fastening an
insert (such as
fastener components described herein); bundling, folding, storing or carrying
the outer cover;
indicia for orienting an insert within an outer cover or vice versa (such as
orientation indicia
described herein), or for other purposes substantially unrelated to the body
features and functions
of the intended wearer as they differ front-to-rear, to affect performance,
comfort, fit and/or
physical appearance of the wearable absorbent article, and/or to economize on
use of materials.
Other asymmetries across outer cover lateral axis 45 may be present as well.
For
example, as suggested by Figs. 2A and 2B, relatively localized outer cover
fastener components
30 may be respectively disposed on fastening ears 29, while a relatively
laterally extended
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receiving fastener component 31 may be disposed on outer cover front region
27, for purposes of
waist opening adjustability as explained above. Fastening ears 29 may form
lateral extensions
from rear region 28 that are not present in kind on front region 27. These are
examples of
differences that create functional and structural asymmetries of the outer
cover across outer cover
lateral axis 45. Because an absorbent article of the type described herein is
usually changed
while the wearer is substantially facing the user, such arrangement enhances
user convenience by
locating these fastening and waist opening adjustability features at the
wearer's front abdominal
region, facing the user.
In another example of asymmetry, materials of differing composition,
construction and/or
properties may predominately form forward region 27 as compared with rearward
region 28. For
example, the material(s) forming rear region 28 may be selected for enhanced
stretch/elastic
properties, as compared with material(s) forming front region 27. In this
example, material(s)
with enhanced stretch/elastic properties may serve to better accommodate,
stretch and contract
over contours of the buttocks, and accommodate body movements such as sitting
and bending
forward at the hips, thereby providing better coverage and fit.
In still another example of asymmetry, outer cover 20 may have structures such
as elastic
bands, anchoring bands and/or other members which differ between front region
27 and rear
region 28.
In still other examples of asymmetry, the materials forming outer cover 20 may
have, or
be imparted with, differing levels of hydrophilicity and/or hydrophobicity,
differing levels of
breathability, differing coefficients of friction, and/or other differing
functional attributes in the
front versus the rear regions.
It will be appreciated, therefore, that outer cover asymmetry across outer
cover lateral
axis 45 is a result of design and construction of the outer cover so as to
have only one front
region and only one rear region, i.e., the front and rear regions are not
interchangeable, if the fit,
comfort, performance and appearance of outer cover 20 are to be optimal.
Examples of Possible Absorbent Insert Details
Examples of features of an absorbent insert 50 will be described with
reference to Figs. 3,
4 and 5A-F.
As noted above, Fig. 3 depicts a disposable absorbent insert 50 that may form
an inner
component of a wearable absorbent article as described herein, shown in
perspective view as it
might appear in a free-standing, relaxed state, apart from an outer cover.
Fig. 4 depicts an
example of an insert 50 shown stretched out and laid flat (against elastic-
induced contraction to a
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position similar to that shown in Fig. 3), body-facing surfaces facing the
viewer. Figs. 5A-5F
depict cross sections of an insert 50 as indicated in Fig. 4, in various
possible examples.
Insert 50 may have a topsheet 51 and backsheet 52 forming an envelope-like
enclosure
for absorbent core materials such as those described further below. Topsheet
51 and backsheet
52 may be affixed together along longitudinal seams 64, and along lateral
seams 69. Insert 50
also may have longitudinal standing cuffs 53 affixed therealong.
Topsheet
Topsheet 51 may be formed of a liquid-permeable nonwoven web material. It may
be
desired that material forming topsheet 51 is compliant, soft-feeling, and non-
irritating to the
wearer's skin. It may be desired that at least a portion of topsheet 51 may be
liquid pervious,
permitting liquids to readily penetrate through its thickness. A suitable
topsheet may be
manufactured from a wide range of materials, such as porous foams, reticulated
foams, apertured
plastic films, or woven or nonwoven materials of natural fibers (e.g., wood or
cotton fibers),
synthetic fibers (e.g., polyester or polypropylene fibers), or a combination
of natural and
synthetic fibers. If topsheet 51 includes fibers, the fibers may be spunbond,
carded, wet-laid,
meltblown, hydroentangled, or otherwise processed as is known in the art.
One suitable material comprising a nonwoven web of staple-length polypropylene
fibers
is manufactured by Veratec, Inc., a Division of International Paper Company,
of Walpole, MA
under the designation P-8. Additional suitable materials comprising formed
films are described
in U.S. Patents Nos. 3,929,135; 4,324,246; 4,342,314; 4,463,045; and
5,006,394. Other suitable
topsheets 30 may be made in accordance with U.S. Patents Nos. 4,609,518 and
4,629,643.
Suitable examples of formed and/or apertured films may include products
produced by The
Procter & Gamble Company of Cincinnati, Ohio as DRI-WEAVE, and by Tredegar
Corporation,
based in Richmond, VA, as FRESHFEEL. Suitable topsheet materials also may
include
laminates of films and nonwoven webs produced by Tredegar as COMFORTFEEL,
COMFORTQUILT, SOFTQUILT and COMFORTAIRE.
In some circumstances it may be desired that at least a portion of topsheet 51
is made of a
hydrophobic material or is treated to be hydrophobic in order to isolate the
wearer's skin from
liquids contained in absorbent core 71. If topsheet 51 is generally made of a
hydrophobic
material, it may be desired that at least a portion of the upper surface of
topsheet 51 is treated to
be hydrophilic so that liquids will transfer through the topsheet more
rapidly. Topsheet 51 can be
rendered hydrophilic by treating it with a surfactant or by incorporating a
surfactant into the
topsheet. Suitable methods for treating topsheet 51 with a surfactant include
spraying the
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topsheet material with the surfactant and/or immersing the material into the
surfactant. A more
detailed discussion of such a treatment and hydrophilicity is contained in
U.S. Patents Nos.
4,988,344 and 4,988,345. A more detailed discussion of some suitable methods
for incorporating
a surfactant in the topsheet can be found in U.S. Statutory Invention
Registration No. H1670. In
another example, however, topsheet 51 may include an apertured web or film
which is
hydrophobic. This may be accomplished by foregoing the hydrophilizing
treatment step from the
production process and/or applying a hydrophobic treatment to the topsheet
material, such as a
polytetraflouroethylene compound like SCOTCHGUARDTM or a hydrophobic lotion
composition, as described below. In such examples, it may be desired that the
apertures be large
enough to allow the penetration of aqueous fluids like urine without
significant resistance
otherwise attributable to hydrophobicity. It may also be desired that the
apertures have sufficient
effective open area and/or aperture size to allow the penetration of low-
viscosity fecal material.
Examples of topsheets meeting these requirements are described in U.S. Pat.
Nos. 5,342,338;
6,414,215; and 6,010,491.
Any portion of topsheet 51 may be coated with a lotion or skin care
composition as is
known in the art. Examples of suitable lotions include those described in U.S.
Patents Nos.
5,607,760; 5,609,587; 5,635,191; 5,643,588; 5,968,025 and 6,716,441. The
lotion may function
alone or in combination with another agent as the hydrophobizing treatment
described above.
Topsheet 51 may also include or be treated with antibacterial agents, some
examples of
which are disclosed in U.S. Patent No. H001,732, published as U.S. Statutory
Invention
Registration H 1732.
Topsheet 51, backsheet 52 or any portion of the topsheet or backsheet may be
embossed
and/or matte finished to provide a more cloth-like appearance.
Topsheet 51 may be fully or partially elasticized or may be foreshortened so
as to provide
a void space between topsheet 51 and core 71. Exemplary structures including
elasticized or
foreshortened topsheets are described in more detail in U.S. Patents Nos.
4,892,536; 4,990,147;
5,037,416; and 5,269,775.
Backsheet
Backsheet 52 is generally that outer liner portion of insert 50 forming the
garment-facing
surface thereof, and prevents the exudates absorbed and contained within
insert 50 from wicking
through and soiling the outer cover. In some circumstances it may be desired
that backsheet 52 is
substantially impervious to liquids.
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Backsheet 52 may be formed of a film, a nonwoven, or a laminate of a film and
a
nonwoven. Backsheet 52 may be formed of a substantially liquid-impermeable
laminate or
composite of film and non-woven web. Backsheet 52 may be formed of a
substantially liquid
impermeable nonwoven web, or laminate of nonwoven web and substantially liquid
impermeable
film, so as to contain and isolate liquid exudates from the outer cover, outer
clothing and/or
environment of the wearer. At the same time, backsheet 52 may be vapor
permeable to provide
for breathability of the insert and the wearable absorbent article, reducing
humidity in the areas
between the insert and the wearer's body, and helping reduce the likelihood of
skin irritation
and/or rashes that may result from over-hydration of the skin.
The material forming backsheet 52 may include a thin plastic film such as a
thermoplastic
film having a thickness of about 0.012 mm (0.5 mil) to about 0.051 mm (2.0
mils). Suitable
backsheet materials also may be breathable materials which permit vapors to
escape while still
preventing liquid from passing therethrough. Suitable examples may include
those manufactured
by Tredegar Corporation, based in Richmond, VA, and sold under the trade names
CPC2,
X15306, X10962 and X10964 film. Other examples may include microporous films
such as
manufactured by Mitsui Toatsu Co., of Japan under the designation ESPOIR NOTM
and by
Exxon Chemical Co., of Bay City, TX, under the designation EXXAIRETM, and
monolithic films
such as manufactured by Clopay Corporation, Cincinnati, OH under the name
HYTRELTM blend
P18-3097. Some additional examples may include breathable composite materials
as described
in PCT Application No. WO 95/16746; and U.S. Patents Nos. 5,938,648;
5,865,823; and
5,571,096. In other examples, backsheet 52 may comprise elastomeric films,
foams, strands, or
combinations of these or other suitable materials with nonwovens or synthetic
films.
In certain embodiments, the backsheet may have a water vapor transmission rate
(WVTR)
of greater than about 2000 g/24h/m2, greater than about 3000 g/24h/m2, greater
than about 5000
g/24h/m2, greater than about 6000 g/24h/m2, greater than about 7000 g/24h/m2,
greater than
about 8000 g/24h/m2, greater than about 9000 g/24h/m2, greater than about
10000 g/24h/m2,
greater than about 11000 g/24h/m2, greater than about 12000 g/24h/m2, greater
than about 15000
g/24h/m2, measured according to WSP 70.5 (08) at 37.8 C and 60% Relative
Humidity. A
higher WVTR may be desired in this particular application, since the insert
backsheet 52 will not
form the outer surface of the wearable article, as a conventional disposable
diaper backsheet
would, but rather, will be covered by the one or more layers of the outer
cover material(s) -
which themselves may act in some circumstances to reduce WVTR of the composite
structure.
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11564-DW 23
Backsheet 52 may be joined to topsheet 51, absorbent core 71 or any other
element of
insert 50 by any suitable attachment mechanism known in the art. For example,
the attachment
mechanism may include a continuous line or layer of adhesive, a patterned
layer of adhesive, or
an array of separate lines, spirals, or spots of adhesive. One example of an
attachment
mechanism comprises an open pattern network of filaments of adhesive as
disclosed in U.S.
Patent No. 4,573,986. Other suitable attachment mechanisms include several
lines of adhesive
filaments which are swirled into a spiral pattern, as is illustrated by the
apparatus and methods
shown in U.S. Patents Nos. 3,911,173; 4,785,996; and 4,842,666. Adhesives
which have been
found to be satisfactory are manufactured by H. B. Fuller Company of St. Paul,
Minnesota and
marketed as HL-1620 and HL-1358-XZP. Alternatively, the attachment mechanism
may
comprise heat bonds, pressure bonds, ultrasonic bonds, dynamic mechanical
bonds, or any other
suitable attachment mechanisms or combinations of these attachment mechanisms
known in the
art.
It will be appreciated that the outer cover described above can be constructed
of materials
and construction so as to bear and sustain a majority of the structural
loading generally imposed
upon a disposable diaper, by stretching and accommodation of the wearer's
anatomical features
and body movements, and by absorption, swelling and added weight resulting
from the wearer's
exudations of waste. Thus, lesser requirements for structural strength of an
insert might be
present with use of such an outer cover, as compared with strength required of
inside components
of a disposable diaper. Therefore, an article such as described herein may
include a disposable
absorbent insert manufactured from materials that are different from those
ordinarily used in the
manufacture of disposable diapers, such as petroleum-derived materials, e.g.,
polyethylene and
polypropylene. For example, a disposable absorbent insert having one or more
of a topsheet,
backsheet, standing cuffs and/or other components formed of products of wood,
cotton, flax
(linen), hemp, bamboo, or other cellulose fibers (e.g., paper), in addition to
the materials
identified above, is contemplated. If resistance to aqueous liquid penetration
or substantial liquid
impermeability is desired, e.g., for a backsheet and/or standing cuffs, a
material formed of
ordinarily hydrophilic fibers such as paper may be coated or impregnated with
a hydrophobic
material, such as a skin-compatible oil or wax, to impart the desired
resistance to aqueous liquid
penetration. Each of the materials forming the insert may be selected so as to
be dispersible in
water or an aqueous solution, flushable, biodegradable and/or compostable
(preferably to an
agriculturally usable humus or soil amendment).
CA 02787261 2012-07-16
24
Absorbent Core
Referring to Figs. 5A-F, insert 50 may have an absorbent core 71 within the
envelope-like
structure formed by topsheet 51 and backsheet 52. Absorbent core 71 may
comprise any
absorbent material which is generally compressible, conformable, non-
irritating to the wearer's
skin, and capable of absorbing and retaining liquids such as urine and other
certain body
exudates. Absorbent core 71 may comprise a wide variety of liquid-absorbent
materials
commonly used in disposable diapers and other absorbent articles such as
comminuted wood
pulp, which is generally referred to as airfelt. Examples of other suitable
absorbent materials
include creped cellulose wadding; meltblown polymers, including coform;
chemically stiffened,
modified or cross-linked cellulosic fibers; tissue, including tissue wraps and
tissue laminates;
absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling
materials; or
any other known absorbent material or combinations of materials.
Absorbent core 71 may include liquid acquisition/distribution material 65, and
storage
material 66. Generally, acquisition/distribution material 65 may have
comparatively rapid
absorption and wicking properties, but also may have limited absorption
capacity. Conversely,
generally, storage material 66 may have comparatively slower absorption and
wicking properties,
but also may have greater absorption capacity. Thus, acquisition/distribution
material 65 may
serve to rapidly absorb and distribute gushes of liquid such as urine, while
storage material 66,
having greater absorption capacity, may serve to absorb such liquid from the
acquisition/distribution material and store it for the time needed until the
insert may be replaced.
Absorbent core 71 may be manufactured in a wide variety of sizes and shapes
(e.g.,
rectangular, hourglass, "T"-shaped, etc.). The configuration and construction
of absorbent core
71 may also be varied (e.g., the absorbent core(s) or other absorbent
structure(s) may have
varying caliper zones, hydrophilic gradient(s), a superabsorbent gradient(s),
or lower average
density and lower average basis weight acquisition zones; or may comprise one
or more layers or
structures). Examples of absorbent structures for use as absorbent core 71 may
include those
described in U.S. Patents Nos. 4,610,678; 4,673,402; 4,834,735; 4,888,231;
5,137,537;
5,147,345; 5,342,338; 5,260,345; 5,387,207; and 5,625,222.
To reduce the overall size and/or thickness of the absorbent core, and thereby
improve
wearer comfort and reduce the volume of disposable waste created by a soiled
insert, it may be
desired to construct an absorbent core using the lowest volumes of core
materials possible within
performance constraints. Toward this end, examples of suitable materials and
constructions for a
suitable absorbent core are described in, but are not limited to, copending
U.S. Publication Nos.
CA 02787261 2012-07-16
2008-0312617; 2008-0312618; 2008-0312619; 2008-0312620; 2008-0312621; 2008-
0312622;
2008-0312625; 2008-0312623; and 2008-0312624. These applications generally
describe
absorbent core constructions that minimize or eliminate the need for and
inclusion of airfelt or
other forms of cellulose fiber in combination with particles of superabsorbent
polymer
(hereinafter, "substantially airfelt-free cores"). Airfelt and other cellulose
fiber have been used as
absorbent fillers in absorbent cores of disposable diapers. Such fiber
possesses absorbent
properties and imparts some absorption capacity to an absorbent core, but also
is included to
provide a structural matrix to hold dispersed particles of superabsorbent
polymer and/or
absorbent gelling material. While inclusion of such particles enhances
absorption capacity,
keeping such particles suitably dispersed may be important to prevent the
particles from "gel-
blocking" in use as they swell with absorbed liquid, causing loss of
absorption capacity. The
inclusion of airfelt or other cellulose fiber as a matrix for superabsorbent
particles can serve to
reduce or prevent gel-blocking. However, it also imparts bulk to an absorbent
core, even before
absorption of any liquids.
In accordance with the disclosures in the co-pending applications identified
immediately
above, referring to the examples depicted in Figs. 5C and 5E herein, an
absorbent core 71 having
a portion that is substantially airfelt-free may be disposed between the
topsheet 51 and the
backsheet 52. The core 71 may include a layer formed at least in part of a
substrate, distributed
absorbent particles 66 of a superabsorbent polymer or absorbent gelling
material, and a
thermoplastic adhesive composition capturing the distributed absorbent
particles 66 and adhering
to at least portions of the substrate, thereby immobilizing the absorbent
particles 66 on or
proximate to, and relative to, the substrate.
Features of an outer cover 20 as described herein provide for a wearable
absorbent article
that has a relatively improved, garment-like (or underwear-like) fit, comfort
and appearance (as
an outer garment or under other clothes), as compared with many types of
wholly disposable
diapers currently available. If an outer cover 20 having such attributes is
used with an insert 50
having an absorbent core 71 incorporating substantial amounts of airfelt or
other cellulose fiber,
the improved, garment-like fit, comfort and appearance provided by the outer
cover 20 may be
compromised by the bulkiness of the insert. In order to better preserve some
or most of the
improved, garment-like fit, comfort and appearance of the outer cover 20,
therefore, it may be
desirable to construct absorbent core 71 of insert 50 with features as
described in one or more of
patent applications cited immediately above, which provide for a relatively
thin absorbent core.
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In addition to providing an absorbent core having reduced bulk, the
substantially airfelt-
free core may generally be more flexible than an absorbent core containing
substantial amounts
of airfelt or other cellulose fiber. This enhanced flexibility may enable the
core and the
associated insert to better conform about the wearer's body when in use,
providing for improved
comfort and less bulky appearance of the wearable article 10.
Additionally, by reducing or eliminating airfelt or other cellulosic fiber
material, the
substantially airfelt-free core reduces the amount of materials consumed in
manufacturing,
reduces the amount of space (and in some circumstances, weight) per unit which
must be
packaged and shipped, conserving resources in that regard, and reduces the
amount of materials
and bulk which must be disposed of in connection with disposing of a
used/soiled insert.
Sublayer
Insert 50 may also include a sublayer disposed between topsheet 51 and
backsheet 52.
The sublayer may be any material or structure capable of accepting, storing or
immobilizing
bodily exudates. Thus, the sublayer may include a single material or a number
of materials
operatively associated with each other. Further, the sublayer may be integral
with another
element of insert 50 or may be one or more separate elements joined directly
or indirectly with
one or more elements of insert 50. Further, the sublayer may include a
structure that is separate
from the core 71 or may include or be part of at least a portion of the core
71.
Suitable materials for use as the sublayer may include large cell open foams,
macro-
porous compression resistant nonwoven highlofts, large size particulate forms
of open and closed
cell foams (macro and/or microporous), highloft nonwovens, polyolefin,
polystyrene,
polyurethane foams or particles, structures comprising a multiplicity of
vertically oriented looped
strands of fibers, absorbent core structures described above having punched
holes or depressions,
and the like. One example of a sublayer includes a mechanical fastening loop
landing element,
having an uncompressed thickness of about 1.5 millimeters available as XPL-
7124 from the 3M
Corporation of Minneapolis, Minnesota. Another example includes a 6 denier,
crimped and
resin-bonded nonwoven highloft having a basis weight of 110 grams per square
meter and an
uncompressed thickness of 7.9 millimeters which is available from the Glit
Company of Wrens,
Georgia. Other suitable absorbent and nonabsorbent sublayers are described in
U.S. Patents Nos.
6,680,422 and 5,941,864. Further, the sublayer, or any portion thereof, may
include or be coated
with a lotion or other known substances to add, enhance or change the
performance or other
characteristics of the element.
CA 02787261 2012-07-16
27
Standing Cuffs
Insert 50 also may have a pair of longitudinal standing cuffs 53 attached
partially or
entirely along the length thereof. Suitable longitudinal standing cuffs (in
various published
examples identified as "leg cuffs", "barrier cuffs" "gasketing cuffs," etc.,
may be formed of
materials and construction such as described in, but not limited to,
U.S. Patents Nos. 6,786,895; 6,420,627; 5,911,713; 5,906,603; 5,769,838;
5,624,425; 5,021,051
and 4,597,760; and copending U.S. Published Application No. 2007/0239130 and
U.S. Patent
No. 8,002,760. As shown in Fig. 3, standing cuffs 53 may have one or more
strands or strips of
cuff elastics 58a, 58b disposed longitudinally therealong. If such cuff
elastics 58a, 58b are pre-
strained prior to being affixed to the web material forming standing cuffs 53,
resulting
longitudinal tensile forces therealong will cause the web material forming
standing cuffs 53 to
gather as shown, and cause the cuffs to extend from the body of the insert
(upwardly relative to
Fig. 3), or causing them to "stand". This feature causes standing cuffs 53 to
form a gasketing
structure along the wearer's body when the article including insert 50 is
worn, longitudinally on
either side of the anatomical features where waste is exuded. Thus, standing
cuffs 53 may serve
to enhance the exudate containment capability of insert 50 and, and as a
result, of the wearable
absorbent article. As with backsheet 52, standing cuffs 53 may be formed of a
substantially
liquid impermeable web so as to contain and isolate liquid exudates from the
outer cover, outer
clothing and environment of the wearer. At the same time, standing cuffs 53
may be vapor
permeable to provide for breathability of the insert and the wearable
absorbent article, reducing
humidity in the areas between the insert and the wearer's body, and helping
reduce the likelihood
of skin irritation and/or rashes that may result from over-hydration of the
skin.
In another example, the material forming standing cuffs 53 may be integral
with the
material forming backsheet 52, such as described in, by way of non-limiting
example, copending
U.S. Published App. No. 2007/0239130. In this particular example, referring to
and relative to
the view in Fig. 3, a continuous piece of material may form one standing cuff
53, wrap beneath
the insert to form backsheet 52, and wrap up the other side to form the other
standing cuff 53.
This example of a wraparound construction may provide improved liquid
containment capability
to insert 50, by eliminating seams along the outer liquid-containing surfaces
that include standing
cuffs 53 and backsheet 52. Another example of this construction is depicted
and described in
U.S. Patent No. 4,808,178.
In some circumstances, however, manufacturing and/or economic constraints may
discourage such construction, or else, it may be desirable for the materials
forming standing cuffs
CA 02787261 2012-07-16
28
53 and backsheet 52 to have differing properties. For example, in some
applications it may not
be deemed necessary for standing cuffs 53 to be substantially liquid
impervious, if they are
otherwise formed of a nonwoven web material comprising closely situated
hydrophobic fibers,
which may still tend to repel and contain fluid, but may be generally more
breathable than
substantially liquid impervious laminates including films. In this event,
improved strength and
liquid containment attributes can still be imparted by having the material
forming standing cuffs
53 wrap only partially beneath the lower longitudinal corners of the insert,
and affixed at seams
beneath the insert, rather than at its outermost lower corners as suggested by
Fig. 3. One
example of this construction is depicted and described in U.S. Patent No.
7,695,463, and in
particular, Fig. 13 therein and associated descriptive text.
Insert Asymmetry
Referring to Fig. 4, insert 50 will have an insert lateral axis 70 that
equally divides its
longitudinal length. Insert 50 may have a structure that is asymmetric across
insert lateral axis
70. For purposes of this description, with used with respect to an insert,
"asymmetric" and
"asymmetry" mean that features, geometry (e.g., shape), materials and/or
construction on one
side of insert lateral axis 70 differ substantially in some respect from those
on the other side of
insert lateral axis 70. Such asymmetric construction results from having
various features of
insert 50 designed to accommodate the body features and functions of the
intended wearer (i.e.,
body contours, excretory and eliminatory functions) as they differ front-to-
rear, to enhance
containment/absorbency performance, comfort, fit and/or appearance of the
wearable absorbent
article, to economize on use of materials and/or to reduce volume of
disposable waste.
"Asymmetric" and "asymmetry" do not refer to differences across the insert
lateral axis that are
attributable to features that may be included on an insert only for purposes
of: purely cosmetic
coloration or surface decoration; fastening to an outer cover (such as
fastener components
described herein); user grasping of the insert (such as a grasping structure
described herein); as
indicia for orienting an insert within an outer cover (such as orientation
indicia described herein);
or for other purposes substantially unrelated to the body features and
functions of the intended
wearer as they differ front-to-rear, to affect performance, comfort, fit
and/or physical appearance
of the wearable absorbent article, to economize on use of materials and/or to
reduce volume of
disposable waste.
As one example, topsheet 51 may one or more have apertures 63 therethrough,
predominately in the crotch and/or rearward region 55 as suggested in Fig. 4.
Apertures 63 can
permit liquid or low viscosity fecal material to penetrate topsheet 51 and
reach absorbent
CA 02787261 2012-07-16
29
materials in absorbent core 71 more rapidly than would occur without such
apertures, enhancing
liquid feces absorption and containment capability of insert 50.
In another example, a feces management feature may be disposed in the rear of
the
article, including one or more pockets, spacers, low viscosity feces
management elements,
openings in suspended elasticized topsheets, and similar features, for
example, as described in
U.S. Patent Nos. 8,016,803, 7,771,406 and 7,771,408. Thus, topsheet 51 may
comprise one or
more larger apertures in the rear region to provide for unrestricted or
comparatively less
restricted movement of solid or higher viscosity waste therethrough. The size
of an aperture may
be important in achieving the desired fecal waste encapsulation performance.
If the aperture is
too small, the waste may not pass through the aperture, either due to poor
alignment of the
exudation point and the aperture location, or due to fecal masses having a
size greater than the
aperture. If the aperture is too large, however, the area of skin that may be
exposed to "rewet"
from the contained waste matter is increased. An aperture may have an area of
between about 10
cm2 and about 50 cm2. In some circumstances it may be desired that an aperture
has an area of
between about 15 cm2 and 35 cm2.
An insert may have asymmetry in its absorbent core (absorbent core asymmetry).
Absorbent core asymmetry may result from arrangement of materials and features
within the
absorbent core to locate particular materials and features of the absorbent
core where they are
most needed and/or most effective, in accordance with features and functions
of wearer anatomy
as they differ front-to-rear.
For example, all or a portion of the rearward region 55 of insert 50 may
include
acquisition/distribution material 71 but less or no storage material 66 as
compared with forward
region 54, as may be seen by comparison of Figs. 5A and 5B, 5C and 5D, and 5E
and 5F,
respectively. By this particular absorbent core asymmetry, storage material 66
may be located
predominately in the front of the wearable absorbent article when worn. This
may provide a
predominate proportion of the insert's urine storage capacity closer to the
urine exudation point
of the wearer to reduce the likelihood of leakage, and remove potentially
uncomfortable and/or
unsightly size and bulk from between the wearer's legs or the wearer's
backside area, particularly
relevant when storage material 66 becomes swollen with absorbed liquid.
Additionally, this
particular asymmetry provides for economization of the amount of storage
material 66 used, by
locating it in only a portion of the insert rather than substantially along
the entire insert. The
liquid storage capacity of the forward region of the absorbent core may be
greater than that of the
rearward region of the absorbent core as measured by the Teabag Centrifuge
Capacity test
CA 02787261 2012-07-16
disclosed in U.S. Patent No. 6,278,037. The liquid storage capacity of the
forward region of the
absorbent core may be at least about 10%, 20%, 50%, or even 100% or more
greater than that of
the rearward region. With such an arrangement, acquisition/distribution
material 65 located in
both forward and rearward regions 54, 55 can serve to acquire and move liquid
(usually, urine) to
the storage material 66 located predominately in the forward region 54.
Alternatively, or
additionally, the area and/or basis weight of the acquisition system or
component materials in the
forward region of the insert may be at least about 10%, 20%, 50%, or even 100%
or more greater
than that of the rearward region. Alternatively, or additionally, the surface
area, cross-sectional
area and/or lateral width of absorbent core 71 may be greater in the forward
region 54 as
compared with the rearward region 55. For example, the surface area, cross-
sectional area and/or
lateral width of absorbent core 71 may be greater in the forward region 54 as
compared with the
rearward region 55, to accommodate a greater proportion of the
acquisition/distribution and/or
storage material present in the forward region of the absorbent core.
Referring to Figs. 5A, 5C and 5E, in other examples, absorbent material 66 in
forward
region 54 may be, respectively, dispersed within acquisition/distribution
material 65 (Fig. 5A),
contained within a separate liquid permeable structure or envelope 67 in fluid
communication
with acquisition/distribution material 65 (Fig. 5C); or dispersed on, or
within an adherent matrix
of, retaining material 68, and in fluid communication with
acquisition/distribution material 65
(Fig. 5E). Conversely, the rearward region 55 may predominately contain
acquisition/distribution material 65, but less storage material 66 as compared
with forward region
54, or none (Figs. 513, 5D, 5F). Materials in forward region 54 also may be
disposed according
to construction described in one or more of co-pending U.S. Publication Nos.
2008-0312617;
2008-0312618; 2008-0312628; 2008-0312619; 2008-0312620; 2008-0312621; 2008-
0312622;
2008-0312625; 2008-0312624; and U.S. Patent No. 8,017,827, with a differing
construction in
rearward region 55.
In another example, storage material 66 and acquisition/distribution material
65 may
occupying differing, distinct layers of absorbent core 71, as suggested by
Fig. 5C. It may be
desirable in some circumstances to make the layer containing
acquisition/distribution material 65
larger in surface area (i.e., plan view surface area relative to the insert
laid flat, as shown in Fig.
4) than the layer containing storage material 66, or vice versa. For example,
if the layer
containing acquisition/distribution material 65 is formed so as to have a
larger surface area
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laterally across the insert in the forward region 54, this may serve to
provide space for a greater
quantity of acquisition/distribution material in the forward region. This may
impart greater
capacity in the forward region to rapidly absorb and distribute relatively
large gushes of urine
discharged toward the forward region, as may be desired for wearable absorbent
articles for, e.g.,
older male babies and toddlers - enhancing containment capability of the
insert.
In another example, however, such as for newborns and young babies, large
gushes of
urine might not be expected, but comparatively substantial quantities of
liquid or low-viscosity
fecal material may be. Thus, a wearable absorbent article for this group of
intended wearers may
include an acquisition/distribution layer of larger size, occupying a greater
surface area, in the
rearward region 55 of the insert. This may impart greater capacity in the
rearward region to
rapidly absorb gushes of liquid or low viscosity fecal material discharged
toward the rearward
region, and thereby enhance containment capability of the insert.
Differences between forward and rearward regions also may be included for
purposes of
sleep-use inserts. While an insert designed for awake-use may have the
predominate proportion
of its liquid-storage capacity in the forward region 54 as described above, an
insert designed for
sleep-use with, e.g., young babies, may have the predominate proportion of its
liquid-storage
capacity in the rearward region 55, to accommodate babies who sleep lying on
their backs, by
locating the predominate proportion of storage capacity where fluid exudates
will flow under
influence of gravity.
It also may be desired to dispose a thickening agent in the absorbent core in
the rearward
region 55 of the insert. A thickening agent may be useful for providing
additional assurance that
liquid or low viscosity fecal material will be thickened and thereby more
immobilized, and more
likely to be contained within the insert.
Insert 50 also may have overall shape/backsheet asymmetry. For example, viewed
in a
laid-flat position as shown in Fig. 4, insert 50 may occupy a larger surface
area on one side of
insert lateral axis 70 than on the other. This may be useful for purposes of
comfort, body
coverage, appearance, performance and/or economization in use of backsheet
material(s). For
example, in conjunction with including a predominate proportion of storage
material 66, the
forward region 54 of insert 50 may occupy a larger surface area, associated
with a larger space
within the insert to contain the storage material, e.g., so as to improve
overnight absorption and
containment capacity for wearers who sleep on their stomachs, and allow for
the insert to remain
flatter, particularly relevant when the absorbent material becomes swollen
with absorbed liquid.
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Such larger surface area may be greater on one side of insert lateral axis 70
than the surface area
occupied by the rearward region 55 on the other side of insert lateral axis
70.
Insert 50 also may have a narrowed region in the area which rests in the
crotch region of
the outer cover. This narrowing in the crotch region may serve to enhance
wearer comfort by
eliminating size and bulk between the legs. Referring to Fig. 2B, it may also
serve to better
enable the crotch region 26 of outer cover 20 to contain and maintain a
laterally centered position
of insert 50, by ensuring that insert 50, by having limited quantities of
absorbent materials therein
and limited width, does not swell beyond the space capacity of crotch region
26 of outer cover
20. Such narrowing may continue, for example, into the rear portion of the
insert, thereby
creating overall shape/backsheet asymmetry.
Insert 50 may also be asymmetrical across insert lateral axis 70 in other
ways, to serve the
same, related or other purposes as those described above.
It will be appreciated, therefore, that insert asymmetry across insert lateral
axis 70 is a
result of design and construction of the insert so as to have only one front
region and only one
rear region, i.e., the front and rear regions are not interchangeable, if the
designed fit, comfort,
performance and appearance of insert 50 are to be fully realized.
Grasp Structures
Referring to Figs. 2F, 3 and 4, insert 50 also may include respective forward
and rearward
user grasp structures 59, 61. User grasp structures 59, 61 may be provided to
enable the user to
quickly and easily grasp insert 50 proximate its respective ends.
Grasp structures as shown and/or suggested may enable the user to more quickly
grasp
and stretch insert 50 from a contracted position similar to that depicted in
Fig. 3, to an extended
position similar to that depicted in Fig. 4, which may be desirable for
installing insert 50 into an
outer cover. If user grasp structures 59, 61 are centered proximate to the
respective ends of insert
50 as shown, this may also provide visual assistance to the user for co-
locating respective
centered fastener component pairs, described in more detail below.
Additionally, user grasp structures 59, 61 may serve to enable the user to
quickly and
easily grasp insert 50 proximate to its respective ends, which as a result of
their distance from
exudation points on a wearer's body, are less likely to be soiled at the time
replacement of insert
50 becomes necessary or desirable. Thus, the user may be better enabled to
avoid contacting the
wearer's exudates with the user's hands when removing a soiled insert 50 from
an outer cover
20.
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Referring to the example depicted in Fig. 2F, it may be desirable in some
circumstances
to include more than one grasp structure 59 on the insert. This may be deemed
useful in
examples such as depicted in Fig. 2F, where more than one fastener component
56 is disposed on
an end of an insert. In such circumstances, including a separate grasp
structure 59 associated
with and proximate to each fastener component 56 may enable a user to
manipulate portions of
an insert to more easily accurately locate and install it within an outer
cover with fastener
components 59, 33 suitably co-located and/or aligned. It may also enable a
user to more easily
tug the fastener components 56 away from paired fastener components 33 to
separate them, when
it is necessary to remove the insert from the outer cover, by localizing or
focusing the user's
tugging forces where they are needed to effect such separation.
User grasp structures 59, 61 may include tab-like extensions as shown in Figs.
2F, 3 and
4, with free ends unattached to the outer cover 20 when insert 50 is installed
therein, which are
easily graspable. User grasp structures may have different forms as well. By
way of non-
limiting example, user grasp structures may take the form of loop-like
extensions (not shown)
extending from the ends of insert 50, finger holes (not shown) through insert
50 proximate the
ends thereof, pockets with openings facing the lateral centerline 70 of the
insert, and other
structures that facilitate grasping and pulling of insert 50 at locations
proximate to its ends.
Additionally, grasp structures 59, 61 may be formed of materials having a high
coefficient of friction (e.g., at least about 0.5), resiliently compressible
materials and/or surfaces
having three-dimensional relief, to facilitate secure gripping and pulling the
insert by the user.
Grasp structures 59, 61 also may be configured or adapted so as can be folded
over or
under the respective ends of insert, toward the lateral centerline of the
insert. This can serve to
conceal the grasp structures behind other materials and protect them from
contamination by
bodily exudates. Alternatively or in addition, it can serve to add convenience
for the user.
Insert/Outer Cover Fastener Components; Orientation Indicia; Other Possible
Features
Referring back to Figs. 2B, 3 and 4, as previously noted, outer cover 20 may
have one or
more insert fastener components such as front and/or rear insert fastener
components 33, 32
disposed thereon. Insert 50 may have front and/or rear fastener components 56,
57 disposed
thereon. Respective front and/or rear fastener components 56, 57 on insert 50
may be selected
and/or adapted to be cooperative to enable fastening with respective front
and/or rear insert
fastener components 33, 32 disposed on outer cover 20.
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Types, Locations and Localization of Fastening Locations
In one example, to enable fastening of respective front and rear fastener
components 56,
57 of insert 50 with respective front and rear insert fastener components 33,
32 on outer cover 20,
respective fastening pairs 56, 33 and 57, 32 may include cooperating fastener
components. An
example of a suitable hook-and-loop fastening system is a VELCRO system, a
product of Velcro
Industries B.V., components of which are available from Velcro USA, Inc.,
Manchester, New
Hampshire. A hook-and-loop fastening system provides certain advantages.
Because the
respective hook and loop components are supplied in sheet or strip form, they
may be cut into
suitably shaped patches that can be affixed to a cloth substrate by various
mechanisms, including
adhesive bonding, mechanical bonding, ultrasonic bonding, sewing, stitching,
serging, edging,
and the like. If respective hook-and-loop patches are used as fastener
components, relative ease
of fastening, simplicity and convenience for the user (as compared with, for
example, fastener
components such as a button and button hole) are one among several advantages
provided,
because fastening is effected simply by placing the fastener components in
face-to-face contact
and applying gentle pressure.
Some types of hook components may, in some circumstances, tend to snag or
catch
undesirably on a variety of materials in addition to intended corresponding
loop components,
while most types of loop components currently available do not have this
tendency. Thus, in
some circumstances it may be desired that patches of loop components form one
or both of insert
fastener components 33, 32, while patches of hook components form one or both
of fastener
components 56, 57. This arrangement places a non-snagging insert fastener
component on the
outer cover. This may be desirable in some circumstances, such as when the
outer cover 20 is
designed to be reusable - reducing the likelihood that components on an outer
cover 20 will
undesirably snag on other parts of outer cover 20 or on other articles, such
as clothing articles,
being stored or laundered along with outer cover 20.
However, fastening pairs 56, 33 and 57, 32 need not necessarily include
respective
components of a hook-and-loop fastening system, and need not necessarily
include respective
components of a two-component fastening system. Rather, a fastening system may
require only
one fastener component, or use other types of fastener components. Fastener
components used
may be adapted to engage, retain, and otherwise hold the insert or a portion
thereof. A fastener
component on outer cover 20 may include a patch of adhesive; a structure
having a region of
relatively high coefficient of friction; a pocket; flap; strap; or other
capturing, holding and/or
retaining surface, device or structure. Thus, referring to Fig. 2C in one
example, the inside of
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outer cover 20 may include one or more pocket structures 32a, 33a situated on
or along the inner
surface 25 of outer cover 20, in, e.g., the front region 27 or rear region 28.
Such a pocket
structure may have an opening facing downward or upward (relative to the
wearer in a standing
position, and relative to Fig. 2B). A pocket structure may be adapted to
receive, fit and capture,
for example, the forward edge and a portion of forward region 54 of insert 50.
A pocket structure
33a, 33b may have an opening facing lateral axis 45, such that an end of
insert 50 may be
inserted therein and retained thereby. A pocket structure may alternatively
have an opening
facing away from lateral axis 45, such that an end of insert 50 may be
inserted therein and
retained thereby, and then insert 50 may be folded back over such opening and
toward lateral
axis 45. Referring to Fig. 2D, in another example, one or more pockets 32b,
33b may be
provided in the front and/or back region on the inner surface of the outer
cover 20 positioned
such that a corner of an insert 50 may be inserted into and retained by the
pocket. Such pockets
may have respective openings defined by edges of material 32c, 33c forming an
angle with
respect to both the lateral and longitudinal axes of between about 0 and 90
degrees, but more
preferably, between about 30 degrees and 60 degrees. One or more of such
fastener components
may be provided in lieu of, in addition to, or in combination with, other
fastener components
disposed at the front region of the outer cover 20 and forward region of
insert 50. As one
example, an outer cover 20 may have a pocket structure 33a in front region 27
(see Fig. 2C) in
combination with a patch of loops component forming rear fastener component 32
(see Fig. 2B).
With such a structure and a suitably adapted insert 50 having a patch of hooks
as fastener
component 57, to install the insert the user may insert the forward edge of
insert 50 into the
pocket structure 33a, and then fasten the rearward portion of insert 50 into
the rear region of the
outer cover 20 by engaging respective fastener components 32, 57.
In another example, fastener components 32, 33 may be respective patches of
hook
components, while fastener components 56, 57 may simply be surfaces formed of
woven or
nonwoven material adapted to be attachably engageable by such hook components.
In yet
another example, fastener components 56, 57 may include respective patches of
hook
components, while fastener components 32, 33 may simply be surfaces formed of
woven or
nonwoven material suitable for, or adapted to be, attachably engageable by
such hook
components.
Also, a fastener component in any form, including a respective component of a
fastening
pair 56, 33 and 57, 32 may be disposed on either of insert 50 or outer cover
20. For example, a
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hook patch may be disposed on either of insert 50 or outer cover 20, with a
cooperating loop
patch disposed on the other of insert 50 or outer cover 20.
An insert fastener component such as component 32 on outer cover 20 may be
attached or
connected to at least a portion of an anchoring system, such as an anchoring
band 38, or diagonal
anchoring band 38a. This may provide, as one advantage, the distribution of
structural loading
resulting from the weight of absorbed or contained exudates, as described in
one or more of the
patent applications cited above, in the description of anchoring bands.
Fastening locations may be multiply disposed, for example, at each of the four
corners of
insert 50 and corresponding locations on outer cover 20, and even at other
locations along insert
50 and outer cover 20, created by fastener components suitably selected and
disposed. For
example, fastener components may be disposed along the longitudinal sides
proximate the ends
of the insert in the forward and/or rearward region of the insert. Fastener
components may be
disposed adjacent an edge of the insert, or may be disposed laterally and
longitudinally inboard
of the edge. For example, a fastener component may be disposed at least 1, 2,
or 3 cm from all
edges of the insert. In certain embodiments, at least one fastener component
is disposed at least a
distance from the lateral or longitudinal edge, or both, of the insert
equivalent to one-fourth the
width of the insert. In one embodiment, a fastener component is disposed along
at least about
one-fifth of the length of the longitudinal axis.
In another example, a fastening system such as either of fastener component
pairs 56, 33
and 57, 32 may form a singularized and localized fastening location proximate
each of, or either,
the forward/front and/or rearward/rear ends/regions as suggested in the
Figures. Having only two
respectively singularized, localized fastening locations substantially
laterally centered on the
insert and the outer cover, as suggested in Figs. 2B and 3, provides an
advantage of simplicity
and ease of installation for the user, by presenting only two locations at
which the user must co-
locate and fasten insert 50 to outer cover 20.
Additionally, having a single, localized fastening location proximate only one
or two ends
of insert 50, such as suggested in Figs. 2B and 3, provides a partially force-
decoupled attachment
of insert 50 within outer cover 20. This may be especially desired in the rear
region 28 of outer
cover 20, where extensibility and/or elasticity of outer cover 20 may be
especially desired to
maintain fit, comfort and appearance while accommodating body contours and
movements of the
wearer about the buttocks and hips. With this force-decoupled arrangement, the
portions of outer
cover 20 surrounding fastening element (s) 33, 32, such as waistband portions
34, 35, and front
and rear regions 27, 28, may laterally stretch and contract substantially
independently of and
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unimpeded by the structure of insert 50 and portions thereof. This may avoid
lateral bunching of
the ends of insert 50 with lateral contraction of the outer cover 20, and/or,
conversely, may avoid
having the structure of insert 50 restrict outer cover 20 from stretching or
contracting laterally, as
a result of a more force-coupled arrangement therebetween. Such lateral
bunching or restricting
otherwise may be incidental to fastening insert 50 within outer cover 20 in a
manner that force-
couples a greater portion of the width of insert 50 to outer cover 20, e.g. by
use of more than one
fastening location across the width of insert 50 proximate a given
longitudinal location, or by use
of a laterally delocalized/extended continuous fastening location along a
larger portion of the
width of insert 50. Force-decoupling, therefore, may provide for enhancement
of fit, appearance
and wearer comfort, as well as improved capability for maintenance of intended
insert shape and
performance while worn.
Thus, in one example, referring to Fig. 4, a patch of hook components forming
a fastener
component 56 and/or 57 attached to insert 50 may be substantially laterally
centered on the insert
as suggested in the figure, and may have an width Wf attached along insert 50
that extends no
more than about 50% of the lateral width W; of the insert 50 at forward region
54 and/or rearward
region 55. This provides that no more than about 50% of the width of the
insert 50 at, e.g.,
forward region 54 and/or rearward region 55, will be force-coupled to the
outer cover by
operation of the patch of hook components, and that, correspondingly, about
50% of such width
(i.e., that portion of width W; that is not attached to, or force-coupled to,
the insert along width
Wf) is force-decoupled from the outer cover 20 when insert 50 is installed
therein. In some
circumstances, it may be desired that the portion of the lateral width of
forward region 54 and/or,
especially, of rearward region 55 of insert 50 that is force-decoupled from
the outer cover is even
greater than about 50%. Thus, it may be desired that the width Wf of a
fastener component 56 or
57, comprising, e.g., a continuously attached patch of hooks, is no more than
about 40%, no more
than about 30%, or even no more than about 20%, of the lateral width W; of the
insert at the
region where the fastener component is situated. In another example, it may be
desired in some
circumstances that at least about 50% of the lateral width of the insert 50 in
the front and/or rear
region 54, 55, is force-decoupled from the outer cover. In some circumstances
it may be desired
that more than about 50%, more than about 60%, more than about 70%, or even
more than about
80%, of the lateral width of the insert at any longitudinal location, is force-
decoupled from the
outer cover when installed therein.
As depicted in Figs. 2E and 2F, examples are contemplated wherein
singularized/localized force-decoupled fastener component pairs 32, 57 may be
employed in the
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rear region 28 of the outer cover 20 and rearward region 55 of the insert 50,
while fastener
component pairs 33, 56 effectively controlling the forward corners of the
insert 50 may be
employed in the front region 27 of the outer cover 20 and forward region 54 of
the insert 50.
This may allow force decoupling of the stretchable outer cover in the back of
the article, while
maintaining control over the front corners of the insert.
Other fastener components that provide such singularized and relatively
laterally
localized fastening locations, providing limited force-coupling across the
lateral width of at least
one end of insert 50, are possible. Other suitable fastener components may
include tab and slot
fasteners, macro hook and loop fasteners, button fasteners, interlocking
fasteners, hook and slot
fasteners, snap fasteners and other fastener types available.
In some insert embodiments, as implied above, the corners of the insert 50
when in use
may be prone to buckling, sagging or rotating toward the insert lateral axis
70, or out of the
contour of the body of the insert, in response to forces resulting from wearer
motion or position,
or exudate loading, e.g., in the crotch region. Also, referring to Fig. 3, and
from the description
of standing cuffs 53 with cuff elastics 58a, 58b set forth above, it can be
appreciated that, if
longitudinal tensile forces are imparted by pre-strained cuff elastics 58a,
58b, standing cuffs 53
may tend to pull the respective outer corners of insert 50 longitudinally
toward each other. If
there is not structure present to resist these forces, the outer corners of
insert 50 may sag or
buckle, and standing cuffs 53 may be loosened, sag or even collapse. This may
lead to gaps
between the edges 58 of the cuffs and the wearer's body. In turn, this may
compromise the cuffs'
gasketing function, and increase the risk of leakage.
While it may be important at both ends of the insert, control of the insert
corners may be
particularly important in the forward region 54, due to its closer proximity
to the urethra. Insert
designs in which exuded urine is predominately stored in the forward region
also may
concentrate the weight and expansion stress of exudate loading in the forward
region 56, and
thus, on the forward corners of the insert 50.
Control of the corners to reduce the likelihood of such sagging and rotation
may be
improved, in one group of examples, by placement and/or shaping of fastener
component pairs.
Referring again to Figs. 2E and 2F, it can be seen that fastening component
pairs 33, 56 in, e.g.,
the respective front/forward regions of the outer cover 20 and insert 50 may
be arranged, shaped,
sized and/or placed such that the forward corners of insert 50 are effectively
captured and held to
the outer cover 20 when insert 50 is installed therein. The fastener
component(s) 56 disposed on
the insert may, accordingly, have a width Wf at least equal to about one-
fourth, or one-half, of the
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width of the insert. In some examples, the width Wf of the fastener
component(s) may be
between about 50% and 100%, or between about 75% and 100%, or even between
about 85%
and 100% of the width W, of the insert (not including cuffs 53). If multiple
fastener components
56 are included, e.g., in a line, array, or other pattern, the fastener
component width is considered
to be the lateral distance between the outermost edges of the fastener
components 56.
Insert End Support Stiffeners
In some circumstances, inclusion of fastening component pairs which attach the
outer
corners of the insert to the outer cover may be undesirable for reasons of
cost and/or complexity,
or may sacrifice the advantages of having only one singularized/localized
fastening location
proximate each end of insert 50, as described above. Particularly in the rear
region of the outer
cover 28, a singularized and relatively localized fastening location providing
a force-decoupled
arrangement may be desirable, for the reasons described above.
In this circumstance, it may be desirable to include a stiffening component
proximate to
one or both ends of the insert, but especially an end adapted with a
singularized and relatively
localized fastening location providing a force-decoupled arrangement.
Referring to Figs. 3 and 4,
end support stiffeners 60 and 62 may be included. Such end support stiffeners
may serve to aid
the user in engaging the insert with the outer cover, and to help insert 50
maintain its intended
shape and configuration while being worn beneath an outer cover, i.e., help
maintain the intended
position and gasketing function of the standing cuffs 53. End support
stiffeners 60, 62 also may
help control the corners of the insert regardless of the size, type or
location of fastener
components included on the insert. In addition to providing resistance to
longitudinal pull of cuff
edges 58, end support stiffeners 60, 62 may provide resistance to bending in
any direction or
plane.
End support stiffeners 60, 62 may be affixed to, or incorporated within,
insert 50
proximate the ends thereof as suggested by Figs. 3 and 4. In addition to
increasing the tendency
of insert 50 to maintain optimal shape while in use, such end support
stiffeners may increase the
tendency of the respective ends of insert 50 to stay open and flat before
insert 50 is installed in an
outer cover. Because the ends of insert 50 may otherwise be folded over or
bunched while being
stored and/or carried by the user before installation, end support stiffeners
may enhance user
convenience, by causing the ends of insert 50 to maintain or seek a
shape/configuration that
requires less manipulation by the user to install it in an outer cover.
Referring to Fig. 4, one or more end support stiffeners 60, 62 may be disposed
in a lateral
orientation with respect to the insert and formed of any flat, sheet-like or
card-like material, or
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any flat, stiffened assembly. In one example, an end support stiffener may be
formed by folding
over a portion of the insert end material(s) to create a stiffened region
comprising folded layers of
material. In another example, end support stiffeners 60, 62 may be formed by
depositing onto
the ends of insert 50 lateral bands, strips or other shapes or patterns of
deposits of liquid or semi-
liquid adhesive or other material that cures or cools to a stiffened state,
and thereby imparts
added stiffness to the substrate to which it is applied. In another example,
end support stiffeners
may be formed of cardboard or like material. One example of suitable stiffener
material is 0.031
in. thick VOLARA foam supplied in sheet form (a product of Sekisui Voltek,
LLC, Lawrence,
MA). Stiffener materials may be laminated with or adhesively applied to
portions of insert 50 to
be stiffened, or applied, affixed or included by any other suitable method.
Other examples of
suitable stiffening materials may include added layers of nonwovens, tufted
nonwovens, films,
laminates of films and nonwovens, patches of fastener loops or hooks
components, portions of a
suitable grasp structure, etc.
It may be desired that the portions of insert 50 including one or more end
support
stiffeners 60, 62 are sufficiently stiff to effectively resist the tension
forces in standing cuffs 53
and substantially maintain standing cuffs 53 in their gasketing configurations
while insert 50 is in
use, and substantially maintain the corners of insert 50 in laterally extended
positions, preventing
buckling or bunching of the same. The amount of stiffness desired may depend
upon various
factors including the inherent stiffness of the insert materials without a
supplemental end support
stiffener, and the amount and/or range of tension in the standing cuffs when
the article is worn.
At the same time, for purposes of wearer comfort and safety, it may be
desirable that the portions
of the insert including the one or more end support stiffeners 60, 62 are
pliable enough to flex
comfortably with the wearer's body movements, and to collapse before any form
of contusion or
impalement injury hazard would be presented. It also may be desirable that
stiffened portions are
elastic in nature, in they will tend to return to a substantially flat
configuration after being bent,
folded or twisted.
End support stiffeners 60, 62 may increase planar, lateral and/or longitudinal
stiffness of
the areas of insert 50 in which they are located, as compared with portions of
the insert adjacent
such stiffeners with respect to a plan view (such as Fig. 4). These differing
orientational aspects
of stiffness may affect various attributes of the insert. For example,
referring to Fig. 3, it can be
seen that the ability of a portion including an end support stiffener 60, 62
(stiffened portion) to
resist longitudinal tension forces in standing cuffs 53, may be affected by
one or more of planar
and longitudinal stiffness of the stiffener. The pliability and relative
comfort or discomfort for
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the wearer, associated with a presence of a stiffened portion, may be affected
by planar stiffness
of the stiffener.
One measure of stiffness relevant to the ability of a stiffened portion to
resist longitudinal
tension forces in standing cuffs is Edge Deflection Force, which is measured
according to the
Edge Deflection Force Measurement Method set forth below. In view of the
potentially
competing objectives of structural rigidity and comfort, it may be desired
that a stiffened portion
of an insert end, i.e., the portion of an end that includes an end support
stiffener, have an average
Edge Deflection Force from 0.2 N to 3.0 N, or from 0.4 N to 2.0 N, or even
from 0.50 N to 1.70
N, as measured by the Edge Deflection Force Measurement Method set forth
below.
Another measure of stiffness relevant to the comfort of a stiffened portion is
the Peak
Bending Force and Bending Stiffness, which are measured according to the
Bending Stiffness
Measurement Method set forth below. In view of concerns for comfort, it may be
desired that a
stiffened portion of a an insert end, i.e., the portion of an end that
includes an end support
stiffener, have an average Peak Bending Force of no more than 4.0 N, or even
no more than 3.7
N, and an average Bending Stiffness of no more than 675 N/mm, or even no more
than 630
N/mm.
End support stiffeners 60, 62 may be located adjacent or near one or both ends
of insert
50 and may extend laterally from the lateral center thereof to stiffen the
insert along a substantial
portion of its width. Alternatively, the stiffeners may be located at least
about 0.5, 1, or 2 cm
from the end of insert 50, and may be substantially centered about the
longitudinal center line of
the insert. The one or more end support stiffeners may have a width of from
about 50% to about
100% of the lateral width of the insert, or may extend beyond the longitudinal
edges of other
materials forming the insert. The end support stiffeners may have any
longitudinal dimension,
although, in some circumstances, a longitudinal dimension less than 25% of the
insert length may
better assure comfort for the wearer, and therefore, may be desired. In some
examples, the
longitudinal dimension of an end support stiffener may range from about 5 mm
to about 50 mm.
A stiffener also may extend longitudinally beyond the lateral edge of other
materials forming the
insert. One or both ends of the insert may include an end support stiffener.
In examples wherein
the insert comprises more than one end support stiffener, the respective end
support stiffeners
may have differing shapes, dimensions, stiffness, thickness, color, structure,
placement,
material(s) or composition. An end support stiffener also may include, or be
integral with, a
grasp structure or fastener component as described above, and as suggested in
Fig. 3 (end support
stiffener 60 is depicted as integral with grasp structure 59).
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Targeting, Orientation and Alignment Indicia
As discussed above, an insert 50 may be imparted with features that make it
asymmetric
about its lateral axis. Despite such asymmetrical configuration, as suggested
by Fig. 4, insert 50
may have an overall profile that does not appear to be asymmetric about its
lateral axis. For
example, as depicted in Fig. 4, insert 50 may have an overall profile, when
opened and laid flat,
that is substantially rectangular, and thus, appears to be symmetric about its
lateral axis 70.
Other insert profiles are possible as well, which have overall profiles which
appear symmetric
about a lateral axis. Additionally, even where an insert 50 has an overall
profile that is
asymmetric about its lateral axis, it may not be clear just from the profile
which portion is the
forward portion and which portion is the rearward portion. Thus, absent a
sufficiently
perceptible signal indicating which portion of the insert is the forward
portion and which is the
rearward portion, a user may have difficulty determining the same, and as a
result, may attempt
to install an insert into an outer cover with incorrect relative front-rear
orientation - in turn,
resulting in sub-optimal fit, appearance, exudate containment and/or comfort.
The insert and/or outer cover may comprise one or more insert targeting
indicia to
indicate, facilitate and/or compel correct positioning and association of
portions of the insert
within the outer cover. The insert targeting indicia may comprise verbal or
non-verbal
instructive indicia, visual targeting indicia, cooperating geometrical
features, cooperating types
of fastener components, or cooperating designs of fastener components sized
and formed to
indicate or compel the engagement of the insert with the correct region of,
and in correct
orientation with, the outer cover so as to enable the optimum performance of
the wearable
absorbent article. Other examples of possible targeting indicia components
include one or more
cooperating colors, shapes, patterns, lines, outlines, silhouettes, other
geometrical features,
protrusions or depressions, textures, patterns, targeting lines or crosshairs,
bulls-eye
representations, and the like, disposed on the outer cover and/or the insert
to indicate correct
positioning of the insert within the outer cover. In one example, the inner
surface of the outer
cover may be imprinted with an outline of an insert, or a silhouette of an
insert. Alternatively,
one or both of the forward and rearward regions 54, 55 of the insert may have
disposed thereon a
pictogram showing the outer cover shape, or a generalized version thereof,
with the front and
back of the outer cover indicated via size, color, contrast, or some other
indicator, showing the
correct insert installation orientation. For example, an outer cover pictogram
disposed in the
rearward region 55 of the insert may have the rear outer cover region, or
portions thereof,
indicated with a brighter color, an arrow, a circle, etc., while an outer
cover pictogram disposed
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in the forward region 54 of the insert may have the front outer cover region,
or portions thereof,
indicated similarly.
Targeting indicia also may comprise at least two cooperating components, one
on the
outer cover 20 and one on insert 50, such that when these two components are
associated, the
respective components of outer cover/insert system will be properly oriented
with respect to one
another and will perform most optimally. In one example, the inner surface of
the outer cover
may be imprinted with a first arrow pointing at an insert location, and the
insert may be imprinted
with a second arrow pointing at the first arrow when the insert and outer
cover are correctly
relatively positioned.
Indicia may be cognitively correlating, or non-correlating, a correlation
indicating a
correct optimal placement, and a non-correlation indicating an incorrect sub-
optimal placement.
Respective cognitively correlating targeting indicia may include an indicium
on the outer cover
that cognitively correlates with an indicium on the insert, indicating to the
user the correct
relative positioning and engagement of the insert and the outer cover. For
example, respective
cognitively correlating indicia on the insert and outer cover may have a
common color, shape, or
texture. (As used herein, "common color" includes any first color and
recognizable shades or
variants thereof, which in view of all features of the article is visibly and
cognitively
distinguishable from another color on the article.)
Referring to Figs. 2B, 3 and 4, when an insert 50 is asymmetrical as described
above, it
may have only one optimal forward region 54 and only one optimal rearward
region 55.
Similarly, when an outer cover 20 is asymmetrical as described above, it may
have only one
optimal front region 27 and only one optimal rear region 28. Thus, in the
event either or both of
these asymmetries are substantial, installation of insert 50 into outer cover
20 with incorrect
relative front-rear orientation may cause the wearable absorbent article not
to fit and/or function
optimally. Accordingly, it may be desirable in some circumstances to
incorporate one or more
indicia into the outer cover 20 and/or insert 50 that are adapted to inform
the user as to the
correct respective front-rear orientation of these components. Such indicia
may provide such
information to the user functionally, tactilely and/or visually.
Functional indicia may include fastener components that function properly,
effectively
and/or optimally with correct front-rear orientation, but do not function
properly, effectively
and/or optimally with incorrect front-rear orientation.
For example, referring to Figs. 2B and 3, front insert fastener component 33
on outer
cover 20 may be cooperative to effect optimal/maximum fastening security only
with front
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fastener component 56 on insert 50, but not with rear fastener component 57 on
insert 50.
Similarly, rear insert fastener component 32 on outer cover 20 may be
cooperative to effect
optimal/maximum fastening security only with rear fastener component 57 on
insert 50, but not
with front fastener component 56 on insert 50.
In a more specific example conceptually appreciated from Fig. 2H, front insert
fastener
component 33 on outer cover 20 may include a patch of loops, while front
fastener component 56
on insert 50 may include a mating patch of hooks (mating relationship
indicated by hatching of
components 33, 56 in Fig. 2H). Correspondingly, rear insert fastener component
32 on outer
cover 20 may include a patch of hooks, while rear fastener component 57 on
insert 50 may
include a mating patch of loops (mating relationship indicated by absence of
hatching of
components 32, 57 in Fig. 2H). Thus, in this particular example, if a user
mistakenly attempts to
fasten rear fastener component 57 on insert 50 (loops) to front insert
fastener component 33 on
outer cover 20 (loops), proper or optimal fastening will not be effected,
which will communicate
to the user that he/she must rotate insert 50 by 180 degrees to install it
with correct/optimal front-
rear orientation on the outer cover.
In another specific example also conceptually appreciated from Fig. 2H, front
insert
fastener component 33 on outer cover 20 may include a female snap fastener
component, while
front fastener component 56 on insert 50 may include a mating male snap
fastener component
(mating relationship indicated by hatching of components 33, 56 in Fig. 2H).
Correspondingly,
rear insert fastener component 32 on outer cover 20 may include a male snap
fastener
component, while rear fastener component 57 on insert 50 may include a mating
female snap
fastener component (mating relationship indicated by absence of hatching of
components 32, 57
in Fig. 2H). Thus, in this particular example, if a user mistakenly attempts
to fasten rear fastener
component 57 on insert 50 (female snap fastener component) to front insert
fastener component
33 on outer cover 20 (female snap fastener component), the components will not
fit properly
together and proper/optimal fastening will not be effected, which will
communicate to the user
that he/she must rotate insert 50 by 180 degrees to install it with
correct/optimal front-rear
orientation.
Thus, functional indicia may include any fastener components that will
function properly
and/or optimally to effect fastening and maximum fastening security between
insert 50 and outer
cover 20 when the two are properly oriented, but will not function properly or
optimally
otherwise. Any different types of fastener components or systems may be
combined to
differentiate the forward and rearward regions of the insert and indicate
correct orientation within
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the outer cover. Generally, with the use such functional indicia, the fastener
components types in
the forward region of the insert and front region of the outer cover are
respectively incompatible,
or significantly less effective, with the respective fastener components types
in the rearward
region of the insert and rear region of the outer cover. As another example of
such functional
indicia, the front insert fastener pair 33, 56 may be a hook and loop
fastening system, while the
rear insert fastener pair 32, 57 may be a snap fastening system. In another
example, the front
insert fastening component(s) may include a pocket or flap structure, while
the rear fastening
components embody a dissimilar fastening system. The front and rear insert
fastening systems
may comprise any two different fastening systems as disclosed herein, or as
otherwise available.
In another example, functional indicia may be embodied by fastener pairs 33,
56 and 32,
57 having mutually exclusive geometries of similar or compatible fastening
system types. For
example, as depicted in Figs. 2E and 2F, the front fastener pair 33, 56 may
have a first placement
and geometry, while the rear fastener pair 32, 57 may have a second placement
and geometry,
such that if installation of insert 50 within outer cover 20 with incorrect
front-rear orientation is
attempted, the fastener pairs will not align to provide visibly correct and
functionally effective
attachment, communicating to the user that that he/she must rotate insert 50
by 180 degrees to
install it with correct/optimal front-rear orientation. In another similar
example (not depicted),
the front insert fastening system may have an open circle, or doughnut-like,
geometry, while the
rear insert fastening system may have a geometry of a circle with a diameter
less than that of the
central opening in the open circle of the front insert fastening system. In
yet another example
(not depicted), the front and rear insert fastening systems may be located
primarily on one side of
the longitudinal axis of the article (i.e., the longitudinal axes of both the
insert and the outer
cover). In this example, if the insert is applied to the outer cover in the
incorrect front-to-back
orientation, the insert fastening components and fastening components will not
align correctly.
In another example (not depicted), the front insert fastening system may
comprise an interlocking
fastener oriented along the direction of the longitudinal axis of the article,
while the rear
fastening system may comprise an interlocking fastener oriented along the
direction of a waist
edge or lateral axis of the article. In another example which may be
conceptually appreciated
from Fig. 2F, the front fastening system may include one or more fastening
components 33, 56
disposed along the longitudinal edges of the insert, while the rear fastening
system may include a
single fastening pair 32, 57 having a width less than the insert width and
disposed on the
longitudinal axis of the article.
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Functional indicia need not necessarily be limited to fastener components.
Functional
indicia also may be embodied in other features of the outer cover and insert
that affect how the
two fit or function together in correct, optimal front-rear orientation versus
incorrect (reverse),
sub-optimal front-rear orientation. Thus, functional indicia may additionally
be associated with
or combined with another functional element of the outer cover or insert.
Indicia may be
associated with elements of the outer cover such as a waistband, side panel,
stretch element, leg
cuff, physical retention fastener component (e.g., a pocket or retaining
strap), and the like.
Indicia may be associated with elements of the insert, such as a waist cap,
waist band, standing
cuff, fecal management feature, insert positioning aid, insert stiffening aid,
insert removal aid, or
insert disposal aid.
From the foregoing it will be appreciated that other forms of functional
orientation indicia
are possible, within the principle of the foregoing description. Additionally,
any of the differing
types of indicia described may be included in a single article, in any
combination.
In other possible examples, instead of respective functionally
cooperative/uncooperative
pairs of components as described above, insert 50 and outer cover 20 may
include respective
non-functional indicia, such as tactile or other sensory indicia.
For example, the front insert and outer cover fastener components may be
selected or
formed so as to have a first tactile attribute, while the rear insert and
outer cover components may
be selected or formed so as to have a second tactile attribute. In another
example, features of the
insert and outer cover may have features such as 3-dimensional shapes that are
mating or
geometrically cooperating with optimal front-rear orientation, but not mating
or geometrically
cooperating with reversed, suboptimal front-rear orientation.
In other possible examples, instead of or in addition to respective
functionally
cooperative/uncooperative pairs of fastener components or tactile indicia
components as
described above, insert 50 and outer cover 20 may include respective visual
indicia. Outer cover
20 may include respective front and rear visual indicia 73, 74 disposed on the
front region 27 and
rear region 28, respectively. Respective visual indicia disposed on insert 50
and outer cover 20
may be adapted to provide a visual cue to the user of correct/optimal
orientation and placement
of insert 50 within outer cover 20.
For example, components of visual indicia and a visual cue may involve use of
a common
color. In one particular example, front and/or rear visual indicia 73, 74
disposed on outer cover
20 may comprise respective common colors visibly distinct from one another.
(As used herein,
"common color" includes any first color and recognizable shades or variants
thereof, which in
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view of all features of the article is visibly and cognitively distinguishable
from another color on
the article.) Insert 50 may have respective cooperating indicia disposed or
embodied thereon.
Thus, for example, forward and rearward user grasp structures 59, 61 on insert
50 may bear or be
colored with colors respectively common and corresponding with those comprised
by front
and/or rear visual indicia 73, 74. More particularly, for example, front
visual indicium 73 and an
insert feature such as forward user grasp structure 59 may both bear or be
colored a first common
color, and rear visual indicium 74 and a feature such as rearward user grasp
structure 61 may
either or both be colored a second common color, visibly distinguishable from
the first common
color.
In another particular example which may be conceptually appreciated from Figs.
2G, 21
and 3, front and rear visual indicia 73, 74 disposed on outer cover 20 may
embody, or bear
images of, respective shapes or sizes to match, or cognitively correlate
visually correlate with,
corresponding shapes or sizes embodied, or pictured on, insert features such
as forward and
rearward user grasp structures 59, 61 and/or fastener components 56, 57. More
particularly, for
example, front visual indicium 73 or forward user grasp structure 59 may both
embody or bear
images of triangles, and rear visual indicium 74 or rearward user grasp
structure 61 may both
embody or bear images of circles. Other examples of cognitively correlating
indicia respectively
disposed on an insert and corresponding location on an outer cover include: a
baseball and
glove, soccer ball and goal, bird and nest, and any other images of components
of well-
recognized pairings which would indicate to a user that two portions bearing
or embodying such
images are to be brought together during installation of insert 50 within
outer cover 20.
In another particular example, front and rear visual indicia 73, 74 disposed
on outer cover
20 may bear images of words or symbolic indications for "front" and "rear", to
match
corresponding words or symbolic indications on insert features such as forward
and rearward
user grasp structures 59, 61. In a more particular example, front visual
indicium 73 and forward
user grasp structure 59 may both bear an image of the letter "F" (i.e., for
"front"), and rear visual
indicium 74 and rearward user grasp structure 61 may both bear an image of the
letter "R" (i.e.,
for "rear").
In another particular example, front and/or rear visual indicia 73, 74
disposed on outer
cover 20 may embody, or bear images of, respective portions of expectedly user-
recognizable
shapes, characters, objects, etc., to match corresponding portions of
expectedly user-recognizable
shapes, characters, objects, etc., embodied, or pictured on, insert features
such as forward and/or
rearward user grasp structures 59, 61. In a more particular example, front
visual indicium 73 and
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forward user grasp structure 59 may both embody or bear respective portions of
a first image
that, when brought together properly, form a cognitively complete image of an
expectedly user-
recognizable first shape, character, object, etc.; and/or rear visual indicium
74 and rearward user
grasp structure 61 may both embody or bear respective portions of a second
image that, when
brought together properly, form a cognitively complete image of an expectedly
user-recognizable
second shape, character, object, etc., distinctive from the first.
In yet another particular example, visual orientation indicia may be
simplified into a
single pair of visual indicia appearing, respectively, on outer cover 20 and
insert 50. In one such
example, an inner surface 25 of outer cover 20 may bear an image of an arrow
pointing
longitudinally toward front edge 21, and insert 50 may bear an image of an
arrow pointing
longitudinally toward its forward end.
Examples of other suitable visual orientation indicia adapted to provide
orientation
information may include alphanumeric text including words, arrows, symbols,
diagrams,
pictographs, icons, cartoons, schematics, and any other visual indicia.
It may be desired that indicia associated with the front portions of the outer
cover and
insert will not cognitively correlate, or will cognitively not correlate, with
indicia associated with
rear portions of the outer cover and insert, and vice versa, when the user
views both sets of
indicia.
From the foregoing it will be appreciated that other forms of visual
orientation indicia are
possible, within the principle of the foregoing description.
In addition to providing indicia that indicate and/or compel the correct front-
rear
orientation of the insert with respect to the outer cover, it also may be
desirable to provide indicia
that indicate and/or compel correct longitudinal and lateral alignment of the
insert within the
outer cover, in order to provide for the designed optimal containment, fit,
comfort and
appearance of the article. In the examples shown in Figs. 2E-21, respective
fastener component
pairs 32, 57 and 33, 56 are configured and disposed to serve as alignment
indicia. It can be
appreciated from these examples that fastener components may be configured and
disposed to
not only indicate and/or compel correct front/rear orientation, but also
indicate and/or compel
correct longitudinal and lateral alignment of the insert 50 with respect to
the outer cover 20,
because co-location of one or both of these fastener component pairs to effect
proper fastening
will also effect proper longitudinal and lateral alignment. In other examples,
separate visual
indicia may be included for this purpose, such as, for example, longitudinal
alignment indicia
79a, 79b and lateral alignment indicia 78a, 78b disposed respectively on outer
cover 20 and insert
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50 (Fig. 2E). Referring to Fig. 2E, it can be seen that insert 50 may be
longitudinally and
laterally aligned within outer cover 20 by ensuring that alignment indicia
pairs 78a, 78b and 79a,
79b meet, or are closely proximate each other, when insert 50 is installed
into outer cover 20.
Visual alignment indicia may take other forms, including, but not limited to,
matching line
segments, shapes, insert end or corner outline images 80 disposed on the inner
surfaces of outer
cover 20 (see, e.g., Fig. 21), etc.
Article of Commerce
It is contemplated that an article of commerce including one or a plurality of
outer covers
and one or a plurality of inserts, as described herein, may be prepared and
sold as such. For
example, a package containing from one to 12, or more, outer covers, together
with one or a
plurality of associated inserts, may be assembled and sold together as
packaged. The respective
outer cover(s) and inserts in a package may have matching/complementary
fastening systems,
orientation indicia and/or alignment indicia as described herein.
For such an article of commerce it may be desirable to determine a ratio of
inserts to outer
covers suitable to constitute a set of convenient numbers of outer covers and
inserts, respectively.
For example, it may be deemed suitable to include approximately a half day or
day's supply of
inserts for each outer cover included in the set. Thus, for example, the
article of commerce may
include inserts and outer covers in a ratio of inserts to outer covers of 1:1,
2:1, 3:1, 4:1, 5:1 or
even 6:1. Accordingly, for example, a package associating a set may include
one outer cover and
1, 2, 3, 4, 5 or 6 inserts; two outer covers and 2, 4, 6, 8, 10 or 12 inserts;
three outer covers and 3,
6, 9, 12, 15 or 18 inserts, and so on. For a "starter" set for certain
consumers such as first-time
purchasers, or in other circumstances, it may be desirable for a package to
contain from 2 to 14
outer covers - which may correspond roughly to from one day's to one week's
supply of clean
outer covers available before laundering becomes necessary.
It may also be desirable to include, in a set including a plurality of
inserts, inserts of
differing designs, adapted for use under differing circumstances. In one
example, one or more of
the inserts in the plurality may be adapted for extended or nighttime use
(sleep-use), and one or
more for daytime use, with respect to features such as, e.g., location of
absorbent material and
absorbent capacity. Half of the number of inserts in the plurality, or fewer
than half, may be
adapted for sleep-use. In one example of this embodiment, the set also may
include one or more
outer covers decorated with nighttime/sleep themes, such as, for example,
images of the moon,
stars, nighttime sky colors and other nighttime scenes, images of sleeping
animals, sleeping
people, sleeping anthropomorphic characters, etc.; and one or more outer
covers decorated with
CA 02787261 2012-07-16
daytime/play themes, such as, for example, sun, birds, bright colors, daytime
sky colors and other
daytime scenes, images of awake/playing animals, people, anthropomorphic
characters, etc.
In a further embodiment, a set in a package may be specially adapted for
either boys or
girls. For example, a package may include one or more outer covers having
surface decoration
and ornamentation associated with little girls, e.g., inclusion of pink,
lavender and/or other soft
pastel color schemes, images of flowers, butterflies, bunnies, kittens, little
girls, princesses,
feminine cartoon characters or feminine anthropomorphic characters, etc., or
other decorative
features generally associated with little girls. Conversely, a package may
include one or more
outer covers having decoration and ornamentation associated with little boys,
e.g., inclusion of
blue, black, dark or bold color schemes, images of cars, trains, planes,
boats, rockets, spaceships,
objects associated with sports, little boys, masculine cartoon characters or
masculine
anthropomorphic characters, etc., or other decorative features generally
associated with little
boys. A package designed for either boys or girls also may include associated
corresponding
inserts specially adapted for either boys or girls, whether by functional
elements or by non-
functional, ornamental/decorative elements. Alternatively, a package may
contain one or more
outer covers and inserts adapted for use with either boys or girls, having
gender-neutral
decoration/ornamentation and functional elements.
In a further embodiment, a set in a package may include several types of
inserts, having
functional designs that differ in other respects. For example, a package may
include one or more
inserts having one or more of a feces acceptance aperture in a topsheet, space
beneath the
topsheet for isolation of feces, and/or related features such as described in,
for example, co-
pending U.S. Patent Nos. 8,016,803, 7,771,406 and 7,771,408.
In a further embodiment, a set in a package may be specially adapted for use
in specific
circumstances. For example, a set may include one or more outer covers and
associated inserts
adapted for wearing while swimming or public bathing. In this example, the
outer cover(s) and
inserts may be adapted for satisfactory use and to substantially retain
structural integrity while
soaked and/or immersed in water. For example, the included outer cover(s) may
be constructed
of materials which do not substantially lose tensile strength, stretch or sag
when soaked. In this
example, it may be desirable to form the outer cover(s) predominately of
polymeric, hydrophobic
materials and/or elasticized textile materials. Similarly, it may be desirable
to form included
inserts of materials that will withstand immersion and soaking without
substantial loss of
structural integrity during the period of intended use. It also may be
desirable to form such
inserts without inclusion of superabsorbent polymer or absorbent gelling
material. While these
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absorbent materials are often included in the absorbent cores of regular
diapers, they may be
deemed unsuitable for use in articles to be worn while swimming or bathing,
because such
materials would quickly absorb water, and swell and bulge with the absorbed
water, upon being
immersed - giving up their absorptive capacity, adding bulk and weight, and
retaining no benefit.
Within the same set, however, one or more inserts may be included for non-
swimming, non-
bathing use, such that the same outer cover(s) may be used for
swimming/bathing and non-
swimming, non-bathing activities. The one or more inserts for non-swimming,
non-bathing use
may have absorbent cores including superabsorbent polymer or absorbent gelling
material.
In a further embodiment, a set in a package may contain a plurality of durable
outer
covers 20, having leg openings defined by leg opening edges 23 that differ in
dimension from
one durable outer cover to another durable outer cover. Sequential use of such
durable outer
covers may be useful to effect a change in the location(s) at which leg band
portions 36 and leg
opening edges 23 encircle and contact the wearer's skin, each time a durable
outer cover in the
plurality is replaced by another durable outer cover in the plurality having
such differing
dimensions. This may provide the advantage of reducing the likelihood or
severity of chafing of
the wearer's skin in the location(s) of such contact that may result from the
wearer's movements.
Such chafing may otherwise be caused or exacerbated by repeated use of
successive durable
outer covers having leg openings of substantially unchanging dimensions, which
may result in
repeated encircling contact with the skin in a more concentrated or localized
fashion. Thus, for
example, a user may apply a first durable outer cover in the plurality and the
wearer may wear it
for a first period of time (such as a day), and the user may apply a second
durable outer cover in
the plurality and the wearer may wear it for a second period of time (such as
the ensuing night or
following day), and so on - effectively varying the location(s) on the
wearer's skin at which leg
opening edges and leg bands encircle and contact it - and reducing the
likelihood or severity of
chafing. Referring to Fig. 2C, it will be appreciated that varying any of, or
any combination of,
outer cover crotch width WC, outer cover front width WCf, outer cover rear
width WCr, outer
cover length LC and leg band length LLB, can have the effect of varying the
size of the leg
openings of a durable outer cover 20 when applied to the same wearer.
Accordingly, a set of at
least first and second outer cover in a package may have a difference between
them in any of
outer cover crotch width WC, outer cover front width WCf, outer cover rear
width WCr9 outer
cover length LC or leg band length LLB, as measured with each outer cover laid
out horizontally
on a flat surface, extended to its fullest unstretched (relaxed) dimensions.
Any of dimensions
WC,9 WCf9 WCr9 LC or LLB may differ between the first and second durable outer
covers by at
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least about 10%, 15%, 20% or more. In another example, however, the tension
forces in leg
bands 36 may be varied from one durable outer cover to the next, by use of,
for example,
differing types of elastic strands or strips, or differing sizes of elastic
strands or strips, or
differing numbers of elastic strands or strips, respectively included by leg
band portions 36, or
even differing constructions of leg band portions 36 - any of which may effect
differences in
dimensions of leg opening edges 23 from one durable outer cover to another
durable outer cover
within the package.
In a further embodiment, a variety of packages containing a variety of types
of sets may
be presented as a variety of articles of commerce. In one example, one or more
outer covers
forming part of a set in a package may be seasonal in nature, either by
reasons of function or
decorative/ornamental elements or both. Distinctive sets of outer covers may
differ from set to
set in attributes such as material basis weight, insulation properties,
breathability, etc. For
example, a "winter" or "cold weather" outer cover may be formed of materials
individually or in
combination having a relatively higher basis weight, while a "summer" or "warm
weather" outer
cover may be formed of relatively lighter materials and/or materials having
greater breathability
(as may be characterized and compared by WVTR).
In another example, one or more outer covers forming part of a set in a first
package may
all have decorative/ornamental elements designed by a first designer and/or be
labeled or branded
with the first designer's name or brand, while one or more outer covers
forming part of a set in a
second package may all have decorative/ornamental elements designed by a
second designer
and/or be labeled or branded with the second designer's name or brand. In
another example, one
or more outer covers forming part of a set in a first package may all have
decorative/ornamental
elements and/or a label and/or a brand associated with a first particular
"collection" or design
theme of a designer, while one or more outer covers forming part of a set in a
second package
may all have decorative/ornamental elements and/or a label and/or a brand
associated with a
second particular "collection" or design theme of the designer.
In any of the above examples, the outer cover(s) and associated insert(s) in
each
individual article of commerce will be sized to fit optimally with each other.
Thus, in a further
example, respective packages may be prepared and presented with sets of outer
cover(s) and
associated insert(s) distinguished by size. For example, a first package may
contain outer
cover(s) and associated insert(s) adapted for "size 1" children; a second
package may contain
outer cover(s) and associated insert(s) adapted for "size 2" children; and so
on.
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Edge Deflection Force Measurement Method
Edge Deflection Force is measured on a constant rate of extension tensile
tester with a
computer interface (a suitable instrument is the MTS QTest/1L using Testworks
4.0 software, as
available from MTS Systems Corp., Eden Prairie, MN) using a load cell for
which the forces
measured are within 10% to 90% of the limit of the cell. Referring to Fig. 6a,
the movable
(upper) pneumatic jaws 1001 are fitted with 1 inch x 1 inch diamond-faced
grips 1002.
The tensile tester is configured for a compression test. Program the tensile
tester to lower
the crosshead at a rate of 5.0 mm/min until a force of 0.01 N is detected.
Zero the time and
extension channels and begin data collection at an acquisition rate of 100 Hz.
Lower the
crosshead at a rate of 50 mm/min for 10 mm and then return the crosshead to
its original gage
length. From the force versus extension curve, program the software to report
the peak force
(N).
Referring to Figs. 6a and 6b, the lower fixture 1000 consists of a base 1005
base 90 mm
wide by 40 mm deep by 6 mm thick. The base 1005 is affixed to a suitable
mounting device that
includes lower mounting shaft 1006, adapted to connect to the stationary mount
of the tester.
Lower mounting shaft 1006 is threaded as shown and has a locking collar 1007.
When the lower
mounting shaft 1006 is connected to the stationary mount of the tester, the
locking collar 1007 is
turned against the stationary mount to immobilize the base 1005 relative the
stationary mount of
the tester, such that it will remain stationary with the stationary mount,
without any interplay
therebetween, during testing. Mounted on the base 1005 is a V notched block
1003 that is 30
mm wide by 30 mm deep by 30 mm in height which is made of a low friction
material such as
Teflon. Referring to the perspective Fig. 6b, the block 1003 is notched from
side to center with a
"V" at an angle 1004 of 10 degrees. As mounted on the base 1005, the block is
centered front to
back and offset a distance 1012 of 32.7 mm from the center axis of the
mounting shaft 1006, with
the line defined by the vertex of the "V" notch intersecting the center axis
of the mounting shaft
1006.
Obtain 10 samples from 10 inserts for testing as follows: Determine which of
front or
rear portions of the inserts are to be tested, and take all 10 samples from
such portions
accordingly. Lay the insert on a horizontal surface, outer/garment-facing
surface up. Referring
to Fig. 7: Visually identify the inside edge 1022 of the stiffened portion
1009 of the end (i.e., the
portion having end support stiffener 60 or 62). If visually identifying inside
edge 1022 is
difficult due to the particular construction of the insert, inside edge 1022
may be identified by
flattening the insert along the region including the subject end, to its full
longitudinal extent
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(stretching it out against any contraction caused by cuff elastics), laying
one hand over the insert
near the end to hold the insert in the stretched/flattened position, generally
in the location
indicated as 1020, and using the other hand to lift outer end edge 1021
vertically. The insert will
tend to fold first along inside edge 1022, since a natural "hinge" location
will exist at the juncture
between the stiffened portion and the adjacent unstiffened portion. Cut the
stiffened portion
1009 away from the insert, along edge 1022. Stiffened portion 1009 will now be
the sample to
be tested. Do not remove any components such as fastener components, grasp
structures, etc. If
outer edge 1021 is not inherently readily distinguishable from the cut edge by
a distinctive
feature such as a grasp structure 59, 61, mark outer end edge 1021 for later
identification.
All testing is performed in a conditioned room maintained at about 23 C 2 C
and about
50% 2% relative humidity. Precondition samples at about 23 C 2 C and about
50% 2%
relative humidity for 2 hours prior to testing.
Referring to Fig. 6a for directional and positional orientation, locate a
sample 1009 in the
grips 1002 with inside edge 1022 horizontal and oriented upward, and outer end
edge 1021
oriented downward, and in line with the bottom edges of the grips 1002.
Additionally, locate
sample 1009 in the grips 1002 such that distance 1010 is 30 mm, and distance
1011 is 10 mm.
Close the grips 1002 so that sample 1009 is gripped securely enough so as not
to allow it to slip
or rotate during testing, but not so tightly as to cause tearing of the sample
at the grips during
testing.
Zero the load cell and the crosshead position. Start the tensile tester's
program, and
record the data. Report the peak force (Edge Deflection Force) (N) to 0.001
N. For each
sample, perform the test on both the left and right sides (see Fig. 7), and
record the Edge
Deflection Force for both sides. Test 10 samples. Calculate the average Edge
Deflection Force
found of the 10 samples, both sides.
Bending Stiffness Measurement Method
Peak Bending Force and Bending Stiffness are measured using a constant rate of
extension tensile tester with computer interface (a suitable instrument is an
MTS Alliance under
TestWorks 4 software, as available from MTS Systems Corp., Eden Prairie,
Minnesota) fitted
with a 10 N load cell. A plunger blade 2100, shown in Fig. 9 (front view) and
Fig. 10 (side
view), is used for the upper movable test fixture. Base support platforms
2200, shown in Fig. 8,
are used as the lower stationary test fixture. All testing is performed in a
conditioned room
maintained at about 23 C 2 C and about 50% 2% relative humidity.
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Components of the plunger 2100 are made of a light weight material such as
aluminum to
maximize the available load cell capacity. The shaft 2101 is machined to fit
the tensile tester and
has a locking collar 2102 to stabilize the plunger and maintain alignment
orthogonal to base
support platforms 2204. The blade 2103, is 115 mm long 2108 by 65mm high 2107
by 3.25 mm
wide 2109, and has a material contact edge with a continuous radius of 1.625
mm. The bracket
2104 is fitted with set screws 2105 that are used to level the blade and a
main set screw 2106 to
firmly hold it in place after adjustment.
The bottom fixture 2200 is attached to the tensile tester with the shaft 2201
and locking
collar 2202. Two movable support platforms 2204 are mounted on a rail 2203.
Each test surface
2205 is 85 mm wide 2206 by 115 mm long (into plane of drawing) and made of
polished
stainless steel so as to have a minimal coefficient of friction. Each platform
has a digital position
monitor 2208 which reads the individual platform positions, and set screws
2207 to lock their
position after adjustment. The two platforms 2204 are square at the gap edge
and the plate edges
should be parallel front to back. The two platforms form a gap 2209 with an
adjustable gap
width 2210.
Accurately ( 0.02 mm) align the plunger blade 2103 so that it is orthogonal
to the top
surface of the support platforms 2204 and exhibits no skew relative to their
gap edges. Using the
position monitors 2208, accurately set the gap 2210 to 25.00 0.02 mm between
the two gap
edges of the support platforms 2204, with the plunger blade 2103 accurately (
0.02 mm)
centered in the gap. Program the tensile tester for a compression test. Set
the gauge length from
the bottom of the plunger blade 2103 to the top surface of the support
platform 2204 to 15 mm.
Set the crosshead to lower at 500 mm/min for a distance of 25 mm. Set the data
acquisition rate to 200 Hz.
Obtain 10 test samples 1009 as described in the description of the Edge
Deflection Force
Measurement Method, above. (Do not remove any components such as fastener
components,
grasp structures, etc.) Precondition samples at about 23 C 2 C and about 50%
2% relative
humidity for 2 hours prior to testing.
Examine the sample 1009 to be tested for any exposed adhesive and deactivate
any
exposed adhesive by applying baby powder to it as necessary. Place the sample
flat onto the
surface of the support platform 2204 over the gap 2209 with the wearer-facing
surface facing
upward. Center the sample 1009 across the gap, with edge 1022 perpendicular to
the gap. Zero
the load cell; start the tensile tester and the data acquisition.
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Program the software to calculate the maximum peak bending force (N) and
Stiffness (N/m) from the constructed force (N) verses extension (m) curve.
Stiffness is
calculated as the slope of the bending force/extension curve for the linear
region of the curve (see
Fig. 11), using a minimum line segment of at least 25% of the total peak
bending force to
calculate the slope.
Report Peak Bending Force to the nearest 0.1 N and the Bending Stiffness to
the Nearest
0.1 N/m, and record the results. Repeat the test and record the results for
all 10 samples.
Calculate the average Peak Bending Force and average Bending Stiffness.
A two-piece wearable absorbent article having some or all of the features
described
herein may provide advantages over both conventional wholly reusable cloth
diapers and
conventional wholly disposable diapers. The potential for use of semi-durable
materials, and
more so durable materials, to form an outer cover, provides for an outer cover
that may be used
more than once, and, depending upon the materials selected, used and laundered
many times. An
outer cover having some or all of the features described herein may eliminate
the necessity for a
disposable outer cover structure, thereby reducing the volume of soiled waste
the user must
dispose of, as compared with typical disposable diapers. Additionally, because
the possibility of
a reusable outer cover that bears most of the structural loading generally
imposed upon a
disposable diaper is presented, disposable absorbent portions may have more
simplified designs,
reducing manufacturing and material costs as compared with those of disposable
diapers. The
possibility for making a disposable absorbent insert of non-traditional
renewable materials (such
as paper) is presented. At the same time, a disposable absorbent insert and
outer cover having
some or all of the features described herein may in many circumstances prevent
most or all
soiling of the outer cover by the wearer's exudates, thereby mitigating
sanitation and odor
problems associated with handling and storage, reducing the frequency of
laundering necessary,
and reducing the need for laundering resources, efforts and/or expenses,
associated with
conventional cloth diapers. A disposable absorbent insert having some or all
of the features
described herein also may provide better absorbency and better isolation of
exudates from both
the wearer's skin, and the wearer's clothing and environment, than
conventional cloth diapers.
Use of durable materials for an outer cover also may provide other incidental
benefits, in
creating choices in use of materials for improved and/or more appealing
comfort, fit, designs,
colors, patterns, etc. as compared with disposable diapers. An outer cover
having features
described herein provides a wide variety of choices for making a wearable
absorbent article look
CA 02787261 2012-07-16
57
more attractive and/or more like an article of clothing or outerwear. In
addition to the foregoing
advantages, the use of an insert having an asymmetric structure together with
orientation indicia
allows for the design of an insert tailored to wearer anatomy and bodily
functions as they differ
front-to-rear, better performance, and increased economy in design,
construction and use of
materials, while enabling the user to ensure correct front-rear orientation of
the insert within the
outer cover. Other advantages are apparent from the description above.
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 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
modifications can be made without departing from the invention described
herein.
