U.S. patent application number 10/150360 was filed with the patent office on 2002-11-21 for prefastened disposable absorbent articles having a stretch panel.
Invention is credited to Angielski, Brian Walter, De Valk, June Marie, Elsberg, Laura Linda, Janssen, Tim Joseph, McNichols, Patrick Sean, Pozniak, Jennifer Elizabeth, Shafer, Bruce Reed, Stopher, James Bennington, Travis, Gary Lee.
Application Number | 20020173768 10/150360 |
Document ID | / |
Family ID | 23851954 |
Filed Date | 2002-11-21 |
United States Patent
Application |
20020173768 |
Kind Code |
A1 |
Elsberg, Laura Linda ; et
al. |
November 21, 2002 |
Prefastened disposable absorbent articles having a stretch
panel
Abstract
A prefastened, refastenable, disposable absorbent article
includes an absorbent chassis, at least one stretch panel, and a
pair a primary fasteners. The absorbent chassis defines a pair of
longitudinally opposed end edges and a pair of laterally opposed
side edges. The stretch panel is located in one of the waist
regions and defines a waist edge, a pair of laterally opposed
outboard edges which are located laterally beyond the side edges of
the absorbent chassis, and an inward edge which is located
longitudinally inward from the waist edge. The pair of primary
fasteners are located on the laterally opposed outboard edges of
the stretch panel and are releasably prefastened to an opposite
waist region of the absorbent chassis to releasably engage a front
waist region to a rear waist region to provide the prefastened
disposable absorbent article.
Inventors: |
Elsberg, Laura Linda;
(Woodstock, GA) ; Angielski, Brian Walter;
(Neenah, WI) ; De Valk, June Marie; (Appleton,
WI) ; Janssen, Tim Joseph; (Kaukauna, WI) ;
McNichols, Patrick Sean; (Hortonville, WI) ; Pozniak,
Jennifer Elizabeth; (Appleton, WI) ; Shafer, Bruce
Reed; (Green Bay, WI) ; Stopher, James
Bennington; (Neenah, WI) ; Travis, Gary Lee;
(Oshkosh, WI) |
Correspondence
Address: |
KIMBERLY-CLARK WORLDWIDE, INC.
401 NORTH LAKE STREET
NEENAH
WI
54956
|
Family ID: |
23851954 |
Appl. No.: |
10/150360 |
Filed: |
May 17, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10150360 |
May 17, 2002 |
|
|
|
09466490 |
Dec 17, 1999 |
|
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Current U.S.
Class: |
604/391 ;
604/387 |
Current CPC
Class: |
A61F 13/49012 20130101;
A61F 13/496 20130101; A61F 13/5655 20130101 |
Class at
Publication: |
604/391 ;
604/387 |
International
Class: |
A61F 013/15 |
Claims
We claim:
1. A prefastened disposable absorbent article comprising an
absorbent chassis which defines a front waist region, a rear waist
region, a crotch region which extends between and connects said
waist regions, a pair of longitudinally opposed end edges, and a
pair of laterally opposed side edges, said absorbent article
further comprising: a) at least one stretch panel which is located
in one of said waist regions of said absorbent chassis and which
defines a waist edge, a pair of laterally opposed outboard edges
which are located laterally beyond said side edges of said
absorbent chassis, and an inward edge which is located
longitudinally inward from said waist edge; and b) a pair of
primary fasteners which are located on said laterally opposed
outboard edges of said stretch panel and which are releasably
prefastened to an opposite waist region of said absorbent chassis
to releasably engage said front waist region to said rear waist
region to provide said prefastened disposable absorbent
article.
2. The prefastened absorbent article of claim 1 wherein said
absorbent article includes one of said stretch panels in each of
said waist regions of said absorbent chassis.
3. The prefastened absorbent article of claim 1 wherein said
stretch panel comprises a latent elastic material.
4. The prefastened absorbent article of claim 1 wherein said
stretch panel comprises at least one elastic member which is
applied to said stretch panel in a pretensioned configuration.
5. The prefastened absorbent article of claim 1 wherein said
stretch panel is designed to elongate in a lateral direction at
least about 30 percent to assist in positioning said prefastened
disposable absorbent article about a wearer's waist.
6. The prefastened absorbent article of claim 1 wherein said
stretch panel is designed to elongate in a lateral direction at
least about 50 percent to assist in positioning said prefastened
disposable absorbent article about a wearer's waist.
7. The prefastened absorbent article of claim 1 wherein said
primary fasteners are hook and loop type fasteners.
8. The prefastened absorbent article of claim 1 and further
comprising at least one attachment panel which is located on said
opposite waist region wherein said primary fasteners are releasably
engaged to said attachment panel.
9. The prefastened absorbent article of claim 1 wherein said inward
edge of said stretch panel is linear.
10. The prefastened absorbent article of claim 1 wherein said
inward edge of said stretch panel is curvilinear.
11. The prefastened absorbent article of claim 1 wherein said
absorbent chassis includes an outer cover which comprises a necked
nonwoven material.
12. The prefastened absorbent article of claim 1 wherein said
stretch panel is attached to a bodyfacing surface of said absorbent
article.
13. The prefastened absorbent article of claim 1 wherein said
absorbent chassis includes an outer cover and a bodyside liner and
wherein said stretch panel is incorporated between said outer cover
and said bodyside liner.
14. The prefastened absorbent article of claim 1 wherein said
stretch panel is attached to a garment facing surface of said
absorbent article.
15. The prefastened absorbent article of claim 1 wherein said
stretch panel is perforated along a pair of laterally directed
lines on at least one of two laterally opposed sides of said
stretch panel to provide at least one secondary fastener tab, said
secondary fastener tab being configured to releasably engage said
opposite waist region to further conform said waist regions to a
wearer's body after said prefastened disposable absorbent article
is pulled on over a wearer's hips.
16. The prefastened absorbent article of claim 15 wherein said
secondary fastener tab defines a length in a lateral direction
which is at least about 5 percent of a total lateral width of said
stretch panel.
17. The prefastened absorbent article of claim 15 wherein both said
primary fasteners and said at least one secondary fastener tab are
hook and loop type fasteners.
18. The prefastened absorbent article of claim 1 wherein said
inward edge of said stretch panel is substantially fully attached
to said absorbent chassis.
19. The prefastened absorbent article of claim 1 wherein said
stretch panel is located in said rear waist region of said
absorbent chassis, and wherein said primary fasteners are
configured to releasably engage said front waist region of said
absorbent chassis.
20. A prefastened disposable absorbent article comprising an
absorbent chassis which defines a front waist region, a rear waist
region, a crotch region which extends between and connects said
waist regions, a pair of longitudinally opposed end edges, and a
pair of laterally opposed side edges, said absorbent article
further comprising: a) at least one stretch panel which is located
in one of said waist regions of said absorbent chassis and which
defines a waist edge, a pair of laterally opposed outboard edges
which are located laterally beyond said side edges of said
absorbent chassis, and an inward edge which is located
longitudinally inward from said waist edge; b) a pair of primary
fasteners which are located on said laterally opposed outboard
edges of said stretch panel and which are releasably prefastened to
an opposite waist region of said absorbent chassis to releasably
engage said front waist region to said rear waist region to provide
said prefastened disposable absorbent article; and c) a pair of
passive side bonds which are located laterally inward of said
primary fasteners on said one waist region and which releasably
connect an overlapped portion of said one waist region to said
opposite waist region to assist in maintaining said prefastened
absorbent article in a prefastened condition.
21. The prefastened absorbent article of claim 20 wherein said
passive side bonds releasably connect said overlapped portion of
said one waist region to said side edges in said opposite waist
region to assist in maintaining said prefastened absorbent article
in said prefastened condition.
22. The prefastened absorbent article of claim 20 wherein said
passive side bonds are located on said one waist region laterally
inward from said primary fasteners a distance of at least about 1.0
centimeter.
23. The prefastened absorbent article of claim 20 wherein said
overlapped portion of said one waist region defines an overlap
distance of at least about 2.0 centimeters.
24. The prefastened absorbent article of claim 20 wherein said
passive side bonds include at least one point bond.
25. The prefastened absorbent article of claim 24 wherein said
point bond is an ultrasonic point bond.
26. The prefastened absorbent article of claim 20 wherein said
passive side bonds define a peel strength of no more than about
1500 grams.
27. The prefastened absorbent article of claim 20 wherein said
passive side bonds connect a body facing surface of said absorbent
article in said one waist region to a garment facing surface of
said absorbent article in said opposite waist region.
28. The prefastened absorbent article of claim 20 wherein said
passive side bonds connect a body facing surface of said absorbent
article in said one waist region to a body facing surface of said
absorbent article in said opposite waist region.
29. The prefastened absorbent article of claim 20 wherein said
stretch panel comprises a latent elastic material.
30. The prefastened absorbent article of claim 20 wherein said
stretch panel is designed to elongate in a lateral direction at
least about 30 percent to assist in positioning said prefastened
disposable absorbent article about a wearer's waist.
31. The prefastened absorbent article of claim 20 wherein said
stretch panel is designed to elongate in a lateral direction at
least about 50 percent to assist in positioning said prefastened
disposable absorbent article about a wearer's waist.
32. The prefastened absorbent article of claim 20 wherein said
primary fasteners are hook and loop type fasteners.
33. The prefastened absorbent article of claim 20 wherein said
stretch panel is attached to a body facing surface of said
absorbent article.
34. The prefastened absorbent article of claim 20 wherein said
absorbent chassis includes an outer cover and a bodyside liner and
wherein said stretch panel is incorporated between said outer cover
and said bodyside liner.
35. The prefastened absorbent article of claim 20 wherein said
stretch panel is attached to a garment facing surface of said
absorbent article.
36. The prefastened absorbent article of claim 20 wherein said
stretch panel is perforated along a pair of laterally directed
lines on at least one of two laterally opposed sides of said
stretch panel to provide at least one secondary fastener tab, said
secondary fastener tab being configured to releasably engage said
opposite waist region to further conform said waist region to a
wearer's body after said prefastened disposable absorbent article
is pulled on over a wearer's hips.
37. The prefastened absorbent article of claim 36 wherein said at
least one secondary fasteners tab defines a length in a lateral
direction which is at least about 10 percent of a total lateral
width of said stretch panel.
38. The prefastened absorbent article of claim 36 wherein both said
primary fasteners and said at least one secondary fastener tab are
hook and loop type fasteners.
39. The prefastened absorbent article of claim 20 wherein said
inward edge of said stretch panel is substantially fully attached
to said absorbent chassis.
40. A prefastened disposable absorbent article comprising an
absorbent chassis which defines a front waist region, a rear waist
region, a crotch region which extends between and connects said
waist regions, a pair of longitudinally opposed end edges, and a
pair of laterally opposed side edges, and at least one stretch
panel which defines a waist edge which is superposed adjacent said
end edge of said absorbent chassis in one of said waist regions, a
pair of laterally opposed outboard edges which are located
laterally beyond said side edges of said absorbent chassis, and an
inward edge which is located longitudinally inward from said waist
edge, said stretch panel comprising a) a center bridge panel; b) a
pair of laterally opposed side panels which are connected to
opposed lateral edges of said bridge panel and which extend
laterally beyond said side edges of said absorbent chassis; c) a
pair of primary fasteners which are located on said laterally
opposed outboard edges of said stretch panel and which are
releasably prefastened to an opposite waist region of said
absorbent chassis to releasably engage said front waist region to
said rear waist region to provide said prefastened disposable
absorbent article; and d) a pair of passive side bonds which are
located laterally inward of said primary fasteners on said one
waist region and which releasably connect an overlapped portion of
said one waist region to said opposite waist region to assist in
maintaining said prefastened absorbent article in a prefastened
condition.
41. The prefastened absorbent article of claim 40 wherein said side
panels of said stretch panel are substantially non-elastomeric.
42. The prefastened absorbent article of claim 40 wherein said
bridge panel defines a bridge panel width in a lateral direction
which is at least about 10 percent of a width of said absorbent
chassis.
43. The prefastened absorbent article of claim 41 wherein said
bridge panel defines a bridge panel width in a lateral direction
which is about equal to a width of said absorbent chassis, such
that said bridge panel provides stretch in said one waist region
and said side panels remain substantially non-elastomeric beyond
said laterally opposed side edges of said absorbent chassis.
44. The prefastened absorbent article of claim 43 wherein said
bridge panel is designed to elongate in a lateral direction at
least about 30 percent to assist in positioning said prefastened
disposable absorbent article about a wearer's waist.
45. The prefastened absorbent article of claim 40 wherein said
primary fasteners are hook and loop type fasteners.
46. The prefastened absorbent article of claim 40 wherein said
stretch panel is attached to a body facing surface of said
absorbent article.
47. The prefastened absorbent article of claim 40 wherein said
absorbent chassis includes an outer cover and a bodyside liner and
wherein said stretch panel is incorporated between said outer cover
and said bodyside liner.
48. The prefastened absorbent article of claim 40 wherein said
stretch panel is attached to a garment facing surface of said
absorbent article.
49. The prefastened absorbent article of claim 40 wherein said
stretch panel is perforated along a pair of laterally directed
lines on at least one of two laterally opposed sides of said
stretch panel to provide at least one secondary fastener tab, said
secondary fastener tab being configured to releasably engage said
opposite waist region to further conform said waist regions to a
wearer's body after said prefastened disposable absorbent article
is pulled on over a wearer's hips.
50. The prefastened absorbent article of claim 49 wherein said at
least one secondary fastener tab defines a length in a lateral
direction which is at least about 10 percent of a total lateral
width of said stretch panel.
51. The prefastened absorbent article of claim 49 wherein both said
primary fasteners and said at least one secondary fastener tab are
hook and loop type fasteners.
52. The prefastened absorbent article of claim 40 wherein said
inward edge of said stretch panel is substantially fully attached
to said absorbent chassis.
53. A package of prefastened disposable absorbent articles
comprising a container and a plurality of said prefastened
disposable absorbent articles, each of which comprise an absorbent
chassis which defines a front waist region, a rear waist region, a
crotch region which extends between and connects said waist
regions, a pair of longitudinally opposed end edges, and a pair of
laterally opposed side edges, each of said absorbent articles
further comprising: a) at least one stretch panel which is located
on one of said waist regions of said absorbent chassis and which
defines a waist edge, a pair of laterally opposed outboard edges
which are located laterally beyond said side edges of said
absorbent chassis, and an inward edge which is located
longitudinally inward from said waist edge; and b) a pair of
primary fasteners which are located on said laterally opposed
outboard edges of said stretch panel and which are releasably
prefastened to an opposite waist region of said absorbent chassis
to releasably engage said front waist region to said rear waist
region to provide said prefastened disposable absorbent
article.
54. The package of prefastened absorbent articles of claim 53
wherein said absorbent articles further comprise a pair of passive
side bonds which are located inward of said primary fasteners on
said one waist region and which releasably connect an overlapped
portion of said one waist region to said opposite waist region to
assist in maintaining said prefastened absorbent article in a
prefastened condition.
55. The package of prefastened absorbent articles of claim 53
wherein said stretch panel of said absorbent articles comprises: a)
a center bridge panel; and b) a pair of laterally opposed side
panels which are connected to opposed lateral edges of said bridge
panel and which extend laterally beyond said side edges of said
absorbent chassis.
56. The package of refastened absorbent articles of claim 53
wherein said stretch panel of said absorbent articles is perforated
along a pair of laterally directed lines on at least one of two
laterally opposed sides of said stretch panel to provide at least
one secondary fastener tab, said secondary fastener tab being
configured to releasably engage said opposite waist region to
further conform said waist regions to a wearer's body after said
prefastened disposable absorbent article is pulled on over a
wearer's hips.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to disposable absorbent
articles which are adapted to contain body exudates. More
particularly, the present invention relates to prefastened
absorbent articles having stretch panels for improved fit and
performance.
BACKGROUND OF THE INVENTION
[0002] It is desired that absorbent articles such as diapers,
training pants or incontinence garments provide a close,
comfortable fit about the wearer and contain body exudates.
Moreover, it is desirable that such absorbent articles, after being
soiled, can be removed from the wearer in a convenient and clean
manner without undesirably soiling the caregiver or surrounding
area such as the clothes of the wearer. In certain circumstances,
it is also desirable that such absorbent articles are capable of
being pulled up or down over the hips of the wearer to allow the
wearer or caregiver to easily pull the article on and easily remove
the article if it has not been soiled. For example, such absorbent
articles can assist in the toilet training of children.
[0003] Conventional diapers have typically included a front waist
portion and a rear waist portion, which are releasably connected
about the hips of the wearer during use by conventional fasteners
such as adhesive tape fasteners or hook and loop type fasteners.
For example, the conventional fasteners have typically included a
pair of fasteners, such as adhesive tape tabs, located on the
outermost corners of the diaper in the rear waist region of the
diaper and a complimentary fastener, such as a taping panel,
located on the outer surface of the outer cover of the diaper in
the front waist portion of the diaper. In such a configuration, the
diaper has been positioned between the legs of the wearer while the
wearer is lying down and the adhesive tape tabs have been
releasably attached to the taping panel to secure the rear waist
portion to the front waist portion of the diaper to secure the
diaper about the waist of the wearer. Such conventional diapers are
easy to fasten about and remove from the wearer after use without
undesirably soiling the caregiver. However, such conventional
diapers are not provided in a pant-like, prefastened configuration
and, thus, are not configured to be pulled up or down over the hips
of the wearer when the fasteners are attached. Conventional diapers
have also typically included elasticized waistbands to help reduce
the leakage of body exudates. Some conventional diapers have also
included elasticized containment or barrier flaps at the leg or
waist regions of the diaper to further reduce leaks. Further, the
fastening systems of some conventional diapers have also been
elasticized.
[0004] Several attempts have been made to provide absorbent
articles which effectively contain body exudates, are capable of
being pulled up or down over the hips of the wearer, and provide
ease of cleaning and removal after being soiled. For example, some
conventional absorbent articles, such as conventional training
pants, have included integral side panels which connect the front
waist portion to the rear waist portion of the absorbent article.
The side panels have been made stretchable such that the waist
opening of the absorbent article can expand to allow the absorbent
article to be pulled up or down over the hips of the wearer if
desired. Such side panels have also been designed such that they
may be torn to remove the training pant from the wearer after it
has been soiled.
[0005] However, many of such attempts have not been completely
satisfactory. For example, absorbent articles such as training
pants have not always been able to achieve a close conforming fit
to the wearer while still being able to expand enough to be pulled
up and down over the hips of the wearer. Often such training pants
fit the waist of the wearer loosely which can undesirably result in
leaks. As a result, many of such articles have not contained bodily
exudates as effectively as conventional diaper-type articles which
can be adjusted to achieve a more conforming fit to the wearer.
Moreover, the inspection and removal of soiled absorbent articles
which have integral side panels, such as conventional training
pants, have not always been completely satisfactory. For example,
the side panels have been difficult to tear when attempting to
remove the article from the waist of the wearer instead of pulling
the article down over the hips of the wearer.
[0006] Further, diapers having elasticized waistbands or flaps at
their waist regions and elasticized fastening systems have not been
completely satisfactory. For example, such waistbands have
generally been narrow and consequently have not always provided a
reliable sealing surface with the wearer's body, resulting in
leakage. Moreover, although the elasticized fastening systems used
on conventional diapers have improved the fit of the diaper about
the wearer, such systems have typically not been tied in or
connected to the elasticized waistbands and flaps. Thus, the forces
exerted on the fastening system have not been efficiently
transferred and distributed laterally across the waist region of
the diaper along a wide band. As a result, the fit and containment
of conventional absorbent articles have not been completely
satisfactory.
[0007] Accordingly, despite the attempts to develop improved
absorbent articles, there remains a need for absorbent articles
which can provide the benefits of both conventional training pants
and conventional diapers. That is, there remains a need for
absorbent articles which conform to the wearer to effectively
contain bodily exudates, which are capable of being pulled up and
down over the hips and buttocks of the wearer without opening,
which are readily secured about and removed from the wearer in a
convenient and clean manner, and which allow easy inspection by the
care giver to assist in determining whether the article is soiled.
Moreover, there remains a need for improved fit and containment at
the waist regions of absorbent articles.
SUMMARY OF THE INVENTION
[0008] In response to the difficulties and problems discussed
above, new prefastened, refastenable, disposable absorbent articles
which have a stretch panel have been invented.
[0009] In one aspect, the present invention concerns a prefastened,
refastenable, disposable absorbent article which comprises an
absorbent chassis which defines a front waist region, a rear waist
region, a crotch region which extends between and connects the
waist regions, a pair of longitudinally opposed end edges, and a
pair of laterally opposed side edges. The absorbent article also
includes at least one stretch panel which is located in one of the
waist regions and which defines a waist edge, a pair of laterally
opposed outboard edges which are located laterally beyond both of
the side edges of the absorbent chassis, and an inward edge which
is located longitudinally inward from the end edge of the absorbent
chassis. The absorbent article further includes a pair of primary
fasteners which are located on the laterally opposed outboard edges
of the stretch panel and which are releasably prefastened to the
opposite waist region of the absorbent chassis to releasably engage
the front waist region to the rear waist region to provide the
prefastened disposable absorbent article.
[0010] In a particular aspect, the prefastened absorbent article
may further include at least one secondary fastener tab created by
a pair of laterally directed perforations on at least one of two
laterally opposed sides of the stretch panel. The prefastened
absorbent article may further include a pair of passive side bonds
which are located inward of the primary fasteners and which
releasably connect an overlapped portion of the waist regions to
assist in maintaining the prefastened absorbent article in a
prefastened condition.
[0011] In another particular aspect, the stretch panel may comprise
a center bridge panel, and a pair of laterally opposed side panels
which are connected to opposed lateral edges of the bridge panel
and which extend laterally beyond the side edges of the absorbent
chassis. In a particular embodiment, the bridge panel is
elastomeric, and the side panels are non-elastomeric.
[0012] In still another aspect, the present invention concerns a
package of prefastened disposable absorbent articles comprising a
container and a plurality of the prefastened absorbent articles.
Each prefastened, refastenable, disposable absorbent article
comprises an absorbent chassis which defines a front waist region,
a rear waist region, a crotch region which extends between and
connects the waist regions, a pair of longitudinally opposed end
edges, and a pair of laterally opposed side edges. Each absorbent
article also includes at least one stretch panel which is located
in one of the waist regions and which defines a waist edge, a pair
of laterally opposed outboard edges which are located laterally
beyond both of the side edges of the absorbent chassis, and an
inward edge which is located longitudinally inward from the end
edge of the absorbent chassis. Each absorbent article further
includes a pair of primary fasteners which are located on the
laterally opposed outboard edges of the stretch panel and which are
releasably prefastened to the opposite waist region of the
absorbent chassis to releasably engage the front waist region to
the rear waist region to provide the prefastened disposable
absorbent article.
[0013] The present invention advantageously provides prefastened,
refastenable, disposable absorbent articles which include a stretch
panel. In particular, the present invention provides prefastened
disposable absorbent articles which are capable of being reliably
pulled up or down over the hips of the wearer to assist in the
toilet training of the wearer similar to conventional training
pants. Moreover, similar to conventional diapers, the prefastened
disposable absorbent articles of the present invention can
advantageously be applied to and removed from the wearer similar to
conventional diapers after they have been soiled with relative ease
and cleanliness. Further, the prefastened disposable absorbent
articles of the present invention allow easy inspection by the
caregiver to assist in determining whether the article is soiled
similar to conventional diapers.
[0014] Finally, the various aspects of the present invention can
advantageously provide an absorbent article having a more
contouring fit and improved gasketing about the waist of the
wearer, resulting in increased comfort, reduced leakage, and
enhanced aesthetics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will be more fully understood and
further advantages will become apparent when reference is made to
the following detailed description of the invention and the
accompanying drawings wherein like numerals represent like
elements. The drawings are merely representative and are not
intended to limit the scope of the appended claims.
[0016] FIG. 1 representatively shows a perspective view of an
example of a prefastened disposable absorbent article of the
present invention;
[0017] FIG. 2 representatively shows a front plan view of the
prefastened disposable absorbent article of FIG. 1;
[0018] FIG. 3 representatively shows a side view of the prefastened
disposable absorbent article of FIG. 1;
[0019] FIG. 4 representatively shows a plan view of the prefastened
disposable absorbent article of FIG. 1 in an unfastened, stretched,
laid-flat condition with the surface of the article which contacts
the wearer facing the viewer and with portions of the article cut
away to show the underlying features;
[0020] FIG. 5 representatively shows a plan view of the prefastened
disposable absorbent article of FIG. 1 in an unfastened, stretched,
laid-flat condition with the surface of the article which contacts
the wearer's clothing facing the viewer;
[0021] FIG. 6 representatively shows a perspective view of another
example of a prefastened disposable absorbent article of the
present invention;
[0022] FIG. 7 representatively shows a front plan view of the
prefastened disposable absorbent article of FIG. 6;
[0023] FIG. 8 representatively shows a side view of the prefastened
disposable absorbent article of FIG. 6;
[0024] FIG. 9 representatively shows a top plan view of a portion
of the prefastened disposable absorbent article of FIG. 6 in an
unfastened, stretched, laid-flat condition with the surface of the
article which contacts the wearer facing the viewer;
[0025] FIG. 10 representatively shows a top plan view of a portion
of the prefastened disposable absorbent article of FIG. 6 in an
unfastened, stretched, laid-flat condition with the surface of the
article which contacts the clothing of the wearer facing the
viewer;
[0026] FIG. 11 representatively shows a perspective view of another
example of a prefastened disposable absorbent article of the
present invention;
[0027] FIG. 12 representatively shows a top plan view of a portion
of the prefastened disposable absorbent article of FIG. 11 in an
unfastened, stretched, laid-flat condition with the surface of the
article which contacts the wearer facing the viewer;
[0028] FIG. 13 representatively shows a side view of another
example of a prefastened disposable absorbent article of the
present invention;
[0029] FIG. 14 representatively shows a plan view of the
prefastened disposable absorbent article of FIG. 13 in an
unfastened, stretched, laid-flat condition with the surface of the
article which contacts the wearer facing the viewer and with
portions of the absorbent article cut away to show the underlying
features; and
[0030] FIG. 15 representatively shows plan view of the prefastened
disposable absorbent article of FIG. 13 in an unfastened,
stretched, laid-flat condition with the surface of the article
which contacts the wearer's clothing facing the viewer.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention concerns prefastened, refastenable,
disposable absorbent articles which are adapted to be worn adjacent
to the body of a wearer to absorb and contain various exudates
discharged from the body. The prefastened absorbent articles are
configured to closely conform to the body of the wearer to
effectively contain body exudates while being capable of being
pulled up or down over the hips and buttocks of the wearer. The
absorbent articles are also refastenable such that they can be
secured to and removed directly from the waist of the wearer and
easily inspected to determine if they have been soiled during use.
As such, the prefastened, refastenable, disposable absorbent
articles of the present invention can function in a similar manner
to conventional training pants when left in the prefastened
configuration or they can be unfastened prior to or during use to
function in a refastenable manner similar to conventional diapers.
As used herein, the term "disposable" refers to articles which are
intended to be discarded after a limited use and which are not
intended to be laundered or otherwise restored for reuse.
[0032] The prefastened disposable absorbent articles of the present
invention will be described in terms of a disposable, prefastened
diaper article which is adapted to be worn by infants about the
lower torso. In particular, the prefastened disposable absorbent
articles will be described in terms of a prefastened, refastenable,
disposable diaper having a stretch panel. It is understood that the
articles and methods of the present invention are equally adaptable
for other types of absorbent articles such as adult incontinent
products, training pants, feminine hygiene products, other personal
care or health care garments, and the like.
[0033] FIGS. 1-5 representatively show various views of one example
of a prefastened, refastenable disposable diaper, as generally
indicated at 20, of the present invention. FIGS. 6-10
representatively show various views of another example of a
prefastened disposable diaper of the present invention. FIGS. 11-12
representatively show two views of yet another example of a
prefastened disposable diaper of the present invention. FIGS. 13-15
representatively show various views of still another example of a
prefastened disposable diaper of the present invention.
[0034] The illustrated diapers 20 include an absorbent chassis 28
which generally defines a front waist region 22, a rear waist
region 24, and a crotch region 26 which extends between and
connects the front and rear waist regions 22 and 24. The absorbent
chassis 28 further defines a pair of laterally opposed side edges
30, a pair of longitudinally opposed waist edges 32, an interior
bodyfacing surface 34 which is configured to contact the wearer, an
outer garment facing surface 36 (FIG. 5) opposite the interior
surface 34 which is configured to contact the wearer's clothing in
use, a longitudinal direction 38, and a lateral direction 40. As
representatively illustrated in FIG. 4, the absorbent chassis 28
may include an outer cover 42, a bodyside liner 44 which is
connected to the outer cover 42 in a superposed relation, and an
absorbent core 46 which is located between the outer cover 42 and
the bodyside liner 44.
[0035] The front waist region 22 comprises the portion of the
diaper 20 which, when worn, is positioned on the front of the
wearer while the rear waist region 24 comprises the portion of the
diaper 20 which, when worn, is positioned on the back of the
wearer. The crotch region 26 comprises the portion of the diaper 20
which, when worn, is positioned between the legs of the wearer and
covers the lower torso of the wearer. The laterally opposed side
edges 30 of the absorbent chassis 28 of the diaper 20 generally
define leg openings which may be curvilinear. The waist edges 32 of
the absorbent chassis 28 of the diaper 20 are configured to
encircle the waist of the wearer when worn and provide a waist
opening when fastened that defines a waist perimeter dimension.
[0036] The diaper 20 of the different aspects of the present
invention also includes at least one stretch panel 70. For example,
as representatively illustrated in FIGS. 1-5, the diaper 20 may
include a stretch panel located on the bodyfacing surface 34 of the
absorbent chassis 28 in the rear waist region 24 of the diaper 20.
As illustrated in FIG. 4, the stretch panel 70 may generally define
a waist edge 72, a pair of laterally opposed outboard edges 74
which are located laterally beyond the side edges 30 of the
absorbent chassis 28, and an inward edge 76 which is located
longitudinally inward from the waist edge 72.
[0037] The diaper 20 of the present invention further includes a
prefastened, refastenable fastening system 60. The fastening system
60 includes a pair of primary fasteners 62, attached to the
laterally opposed outboard edges 74 of the stretch panel 70. As
representatively illustrated in FIGS. 1-3, the primary fasteners 62
are releasably engaged with the garment facing surface 36 of the
absorbent chassis 28 to provide the prefastened diaper 20. The
fastening system 60 may further include an attachment panel 66
located on the outer surface of the absorbent chassis 28 to which
the primary fasteners 62 are releasably engaged.
[0038] The absorbent chassis 28 is configured to contain and/or
absorb any body exudates discharged from the wearer. Whereas, the
stretch panel 70 and the prefastened, refastenable fastening system
60 are configured to maintain the diaper 20 about the waist of the
wearer and provide a garment-like appearance. The diaper 20 may
further include leg elastics 54, containment flaps 56, and waist
elastics 58 as are known to those skilled in the art. It should be
recognized that individual components of the diaper 20 may be
optional depending upon the intended use of the diaper 20.
[0039] The diaper 20 may be of various suitable shapes. For
example, in the unfastened configuration, the diaper may have an
overall rectangular shape, T-shape or an approximately hourglass
shape. In the illustrated embodiments, the diaper 20 has a
generally hourglass shape in an unfastened configuration. Examples
of diaper configurations suitable for use in connection with the
instant application and other diaper components suitable for use on
diapers are described in U.S. Pat. No. 4,798,603 issued Jan. 17,
1989, to Meyer et al.; U.S. Pat. No. 5,176,668 issued Jan. 5, 1993,
to Bernardin; U.S. Pat. No. 5,176,672 issued Jan. 5, 1993, to
Bruemmer et al.; U.S. Pat. No. 5,192,606 issued Mar. 9, 1993, to
Proxmire et al., and U.S. Pat. No. 5,509,915 issued Apr. 23, 1996,
to Hanson et al., the disclosures of which are herein incorporated
by reference. The various aspects and configurations of the
invention can provide distinctive combinations of softness, body
conformity, reduced red-marking of the wearer's skin, reduced skin
hydration, improved containment of body exudates and improved
aesthetics.
[0040] The various components of the diaper 20 are integrally
assembled together employing various types of suitable attachment
means, such as adhesive, sonic and thermal bonds or combinations
thereof. In the shown embodiments, for example, the outer cover 42
and bodyside liner 44 are assembled to each other and to the
absorbent core 46 with adhesive, such as a hot melt,
pressure-sensitive adhesive. The adhesive may be applied as a
uniform continuous layer of adhesive, a patterned layer of
adhesive, a sprayed pattern of adhesive, or an array of separate
lines, swirls or dots of adhesive. Similarly, other diaper
components, such as the leg elastic 54 and the primary fasteners
62, may be assembled into the diaper 20 article by employing the
above-identified attachment mechanisms. Desirably, the majority of
the diaper components are assembled together using ultrasonic
bonding techniques for reduced manufacturing cost and improved
performance.
[0041] The outer cover 42 of the absorbent chassis 28 of the diaper
20, as representatively illustrated in FIGS. 4 and 5, may suitably
be composed of a material which is either liquid permeable or
liquid impermeable. It is generally preferred that the outer cover
42 be formed from a material that is substantially impermeable to
liquids. A typical outer cover can be manufactured from a thin
plastic film or other flexible liquid-impermeable material. For
example, the outer cover 42 may be formed from a polyethylene film
having a thickness of from about 0.013 millimeter (0.5 mil) to
about 0.051 millimeter (2.0 mils). If it is desired to present the
outer cover 42 with a more clothlike feeling, the outer cover 42
may comprise a polyolefin film having a nonwoven web laminated to
the outer surface thereof, such as a spunbond web of polyolefin
fibers. For example, a stretch-thinned polypropylene film having a
thickness of about 0.015 millimeter (0.6 mil) may have thermally
laminated thereto a spunbond web of polypropylene fibers, which
fibers have a thickness of about 1.5 to 2.5 denier per filament,
which nonwoven web has a basis weight of about 17 grams per square
meter (0.5 ounce per square yard). Methods of forming such
clothlike outer covers are known to those skilled in the art.
[0042] Further, the outer cover 42 may be formed of a woven or
nonwoven fibrous web layer which has been totally or partially
constructed or treated to impart a desired level of liquid
impermeability to selected regions that are adjacent or proximate
the absorbent core 46. Still further, the outer cover 42 may
optionally be composed of a micro-porous "breathable" material
which permits vapors to escape from the absorbent core 46 while
still preventing liquid exudates from passing through the outer
cover 42. For example, the outer cover 42 may comprise a stretched
microporous polyolefin film having a nonwoven web laminated to the
outer surface thereof, such as a spunbond web of polyolefin
fibers.
[0043] The outer cover 42 can also be embossed or otherwise
provided with a matte finish to provide a more aesthetically
pleasing appearance. Additionally, the outer cover 42 may be
comprised of a necked materials such as a necked spunbond web of
polyolefin fibers or elasticized nonwoven materials to allow the
outer cover 42 to stretch more freely in conjunction with the
stretch panel 70. Examples of suitable elasticized materials are
stretch-thermal laminate (STL), neck-bonded laminate (NBL), and
stretch-bonded laminate (SBL). Methods of making such materials are
well known to those skilled in the art and described in U.S. Pat.
No. 4,663,220 issued May 5, 1987 to Wisneski et al., U.S. Pat. No.
5,226,992 issued Jul. 13, 1993 to Mormon, and European Patent
Application No. EP 0 217 032 published on Apr. 8, 1987 in the names
of Taylor et al., the disclosures of which are hereby incorporated
as references.
[0044] The bodyside liner 44, as representatively illustrated in
FIG. 4, suitably presents a bodyfacing surface which is compliant,
soft feeling, and nonirritating to the wearer's skin. Further, the
bodyside liner 44 may be less hydrophilic than the absorbent core
46, to present a relatively dry surface to the wearer, and may be
sufficiently porous to be liquid permeable, permitting liquid to
readily penetrate through its thickness. A suitable bodyside liner
44 may be manufactured from a wide selection of web materials, such
as porous foams, reticulated foams, apertured plastic films,
natural fibers (for example, wood or cotton fibers), synthetic
fibers (for example, polyester or polypropylene fibers), or a
combination of natural and synthetic fibers. The bodyside liner 44
is suitably employed to help isolate the wearer's skin from liquids
held in the absorbent core 46.
[0045] Various woven and nonwoven fabrics can be used for the
bodyside liner 44. For example, the bodyside liner may be composed
of a meltblown or spunbonded web of polyolefin fibers. The bodyside
liner may also be a bonded-carded web composed of natural and/or
synthetic fibers. The bodyside liner may be composed of a
substantially hydrophobic material, and the hydrophobic material
may, optionally, be treated with a surfactant or otherwise
processed to impart a desired level of wettability and
hydrophilicity. In a particular embodiment of the present
invention, the bodyside liner 44 comprises a nonwoven, spunbond,
polypropylene fabric composed of about 2.8-3.2 denier fibers formed
into a web having a basis weight of about 20 grams per square meter
and a density of about 0.13 gram per cubic centimeter. The fabric
may be surface treated with about 0.3 weight percent of a
surfactant commercially available from Hodgson Textile Chemicals,
Inc. under the trade designation AHCOVEL Base N-62. The surfactant
may be applied by any conventional means, such as spraying,
printing, brush coating or the like. The surfactant may be applied
to the entire bodyside liner 44 or may be selectively applied to
particular sections of the bodyside liner 44, such as the medial
section along the longitudinal centerline of the diaper, to provide
greater wettability of such sections. The bodyside liner 44 may
further include a lotion or treatment applied thereto to which is
configured to treat or be transferred to the wearer's skin.
[0046] The absorbent core 46 of the diaper 20, as representatively
illustrated in FIG. 4, may suitably comprise a matrix of
hydrophilic fibers, such as a web of cellulosic fluff, mixed with
particles of a high-absorbency material commonly known as
superabsorbent material. In a particular embodiment, the absorbent
core 46 comprises a matrix of cellulosic fluff, such as wood pulp
fluff, and superabsorbent hydrogel-forming particles. The wood pulp
fluff may be exchanged with synthetic, polymeric, meltblown fibers
or with a combination of meltblown fibers and natural fibers. The
superabsorbent particles may be substantially homogeneously mixed
with the hydrophilic fibers or may be nonuniformly mixed. The fluff
and superabsorbent particles may also be selectively placed into
desired zones of the absorbent core 46 to better contain and absorb
body exudates. The concentration of the superabsorbent particles
may also vary through the thickness of the absorbent core 46.
Alternatively, the absorbent core 46 may comprise a laminate of
fibrous webs and superabsorbent material or other suitable means of
maintaining a superabsorbent material in a localized area.
[0047] The absorbent core 46 may have any of a number of shapes.
For example, the absorbent core may be rectangular, I-shaped, or
T-shaped. It is generally preferred that the absorbent core 46 be
narrow in the crotch area of the diaper 20. It has been found that
the absorbent chassis 28 of the present invention is particularly
useful when the width dimension in the crotch region 26 is from
about 2.5 to about 12.7 centimeters (1.0 to about 5.0 inches) and
desirably no more than about 7.6 centimeters (3.0 inches). The
narrow crotch width dimension of the absorbent chassis 28 allows
the absorbent chassis 28 to better fit between the legs of the
wearer. The size and the absorbent capacity of the absorbent core
46 should be compatible with the size of the intended wearer and
the liquid loading imparted by the intended use of the absorbent
article.
[0048] The high-absorbency material can be selected from natural,
synthetic, and modified natural polymers and materials. The
high-absorbency materials can be inorganic materials, such as
silica gels, or organic compounds, such as crosslinked polymers.
The term "crosslinked" refers to any means for effectively
rendering normally water-soluble materials substantially water
insoluble but swellable. Such means can include, for example,
physical entanglement, crystalline domains, covalent bonds, ionic
complexes and associations, hydrophilic associations such as
hydrogen bonding, and hydrophobic associations or Van der Waals
forces.
[0049] Examples of synthetic, polymeric, high-absorbency materials
include the alkali metal and ammonium salts of poly(acrylic acid)
and poly(methacrylic acid), poly(acrylamides), poly(vinyl ethers),
maleic anhydride copolymers with vinyl ethers and alpha-olefins,
poly(vinyl pyrolidone), poly(vinyl morpholinone), poly(vinyl
alcohol), and mixtures and copolymers thereof. Further polymers
suitable for use in the absorbent core include natural and modified
natural polymers, such as hydrolyzed acrylonitrile-grafted starch,
acrylic acid grafted starch, methyl cellulose, carboxymethyl
cellulose, hydroxypropyl cellulose, and the natural gums, such as
alginates, xanthum gum, locust bean gum, and the like. Mixtures of
natural and wholly or partially synthetic absorbent polymers can
also be useful in the present invention. Such high-absorbency
materials are well known to those skilled in the art and are widely
commercially available. Examples of superabsorbent polymers
suitable for use in the present invention are SANWET IM 3900
polymer available from Hoechst Celanese located in Portsmouth, Va.
and DOW DRYTECH 2035LD polymer available from Dow Chemical Co.
located in Midland, Mich.
[0050] The high absorbency material may be in any of a wide variety
of geometric forms. As a general rule, it is preferred that the
high absorbency material be in the form of discrete particles.
However, the high absorbency material may also be in the form of
fibers, flakes, rods, spheres, needles, or the like. As a general
rule, the high absorbency material is present in the absorbent body
in an amount of from about 5 to about 90 weight percent based on
total weight of the absorbent core 46.
[0051] Optionally, a substantially hydrophilic tissue wrapsheet
(not illustrated) may be employed to help maintain the integrity of
the airlaid fibrous structure of the absorbent core 46. The tissue
wrapsheet is typically placed about the absorbent body over at
least the two major facing surfaces thereof and composed of an
absorbent cellulosic material, such as creped wadding or a high
wet-strength tissue. In one aspect of the invention, the tissue
wrapsheet can be configured to provide a wicking layer which helps
to rapidly distribute liquid over the mass of absorbent fibers
comprising the absorbent body. The wrapsheet material on one side
of the absorbent fibrous mass may be bonded to the wrapsheet
located on the opposite side of the fibrous mass to effectively
entrap the absorbent core 46.
[0052] As representatively illustrated in FIGS. 1 and 4, the
absorbent chassis 28 of the disposable diaper 20 may include a pair
of containment flaps 56 which are configured to provide a barrier
to the lateral flow of body exudates. The containment flaps 56 may
be located along the laterally opposed side edges 30 of the
absorbent chassis 28. Each containment flap 56 typically defines an
unattached edge which is configured to maintain an upright,
perpendicular configuration in at least the crotch region 26 of the
diaper 20 to form a seal against the wearer's body. The containment
flaps 56 may extend longitudinally along the entire length of the
absorbent chassis 28 or may only extend partially along the length
of the absorbent chassis 28. When the containment flaps 56 are
shorter in length than the absorbent chassis 28, the containment
flaps 56 can be selectively positioned anywhere along the side
edges 30 of the absorbent chassis 28. In a particular aspect of the
invention, the containment flaps 56 extend along the entire length
of the absorbent chassis 28 to better contain the body exudates.
Such containment flaps 56 are generally well known to those skilled
in the art. For example, suitable constructions and arrangements
for containment flaps 56 are described in U.S. Pat. No. 4,704,116
issued Nov. 3, 1987, to K. Enloe the disclosure of which is hereby
incorporated by reference.
[0053] The disposable diaper 20 of the different aspects of the
present invention may further include elastics at the waist edge 32
and side edges 30 of the absorbent chassis 28 of the diaper 20 to
further prevent leakage of body exudates and support the absorbent
chassis 28. For example, as representatively illustrated in FIGS.
1, 2 and 4, the diaper 20 of the present invention may include a
pair of leg elastic members 54 which are connected to the laterally
opposed side edges 30 of the absorbent chassis 28 in the crotch
region 26 of the diaper 20 and a waist elastic member 58 which is
connected to the waist edge 32 of the absorbent chassis 28 of the
diaper 20. The leg elastics 54 and waist elastic 58 are generally
adapted to fit about the legs and waist of a wearer in use to
maintain a positive, contacting relationship with the wearer to
effectively reduce or eliminate the leakage of body exudates from
the diaper 20.
[0054] Materials suitable for use as the leg elastics 54 and waist
elastic 58 are well known to those skilled in the art. Exemplary of
such materials are sheets or strands or ribbons of a polymeric,
elastomeric material which are adhered to the outer cover 42 in a
stretched position, or which are attached to the outer cover 42
while the outer cover is pleated, such that elastic constrictive
forces are imparted to the outer cover 42. The leg elastics may
also include such materials as polyurethane, synthetic and natural
rubber.
[0055] The prefastened, refastenable, disposable diaper 20 of the
different embodiments of the present invention further includes at
least one stretch panel 70 located in at least one of the waist
regions 22 and 24 to provide a more comfortable, contouring fit
about the wearer. The diaper 20 may include a stretch panel 70
disposed in both waist regions 22 and 24 and, desirably, the diaper
includes a stretch panel 70 in at least the rear waist region 24.
For example, as representatively illustrated in FIGS. 1-5, the
diaper 20 includes a stretch panel 70 located on the bodyfacing
surface 34 in the rear waist region 24 of the absorbent chassis 28.
The illustrated stretch panel 70 generally defines a waist edge 72,
a pair of laterally opposed outboard edges 74 which are located
laterally beyond the side edges 30 of the absorbent chassis 28, and
an inward edge 76 which is located longitudinally inward from the
waist edge 72. As illustrated in FIG. 5, the stretch panel further
defines a width 71 in the lateral direction 40 and a length 73 in
the longitudinal direction 38.
[0056] The stretch panel 70 is configured to elongate in the
lateral direction 40 at least about 30 percent and desirably at
least about 50 percent to provide an improved fit and appearance of
the diaper about the wearer by initially providing a conforming fit
about the wearer and maintaining such fit throughout the use of
such diaper. The stretch panel 70 is also configured such that the
absorbent chassis 28 has the ability to expand, contract, and
receive body exudates without adversely affecting the positioning
of the stretch panel and the diaper about the waist of the wearer.
Thus, with such a stretch panel 70, movements of the wearer may
move the absorbent chassis 28 but do not adversely affect the
overall positioning of the diaper on the wearer. Such improved fit
results in reduced leakage from the waist and leg regions of the
diaper and a more aesthetically pleasing appearance.
[0057] In a particular embodiment, the stretch panel 70 may be
secured to the absorbent chassis 28 of the diaper 20 such that in
an unstrained configuration the stretch panel 70 effectively
contracts the waist region of the absorbent chassis 28 in the
lateral direction 40. Desirably, the stretch panel 70 may be
secured to the absorbent chassis 28 such that the width of the
stretch panel 70 in the lateral direction 40 between the points at
which it is attached to the absorbent chassis 28 is less than a
fully extended width of the absorbent chassis 28. For example, the
stretch panel 70 may be elongated and attached to the absorbent
chassis 28 of the diaper 20 in an elastically contractible
condition while the chassis of the diaper is in an uncontracted
condition. Alternatively, the stretch panel 70 may be secured to
the absorbent chassis 28 of the diaper when the absorbent chassis
is in a tucked or pleated condition. The stretch panel 70 may
otherwise include a latent elastic material along at least a
portion of its width such that, after activation, the latent
elastic material effectively contracts the waist region of the
absorbent chassis 28.
[0058] In such a configuration, the stretch panel 70 is desirably
secured to the absorbent chassis 28 of the diaper 20 such that, in
an unstrained configuration, the absorbent chassis 28 of the diaper
is gathered from about 3 to about 50 percent, more desirably from
about 5 to about 30 percent, and most desirably from about 7 to
about 20 percent. As a result, the portion of the stretch panel 70
between the side edges 30 of the absorbent chassis 28 may be
capable of elongating in the lateral direction from a relaxed
condition until the absorbent chassis is extended to its full width
to provide the improved fit and containment. To provide even
further extension, the absorbent chassis 28 may include materials
which are capable of extension such as necked or elastic materials.
As a result of it's elastic properties, the stretch panel 70 is
able to snugly fit the wearer's body independent of the absorbent
chassis 28 and any forces exerted on the chassis due to movements
of the wearer and loading for improved performance.
[0059] As illustrated in the various embodiments of the present
invention, the laterally outboard edges 74 of the stretch panel 70
extend beyond the side edges 30 of the absorbent chassis 28 of the
diaper 20. The waist edge 72 of the stretch panel 70 is also
generally coterminous with the end edge 32 of the chassis 28 of the
diaper 20 in the respective waist region 22 or 24 in the
illustrated embodiments. Alternatively, the waist edge 72 of the
stretch panel 70 may extend longitudinally beyond the end edge 32
of the chassis 28 of the diaper 20, or the end edge 32 of the
chassis 28 of the diaper 20 may extend longitudinally beyond the
waist edge 72 of the stretch panel 70. In a particular embodiment,
the waist edge 72 of the stretch panel 70 extends longitudinally
beyond the end edge 32 of the absorbent chassis 28 to provide
improved seals against the body of the wearer.
[0060] The stretch panel 70 also defines an inward edge 76 which
extends longitudinally inward towards the crotch region 26 of the
diaper 20. The inward edge 76 of the stretch panel 70 may be
configured to remain at least partially unattached to the bodyside
liner 44 or absorbent chassis 28 of the diaper 20 when in use to
allow the absorbent chassis 28 to move and expand to receive and
contain body exudates. Alternatively, in a particular embodiment,
the inward edge 76 of the stretch panel 70 remains substantially
fully attached to the absorbent chassis 28 to allow the absorbent
chassis 28 to provide a close fit to the wearer's body for improved
performance. The inward edge 76 of the stretch panel 70 may be
linear. Alternatively, the inward edge 76 of the stretch panel 70
may be curvilinear, such as concave, to better fit the wearer.
Desirably, if the inward edge 76 is curvilinear, the waist edge 72
may also be curvilinear such that consecutive stretch panels 70 for
multiple articles nest within each other and can be provided from a
continuous sheet of material. In such a configuration, the inward
edge 76 of the first stretch panel corresponds to the waist edge 72
of the next stretch panel to improve manufacturing and reduce
waste.
[0061] The longitudinal length 73 of the stretch panel 70 is
generally sufficient to effectively distribute the fastening forces
across a wide cross sectional area to provide improved fit without
excessive irritation of the skin of the wearer. Desirably, the
stretch panel 70 defines a longitudinal length 73 which is at least
about 5 percent and more desirably from about 10 to about 30
percent of the longitudinal length 52 of the diaper 20. Lengths
less than the above-specified ranges do not provide the improved
fit and appearance of the article on the wearer and may result in
excessive red marking. Whereas, lengths greater than the above
specified ranges may extend too far into the crotch region 26 of
the article such that the stretch panel 70 may interfere with the
deposition of body exudates into the diaper article.
[0062] The stretch panel 70 extends laterally across the diaper 20
extending beyond the side edges 30 of the absorbent chassis 28. In
particular, the stretch panel 70 defines a lateral width 71 that is
greater than the width 50 of the absorbent chassis at the
respective waist region to which the stretch panel 70 is attached
to provide the improved fit and performance. As used herein, the
width 50 of the absorbent chassis 28 refers to the distance between
the outermost portions of the backsheet and/or topsheet layer in
the lateral direction 40 at the desired lengthwise location along
the diaper 20. In a particular embodiment, the stretch panel 70
defines a width 71 which is at least about 105 percent, desirably
at least about 115 percent, and more desirably at least about 125
percent of the width 50 of the chassis of the diaper 20 at the
respective waist region. For example, the stretch panel 70 may
define a lateral width 71 of from about 105 to about 150 percent of
the width 50 of the absorbent chassis 28 of the diaper 20 at the
respective waist region. Widths less than the above-specified
ranges do not provide the improved fit and appearance of the diaper
20 on the wearer.
[0063] The stretch panel 70 of the different embodiments of the
present invention may be provided in a variety of ways. For
example, the stretch panel 70 may be a single piece of material or
a combination of individual pieces or panels of material attached
to the diaper using conventional attachment means such as those
described above. Desirably, the stretch panel 70 or at the least
individual pieces or panels of the stretch panel 70 comprise
elastic composite materials or non-stretchable materials which have
been rendered elastically contractible by means known to those
skilled in the art. It is also generally desirable that the stretch
panel 70 be formed from materials which are substantially
impermeable to liquids and which provide a more clothlike feeling.
Such materials are capable of maintaining a close conforming fit
while not irritating the skin of the wearer. Suitable elastomeric
materials include SBL materials, NBL materials, elastomeric films,
elastomeric foams, latent elastic materials and the like and
combinations thereof.
[0064] In the embodiment illustrated in FIGS. 1-5, 6-10 and 13-15,
the stretch panel 70 includes a single piece of elastomeric
material. Such a single piece of material may be modified in any
area or areas to provide the desired elastic properties. For
example, in a particular embodiment, the elastic properties of
portions of the stretch panel 70 may be modified by bonding the
material at specific locations or zones to render such bonded areas
less elastic than the unbonded areas. The effect the bonding has on
the elastic properties of the material can depend upon several
factors, including the area of the bonding or the bond point
density.
[0065] In a particular embodiment wherein the stretch panel 70
includes an elastomeric material, it is desirable that the stretch
panel 70 be capable of providing an elongation in the lateral
direction 40 of at least about 5 percent, more desirably at least
about 15 percent, and even more desirably at least about 30 percent
when subjected to a tensile force load of about 80 grams in the
lateral direction 40 per lineal centimeter of the sample measured
in the longitudinal direction 38. Moreover, it is also desirable
that the stretch panel 70 be capable of providing a tension range
of from about 20 to about 400 grams, more desirably from about 40
to about 275 grams, and even more desirably from about 60 to about
200 grams per lineal centimeter of the sample measured in the
longitudinal direction 38 when subjected to an elongation of 30
percent in the lateral direction 40.
[0066] In another alternative configuration, the stretch panel 70
may be provided by a substantially non-elastomeric material, such
as polymer films, woven fabrics, non-woven fabrics, or the like
such as described above as being suitable for the outer cover 42 or
bodyside liner 44. Such a stretch panel could be modified to render
portions elastically contractible to provide the desired elastic
properties to the stretch panel 70. For example, the stretch panel
70 may be made elastic or stretchable by means well known to those
skilled in the art. For example, different portions of the stretch
panel 70 may include a plurality of elastic strands which are
elongated and adhesively attached in the lateral direction 40 to
the respective portions of the stretch panel 70. Suitable elastic
strands are known to those skilled in the art. For example, a
suitable elastic strand may be composed of a 470 decitex LYCRA
elastomer or a 620 decitex LYCRA elastomer commercially available
from E. I. DuPont de Nemours Co., a business having offices located
in Wilmington, Del., or other elastomers with suitable
characteristics.
[0067] Alternatively, a piece of elastic material may be adhesively
attached to the respective portions of the stretch panel 70 in an
elongated condition to provide the desired stretchability. The
piece of elastic material may include a SBL material, a NBL
material, an elastomeric film, an elastomeric foam material, or the
like as described above. In one embodiment, the piece of elastic
material may be applied to the stretch panel in a pretensioned
configuration. In another example, the elastic material may be
latent, in which case the elastic material would initially have
non-elastomeric properties, but would later be activated to impart
elastomeric properties to the stretch panel by any of various means
known to those skilled in the art. Suitable latent elastic
materials are well known to those skilled in the art.
[0068] Alternatively, the stretch panel 70 may include two or more
pieces or panels of material connected together, For example, as
representatively illustrated in FIGS. 11-12, the stretch panel 70
may generally define a center bridge panel 100 which is flanked by
and connected to a pair of laterally opposed side panels 102 along
attachment zones 106. The side panels 102 are connected to and
extend outward in a lateral direction 40 from the bridge panel 100
beyond the side edges 30 of the absorbent chassis 28 of the diaper
20. In use, the bridge panel 100 is generally configured to be
located on the front or back abdominal regions of the wearer, while
the side panels 102 are generally configured to be located on the
side hips region of the wearer. In such a configuration, the
particular location, size, and elastic nature of each panel of the
stretch panel 70 is important to the performance of the stretch
panel 70 in use.
[0069] On the majority of typical wearers of such absorbent
articles and, in particular, on infants, the small or central
portion of the wearer's back is generally concave (bowed inwards)
or flat in shape and the front abdominal region of the wearer is
generally convex or curved outwards. As a result, it has been
difficult to maintain a tight seal between the absorbent article
and the wearer in these areas. Depending upon whether the stretch
panel 70 of the present invention is located in the front or the
rear waist regions 22 and 24 of the diaper 20, the bridge panel 100
of the stretch panel 70 corresponds to the area of the stretch
panel 70 which is intended to be in contact with either the small
of the wearer's back or the outwardly curved front abdominal region
when in use. The bridge panel 100 is configured to provide a
conforming fit of the stretch panel 70 to these locations on the
wearer.
[0070] As representatively illustrated in FIG. 12, the bridge panel
100 of the stretch panel 70 is typically centered about the
longitudinal centerline of the diaper 20 and defines a width 101
which generally corresponds to the width of the small of the
wearer's back or front abdominal region. For example, the width 101
of the bridge panel 100 of the stretch panel 70 may be from about
10 to about 100 percent and desirably from about 30 to about 70
percent of the width 50 of the absorbent chassis 28 of the article
at the respective waist region. In a particular embodiment, the
width 101 of the bridge panel 70 is at least about 10 percent,
desirably at least about 25 percent, and more desirably at least
about 40 percent of the width 50 of the absorbent chassis 28 of the
article at the respective waist region. For example, the width 101
of the bridge panel 100 on a diaper article which is intended to be
worn by a medium-sized infant weighing from about 16 to about 28
pounds may be from about 10 to about 15 centimeters. Width
dimensions less than the above-specified ranges are not sufficient
to extend along the entire width of the small of the wearer's back
or the wearer's front abdominal region.
[0071] The side panels 102 of the stretch panel 70 are generally
the areas of the stretch panel 70 which are intended to be in
contact with the convex surface of the outer hip regions of the
wearer when in use. As representatively illustrated in FIG. 12, the
side panels 102 of the stretch panel 70 are attached to and
laterally flank the bridge panel 100 of the stretch panel 70. The
illustrated side panels 102 are also attached to and extend
laterally beyond the side edges 30 of the absorbent chassis 28 of
the article. Each of the side panels 102 defines a width 103 which
generally corresponds to the width of the portions of the diaper
article which are intended to be positioned on the hip regions of
the wearer in use. For example, the width 103 of each side panel
102 may be from about 10 to about 70 percent and desirably from
about 35 to about 50 percent of the width 50 of the absorbent
chassis 28 of the article at the respective waist region to which
the stretch panel 70 is attached.
[0072] In the embodiments illustrated in FIGS. 11 and 12, the side
panels 102 of the stretch panel 70 also extend laterally inward
from the side edges 30 of the absorbent chassis 28 to the bridge
panel 100. The distance the side panels 102 extend inwardly will
vary depending upon the desired width 101 of the bridge panel 100.
In a particular embodiment wherein the diaper includes a pair of
longitudinally extending containment flaps located between the side
edges of the article, it is further desired that the side panels
102 of the stretch panel 70 extend laterally inwardly from the side
edges 30 at least to the nearest containment flap for improved
performance.
[0073] In such a configuration, the elastic nature or properties of
each panel are designed such that the stretch panel 70 is capable
of expanding and contracting with the movements of the wearer to
enhance the fit of the article on the wearer. For example, the side
panels 102 of the stretch panel 70 may be configured to be less
elastic or stretchable than the bridge panel 100. Alternatively,
the bridge panel 100 of the stretch panel 70 may be less
stretchable than the side panels 102. Such arrangements will depend
upon several factors including the general size and shape of the
intended wearer, the intended loading of the article on the wearer,
and the size, shape, and dimensions of the different panel sections
of the fit panel.
[0074] In a preferred embodiment, the bridge panel 100 of the
stretch panel 70 is elastomeric, and the side panels 102 of the
stretch panel 70 are substantially non-elastomeric, such that the
bridge panel 100 can stretch about the waist of the wearer to
provide an optimum fit and seal, and such that the side panels do
not stretch and thus do not interfere with the fit and gasketing
properties of the leg elastics 54. For example, the bridge panel
100 and the side panels 102 may be configured such that, when
lateral force is exerted on the stretch panel 70, the bridge panel
elongates in the lateral direction, while the side panels do not
elongate in the lateral direction. In such a configuration, the
bridge panel 100 is configured to elongate in the lateral direction
40, and the side panels 102 are configured not to elongate in the
lateral direction 40, when the diaper article is fit about the
waist and hips of the wearer and fastened thereto. Specifically,
the bridge panel 100 is configured to exert a force about the waist
region of the wearer to provide a close-to-the-body fit and
reliably maintain the diaper about the waist of the wearer. The
elastic properties of the bridge panel 100 of the stretch panel 70
are also configured to distribute most of the forces exerted by the
fasteners and any movements of the wearer such that such forces do
not adversely affect the positioning and movement of the absorbent
chassis 28 of the diaper 20. Further, the non-elastomeric
properties of the side panels 102 are configured so as not to
interfere with the fit and gasketing properties of the nearby leg
elastics 54. To provide such properties in the stretch panel 70,
the bridge panel is generally capable of being elongated in the
lateral direction 40 from about 5 percent to about 200 percent,
desirably from about 15 percent to about 150 percent, and more
desirably from about 30 percent to about 90 percent from a relaxed
condition.
[0075] The stretch panel 70 as representatively illustrated in
FIGS. 11 and 12 can be provided in any suitable manner which
provides the desired fit properties and performance. For example,
the bridge panel 100 and side panels 102 may be provided by three
individual pieces of material, some or all of which may be
elastomeric, which are joined together along their side edges to
provide the stretch panel 70. Suitable elastomeric materials
include those described above as being suitable for a single piece
stretch panel 70.
[0076] The stretch panel 70 of the different embodiments of the
present invention may be attached to the absorbent chassis 28 of
the diaper 20 in any suitable manner which provides the desired
properties. For example, the stretch panel 70 may be attached to
the absorbent chassis using adhesive, ultrasonic, thermal bonding
techniques and the like or combinations thereof. As
representatively illustrated in FIG. 4, the stretch panel 70 may be
attached to the absorbent chassis of the diaper 20 along a lateral
attachment zone 78 and a pair of opposed longitudinal attachment
zones 79. In the illustrated embodiment, the lateral attachment
zone 78 is generally located along or near the end edge 32 of the
absorbent chassis 28 of the diaper 20 while the longitudinal
attachment zones 79 are located along the side edges 30 of the
absorbent chassis 28 in the respective waist region of the diaper
20. The lateral and longitudinal attachment zones 78 and 79,
respectively, generally extend in the lateral and longitudinal
directions 40 and 38, respectively, but may otherwise extend at
angles from the lateral and longitudinal directions depending upon
the configuration of the stretch panel 70 and the desired
distribution of forces across the stretch panel. Such angled
attachment zones can result in improved fit. As illustrated, the
stretch panel 70 need not be attached to the absorbent chassis 28
of the diaper 20 along its entire width or length to allow
additional freedom of movement for the absorbent chassis 28
relative to the stretch panel 70 for improved performance.
[0077] Further, the stretch panel 70 of the present invention may
be attached to the absorbent chassis 28 of the diaper 20 in any
location which provides the desired properties. For example, as
representatively illustrated in FIGS. 1-12, the stretch panel 70
may be attached to the bodyfacing surface 34 of the bodyside liner
44 of the absorbent chassis 28 such that the stretch panel 70
contacts the wearer's skin. In such a configuration, as
representatively illustrated in FIG. 4, the inward edge 76 of the
stretch panel 70 may be unattached to the absorbent chassis 28 such
that a pocket exists to contain body exudates. The illustrated
pocket is defined by the inward edge 76, the lateral attachment
zone 78 and the longitudinal attachment zones 79. Alternatively,
the inward edge 76 of the stretch panel 70 may be substantially
fully attached to the absorbent chassis 28.
[0078] As representatively illustrated in FIGS. 13-15, the stretch
panel 70 may otherwise be attached to the garment facing surface 36
of the outer cover 42 of the absorbent chassis 28 such that the
stretch panel 70 gives a more trim appearance to the diaper 20
during wear. In yet another embodiment, the stretch panel 70 may be
sandwiched between the inner surfaces of both the bodyside liner 44
and the outer cover 42, both of which face the absorbent core
46.
[0079] The prefastened disposable diaper of the different aspects
of the present invention further includes a prefastened,
refastenable fastening system 60 for securing the diaper about the
waist of the wearer. The fastening system 60 includes fasteners
located on one of the waist regions 22 and 24 of the diaper 20
which are configured to releasably engage the opposite waist region
of the diaper 20 to maintain the diaper about the waist of the
wearer. The use of fasteners which are refastenable or releasably
engageable allows for ease of securing and removing the diaper 20
from the waist of the wearer without undesirably soiling the
wearer. The use of refastenable fasteners further readily allows
for the inspection of the inside of the diaper 20 to determine if
it has been soiled with the ability to refasten if it is not
soiled.
[0080] The illustrated prefastened, refastenable fastening system
60 includes a pair of primary fasteners 62, one located on each
laterally opposed side 74 of the stretch panel 70 in the rear waist
region 24 of the diaper 20. In such a configuration, the primary
fasteners 62 are refastenably engaged with the garment facing
surface 36 of the absorbent chassis 28 in the front waist region 22
to provide the prefastened diaper 20. Alternatively, the primary
fasteners 62 may be located on the front waist region 22 and may be
configured to releasably engage the garment facing surface 36 in
the rear waist region 24 of the absorbent chassis 28 to provide the
prefastened diaper 20.
[0081] Desirably, the primary fasteners 62 are refastenably engaged
directly with the garment facing surface 36 of the outer cover 42
of the absorbent chassis 28 of the diaper 20 to provide improved
fit and ease of fastening. Alternatively, as representatively
illustrated in FIGS. 1-3, the disposable diaper of the present
invention may further include an attachment panel 66 located on the
outer cover 42 in one of the waist regions 22 and 24 of the diaper
20. In such a configuration, the primary fasteners 62 are
refastenably engaged with the attachment panel 66 to provide the
prefastened diaper 20 and maintain the diaper 20 about the waist of
the wearer. When the primary fasteners 62 are releasably engaged,
the side edges 30 of the absorbent chassis 28 define leg openings
which are configured to encircle the legs of the wearer and the
waist regions 22 and 24 of the absorbent chassis 28 define a waist
opening which is configured to encircle the waist of the wearer. In
the illustrated embodiments, the attachment panel 66 is a single
piece of material which extends substantially across the respective
waist region of the diaper 20. Alternatively, the attachment panel
66 may include two separate panels located along the opposed side
edges of the absorbent chassis 28 in one of the waist regions 22
and 24 of the diaper 20.
[0082] In the different aspects of the present invention, the
primary fasteners 62 are refastenably engaged with the outer
garment facing surface of the opposite waist region 22 and 24 of
the diaper 20 before the diaper 20 is placed on the wearer to
provide a prefastened, refastenable disposable diaper. In such a
configuration, the prefastened diaper 20 can be pulled on or off
over the legs and hips of the wearer. If the prefastened diaper 20
becomes soiled during use, the primary fasteners 62 can be
disengaged to easily remove the diaper 20 from the waist of the
wearer with reduced risk of undesirably soiling the clothes or legs
of the wearer. The primary fasteners 62 can also be easily
disengaged to inspect the diaper 20 for possible soiling or to
first apply the product to the wearer if desired. Thus, the diaper
20 is configured to be pulled on or off over the hips of the wearer
such as conventional training pants and can be readily applied or
removed by disengaging the fasteners similar to conventional diaper
articles. Moreover, the primary fasteners 62 can be repositioned if
necessary after the prefastened diaper 20 has been pulled on over
the legs and hips of the wearer to adjust the fit of the diaper to
the wearer.
[0083] Suitable fasteners are well known to those skilled in the
art and can include adhesive tape tab fasteners, hook and loop
fasteners, mushroom fasteners, snaps, pins, belts and the like, and
combinations thereof. For example, as representatively illustrated
in FIGS. 1-3, the primary fasteners 62 may be hook type fasteners
and the outer cover 42 or attachment panel 66 may be configured to
function as a complimentary loop type fastener. Desirably, the
primary fasteners 62 are hook type fasteners which are refastenably
engageable directly with the outer cover 42. Such an arrangement
provides the ability to vary the size of the waist opening in very
small increments over a wide range to fit the waist of the
wearer.
[0084] The fastening system 60 on the prefastened disposable diaper
20 of the present invention may also include at least one secondary
fastener tab to provide improved securement of the diaper 20 about
the waist of the wearer after the primary fasteners 62 have been
releasably engaged. In particular, the secondary fastener is
configured to further conform the waist regions 22 and 24 of the
diaper 20 to the waist of the wearer. For example, as
representatively illustrated in FIGS. 6-10, the diaper 20 of the
present invention may include a pair of secondary fasteners 84 and
86. Alternatively, the diaper 20 may include a single secondary
fastener.
[0085] In the illustrated embodiments, the secondary fasteners 84
and 86 are located within the laterally opposed sides 82 of the
stretch panel 70 of the diaper 20. In use, the secondary fastener
tabs 84 and 86 are configured to encircle the hips of the wearer
and engage the garment facing surface 36 of the absorbent chassis
28 of the diaper 20. In the illustrated embodiments, the stretch
panel 70 is located in the rear waist region 24 of the absorbent
chassis 28. In such a configuration, the secondary fastener tabs 84
and 86 are configured to encircle the hips of the wearer and engage
the garment facing surface 36 in the front waist region 22 to
further conform the waist regions to the wearer. Alternatively, if
the stretch panel 70 is located in the front waist region 22, the
secondary fasteners 84 and 86 may be configured to releasably
engage the garment facing surface 36 in the rear waist region 24 of
the absorbent chassis 28 to further conform the waist regions to
the wearer. The secondary fastener of the diaper 20 may also be
provided in other alternative configurations known to those skilled
in the art.
[0086] Desirably, the secondary fastener is releasably engageable
directly with the garment-facing surface 36 of the outer cover 42
of the absorbent chassis 28 to provide improved ease of fastening.
Alternatively, as described above and representatively illustrated
in FIGS. 6-8, the diaper 20 of the present invention may further
include an attachment panel 66 located on the outer cover 42 in one
of the waist regions 22 and 24 of the diaper 20. In such a
configuration, the secondary fastener may also be releasably
engageable with the attachment panel 60 to further conform the
diaper 20 to the waist of the wearer.
[0087] The use of at least one secondary fastener has been found to
be particularly desirable when the primary fasteners 62 are
releasably engaged with the respective waist region of the diaper
20 to provide a prefastened diaper which can be pulled on over the
legs and hips of the wearer. In such a configuration, the waist
opening of the diaper 20 when the primary fasteners 62 are engaged
must be sufficient to allow the prefastened diaper to be pulled
over the hips of the wearer. However, the circumference of the
waist of the wearer is typically less than the circumference around
the hips of the wearer. Thus, the waist opening of the prefastened
diaper may not conform to the waist of the wearer which may
undesirably result in leaks. In such a configuration, the secondary
fastener of the diaper 20 of the present invention is configured to
conform the waist regions of the diaper 20 to the wearer after the
prefastened diaper is pulled on the wearer. Thus, the caregiver is
not required to reposition the primary fasteners 62 to conform the
waist regions 22 and 24 to the waist of the wearer. As a result,
when the diaper 20 is to be removed from the wearer, the care giver
may simply disengage the secondary fastener if necessary and pull
the prefastened diaper down over the hips and legs of the wearer
without having to reposition the primary fasteners 62.
[0088] In such configurations, the secondary fastener is intended
to maintain the diaper 20 in a close conforming fit about the waist
of the wearer to reduce the leakage of body exudates when in use.
The primary fasteners 62 are intended to maintain the front and
rear waist regions 22 and 24 connected in such a manner that the
diaper 20 can be pulled on or off over the hips of the wearer after
the secondary fastener or fasteners have been disengaged. The
secondary fastener may also be selectively disengaged to facilitate
inspection of the diaper 20 to determine if it has been soiled. The
primary fasteners 62 can also provide a "childproofing function" by
maintaining the diaper 20 at least partially secured about the
waist of the wearer if the wearer disengages the secondary
fastener.
[0089] The secondary fastener may be provided in a variety of ways.
For example, as representatively illustrated in FIGS. 6-10, the
stretch panel may include a pair of laterally directed perforations
80 on at least one laterally opposed side 82 of the stretch panel
70 provide at least one secondary fastener tab 84. The illustrated
stretch panel 70 includes such perforations on both sides of the
stretch panel 70 thereby providing a pair of secondary fastener
tabs 84 and 86. The laterally directed perforations 80 may be
either parallel or non-parallel. Further, the perforations 80 may
by either straight or curvilinear. In a preferred embodiment, as
representatively illustrated in FIGS. 6-10, the secondary fastener
tab is provided by a pair of laterally directed, straight, parallel
perforations 80 on at least one laterally opposed side 82 of the
stretch panel 70.
[0090] The perforations 80 are configured such that, in use, the
caregiver would tear the stretch panel 70 along the laterally
directed perforations 80 to create at least one secondary fastener
tab 84. The secondary fastener tab 84 defines both an outwardly
directed, unattached, free end, and an inwardly directed end which
remains attached to the stretch panel 70. In such a configuration,
after the perforations 80 are tom, the free end of the secondary
fastener tab may be elongated in the lateral direction 40 as
representatively illustrated in FIGS. 6, 7 and 10.
[0091] The secondary fastener tab, by virtue of being created out
of the stretch panel 70, may comprise the same fastener type as the
primary fasteners 62 already located on the edges 74 of the stretch
panel 70. For example, as illustrated, the perforations 80 may
extend into the primary fasteners 62 such that, when torn, the
secondary fastener tab includes a portion of the primary fastener
62. Alternatively, the stretch panel 70 may include at least one
separate secondary fastener attached thereto.
[0092] Suitable fasteners for the secondary fastener are described
above as being suitable for the primary fastener. For example, as
representatively illustrated in FIGS. 6-7, the primary fasteners 62
and secondary fasteners 84 and 86 may be hook-type fasteners and
the outer cover 42 or attachment panel 66 may be configured to
function as a complimentary loop-type fastener. Desirably, the
fasteners 62, 84, and 86 are hook-type fasteners which are
releasably engageable directly with the outer cover 42. Such an
arrangement provides the ability to vary the size of the waist
opening in very small increments over a wide range to fit the waist
of the wearer. The fasteners may have any shape and size which
provides the desired fastening of the diaper 20 about the waist of
the wearer.
[0093] The secondary fastener tab may define any length and width
which provides the desired improved fastening and fit about the
wearer. For example, the secondary fasteners tabs 84 and 86 in the
illustrated embodiment, may each define a length 87 in the lateral
direction 40 as illustrated in FIG. 9, which is at least about 5
percent, desirably at least about 20 percent, and more desirably at
least about 35 percent of the lateral width 71 of the stretch panel
70. Further, the secondary fasteners 84 and 86 may each define a
width 88 in the longitudinal direction 38 which is at least about
10 percent, desirably at least about 30 percent, and more desirably
at least about 50 percent of the longitudinal length 73 of the
stretch panel 70.
[0094] The prefastened diaper of the different aspects of the
present invention may further include a pair of passive side bonds
for improved reliability of maintaining the diaper 20 in the
prefastened condition, particularly when it is being pulled on or
off over the hips of the wearer. For example, as representatively
illustrated in FIG. 13-15, the diaper 20 may include a pair of
passive side bonds 90 which releasably connect an overlapped
portion 92 of the rear waist region 24 and stretch panel 70 to the
front waist region 22. In such a configuration, the passive side
bonds 90 assist the fastening system 60 in maintaining the diaper
20 in a prefastened condition as the diaper 20 is pulled up or down
over the hips of the wearer. Moreover, the passive side bonds 90
prevent movement and shifting of the waist regions 22 and 24 and
stretch panel 70 relative to each other for improved fit and
performance. The passive side bonds 90 also provide improved hip
coverage and prevent rollover or folding of the side edges 30 and
waist edges 32 of the absorbent chassis 28 of the prefastened
diaper 20 as it is pulled over the wearer's hips. Such prevention
of rollovers and foldovers can reduce the level of contact between
the fasteners and the skin of the wearer which can desirably result
in reduced skin irritation and redness.
[0095] As shown in the illustrated embodiments, the passive side
bonds 90 are located inward of the primary fasteners 62 on the
stretch panel 70 of the diaper 20. As used herein, the term
"inward" refers to a distance in the lateral direction 40 towards
the longitudinal centerline of the diaper 20 from the respective
element. In such a configuration, the passive side bonds 90 connect
and stabilize the overlapped portion 92 of the rear waist region 24
and stretch panel 70 inward of the primary fasteners 62 to the
front waist region 22. Desirably, the passive side bonds 90 connect
the overlapped portion 92 of the rear waist region 24 to the side
edge 30 of the front waist region 22. For example, in the
illustrated embodiment, the passive side bonds 90 bond a waist edge
72 and a portion of the inward edge 76 of the stretch panel 70 in
the rear waist region 24 to the side edge 30 of the front waist
region 22. In such a configuration, the passive bonds 90 assist in
preventing the edges of the stretch panel 70 and absorbent chassis
28 from rolling over as the diaper 20 is pulled on.
[0096] As illustrated in FIG. 15, the overlapped portion 92 of the
rear waist region 24 defines an overlap distance 94 which is the
distance between the respective side edges 30 of the front and rear
waist regions 22 and 24 when the diaper is prefastened. The overlap
distance 94 is important to ensure that a good seal is provided
around the legs and waist of the wearer. Moreover, the greater the
overlap distance 94, the further inward the passive bonds 90 can be
located which can provide improved reduction in the relative
movement between the front and rear waist regions 22 and 24 and
improved hip coverage during use. The larger overlap distance 94 is
also desirable in the processing of the diaper 20 since the
overlapped portion 92 is typically folded over and attached to the
opposite waist region after the passive side bonds 90 are formed.
To provide such improved fit and performance, it is desirable that
the overlap distance 94 be at least about 2.0 centimeters and more
desirably at least about 4.0 centimeters. As illustrated in FIG.
15, the passive bonds 90 may also be located on the opposite waist
region a distance 96 inward form the side edge 30 of about 0.2 to
about 2.5 centimeters for improved attachment and performance.
[0097] In a particular embodiment, the overlapped portions 92 of
the rear waist region 24 are connected by the passive bonds 90 to
the front waist region 22 along their edges 30 and 32 but remain
unconnected by the passive bonds 90 to the front waist region 22
between the edges 30 and 32. In such an embodiment, the passive
bonds 90 are not continuous along their length in the longitudinal
direction 38. For example, as representatively illustrated in FIG.
15, the passive bonds 90 on each side of the rear waist region 24
may further define an unattached distance 98 in the longitudinal
direction 38 between the respective bond points of at least about
1.0 centimeters and desirably at least about 2.0 centimeters. Such
an arrangement is particularly useful when the fastening system 60
of the diaper 20 includes the secondary fastening tabs 84 and 86
described above such that the secondary fastener tabs 84 and 86 are
allowed to freely be detached from the area created between the
passive bonds 90.
[0098] As illustrated in FIG. 15, the passive side bonds 90 are
located on the rear waist region 24 inward from the primary
fastener 62 a distance 97 to prevent the relative movement or
shifting between the front and rear waist regions 22 and 24 with
respect to each other. In a particular embodiment, at least one of
the bonds of each of the passive side bonds 90 is located on the
rear waist region 24 a distance 97 inward from the primary fastener
62 of at least about 1.0 centimeters and desirably at least about
2.0 centimeters. When the distance 97 is less than the values set
forth above, the front and rear waist regions 22 and 24 may
undesirably shift with respect to each other during the application
or use of the diaper 20. Such shifting of the respective waist
regions 22 and 24 of the diaper 20 can adversely affect the fit of
the diaper 20 on the wearer, which can undesirably lead to
increased leakage.
[0099] In certain aspects of the invention, the location of the
passive bonds 90 and the respective distance 97 and overlap
distance 94 can be selectively varied to tailor the fit of the
diaper 20 for different sized wearers. For example, the location of
the bonds 90 may be varied during the manufacturing process such
that the same process can produce prefastened diapers for use in
conventional Step 3 or Step 4 sizes.
[0100] The passive side bonds 90 may connect the respective front
and rear waist regions 22 and 24 in a facing relationship. For
example, the passive side bonds 90 may connect the bodyfacing
surface 34 of the absorbent chassis 28 in the rear waist region 24
to the garment facing surface 36 of the absorbent chassis 28 in the
front waist region 22. Alternatively, the passive side bonds 90 may
connect the bodyfacing surface 34 of the absorbent chassis 28 in
the rear waist region 24 to the bodyfacing surface 34 of the
absorbent chassis 28 in the front waist region 22. Such a
configuration can lead to improved manufacturability. In such a
configuration, the side edges 30 of the absorbent chassis 28 in the
front waist region 22 may be folded over when the primary fasteners
62 are engaged.
[0101] The passive side bonds 90 can be provided by any type of
bonding such as thermal, adhesive, ultrasonic, cohesive bonding and
the like and combinations thereof as are well known to those
skilled in the art. The passive side bonds 90 may otherwise be
provided by suitable fasteners as are known to those skilled in the
art and described above as being suitable for use as the primary
fasteners 62. The passive side bonds 90 may be discrete point
bonds, dashed lines, continuous lines, discontinuous lines and the
like or combinations thereof. Moreover, the passive side bonds 90
may have any shape such as circular, square, triangular and the
like. In a particular embodiment, the passive side bonds 90 are
ultrasonic point bonds for improved manufacturing efficiency.
[0102] Methods of incorporating the passive side bonds 90 and
making the prefastened diaper 20 of the different aspects of the
present invention are known to those skilled in the art. For
example, in addition to making the diaper by hand, one of such
methods is described in copending U.S. patent application Ser. No.
09/100,911 entitled "METHOD OF MAKING PREFASTENED DISPOSABLE
ABSORBENT ARTICLES" filed Jun. 19, 1998, in the name of Elsberg et
al., the disclosure of which is hereby incorporated by
reference.
[0103] The passive side bonds 90 are configured to assist the
primary fasteners 62 in maintaining the diaper 20 in a prefastened
configuration as the diaper 20 is pulled on and off over the hips
of the wearer and during use. Thus, it is desirable that the
passive side bonds 90 provide adequate shear strength for assisting
the primary fasteners 62. In a particular embodiment, the passive
side bonds 90 define a shear strength of at least about 50 grams
and desirably at least about 100 grams. For example, the passive
side bonds 90 may define a shear strength of from about 100 to
about 4000 grams and desirably from about 500 to about 2000 grams.
As used herein, the term "shear strength" refers to the value
obtained when subjecting the side bonds to the Shear Strength Test
described herein. Shear strength values less than those described
above may not prevent the separation of the front and rear waist
regions 22 and 24 from each other during the application and use of
the diaper 20.
[0104] The passive side bonds 90 are also configured to be readily
tearable such that the caregiver can easily pealingly remove the
diaper 20 from the wearer after it has been soiled. Thus, it is
desirable that the passive side bonds 90 define a relatively low
peak peel strength such that the caregiver can readily disengage
the fasteners 62, 84, and 86, break the passive side bonds 90, and
separate the front and rear waist regions 22 and 24 to remove the
diaper 20 from the waist of the wearer similar to conventional
diapers which are not prefastened. For example, in a particular
embodiment, the passive side bonds 90 define a peel strength of no
more than about 1500 grams, desirably no more than about 1000
grams, and more desirably no more than about 800 grams. As used
herein, the term "peel strength" refers to the value obtained when
subjecting the side bonds to the Peel Strength Test described
herein. Peel strength values greater than those described above may
not be readily tearable and may undesirably result in tearing of
other portions of the diaper 20. Desirably, the peel strength of
the side bonds 90 is less than about 50 percent of the peel
strength of the primary fasteners 62 and more desirably less than
about 20 percent of the peel strength of the primary fasteners
62.
[0105] In another aspect, the present invention provides a package
of the prefastened diapers described above. The package includes a
container such as, for example, a plastic bag, and a plurality of
prefastened disposable diapers. As described above, each
prefastened diaper 20 includes at least one stretch panel 70 which
is located in one of the waist regions 22 and 24 of the diaper 20.
The stretch panel 70 is configured to elongate in the lateral
direction 40 to provide an improved fit and appearance of the
diaper about the wearer by initially providing a conforming fit
about the wearer and maintaining such fit throughout the use of
such article. Such a package provides diapers which can be pulled
on over the legs of the wearer and which can be easily removed from
the waist of the wearer after they have been soiled.
[0106] The different aspects of the present invention
advantageously provide prefastened, refastenable, disposable
absorbent articles, each of which may include the combination of at
least one stretch panel, passive side bonds, and a prefastened,
refastenable fastening system. The stretch panel is configured to
elongate in the lateral direction to provide an improved fit and
appearance of the diaper about the wearer by initially providing a
conforming fit about the wearer and maintaining such fit throughout
the use of such article. The stretch panel is also configured such
that the absorbent chassis has the ability to expand, contract, and
receive body exudates without adversely affecting the positioning
of the stretch panel and the diaper about the waist of the
wearer.
[0107] The primary fasteners are prefastened to refastenably engage
the front and rear waist portions to allow the absorbent article to
be pulled up or down over the hips of the wearer such as
conventional training pants. Moreover, the primary fasteners can be
used to refastenably engage and adjust the front and rear waist
regions of the absorbent article to maintain the absorbent article
about the waist of the wearer after the article has been pulled on
in a similar manner to conventional diapers. Further, the fastening
system may include at least one secondary fastener to provide
improved securement of the diaper about the waist of the wearer
after the primary fasteners have been releasably engaged. The
passive side bonds assist the fastening system in maintaining the
article in a prefastened condition as the article is pulled up or
down over the hips of the wearer. Moreover, the passive side bonds
prevent movement and shifting of the waist portions relative to
each other for improved manufacturability, fit and performance. The
passive side bonds also prevent the rollover or folding in of the
side and waist edges of the prefastened absorbent article as it is
pulled over the wearer's hips.
[0108] As a result, the prefastened absorbent articles of the
present invention are designed to conform to the body of the wearer
to effectively contain bodily exudates while still being capable of
being reliably pulled up or down over the hips of the wearer to
assist in the toilet training of the wearer. Moreover, similar to
conventional diapers, the absorbent articles of the present
invention can advantageously be applied to and removed from the
wearer with relative ease and cleanliness.
[0109] Peel Strength Test
[0110] This test method is designed to quantify, in grams, the peak
strength of the ultrasonic point bonds holding the front waist
region of the absorbent article to the rear waist region. The
direction of removal (peel), in this application, is that direction
in which the fastener material would generally be removed from a
substrate when the product is in use. This direction is generally
perpendicular to a longitudinal centerline of the product.
[0111] Equipment
[0112] 1. Tensile tester capable of obtaining a peak load and
equipped with an appropriate load cell. A suitable tensile testing
system is a Sintech Tensile Tester, commercially available from MTS
Sintech, Research Triangle Park, N.C., under the trade designation
Instron Model 4201 Tensile Tester with Sintech QAD (Quality
Assurance Department) Software.
[0113] 2. Software commercially obtained from MTS Sintech under the
trade designation Sintech Testworks.TM..
[0114] 3. Pnuematic-action grips commercially available from
Instron Corporation, Canton, Mass., under the trade designation
"Instron Model 2712-004."
[0115] 4. 1 by 4 inch grip faces, serrated, commercially available
from Instron Corporation, Canton, Mass.
[0116] 5. Test facility having a temperature of 23.+-.1.degree. C.,
and a relative humidity of 50.+-.2 percent.
[0117] Test Procedure
[0118] 1. A sample to be tested is conditioned in the test facility
for at least 4 hours prior to testing.
[0119] 2. The load cell is calibrated and the software loaded.
[0120] 3. The grips are installed on the tensile tester with the
jaws closed.
[0121] 4. The test condition for the tensile tester are set as
follows:
1 Crosshead speed: 500 millimeters/minute Full-scale load: 5
kilograms Threshold: 5 percent Fail criterion: 95 percent Gage
length: 50 millimeters
[0122] 5. The weight of the clamp is tared out.
[0123] 6. The primary fastener tab of the fastening element on the
rear waist region of the article is inserted into the upper jaw
such that the edge of the grip face is flush with the inner edge of
the hook material.
[0124] 7. The front waist region of the article is inserted into
the lower jaw such that the inner surface of the rear waist region
and the outer surface of the front waist region form a 180.degree.
angle. The lower jaw is closed.
[0125] 8. The crosshead is started in motion.
[0126] 9. The peak load of failure is recorded. It is intended that
the mode of failure is that the rear waist region of the diaper
separates from the front waist region of the diaper. Results are
rejected if the place of failure is any location other than the
ultrasonic point bonds.
[0127] Shear Strength Test
[0128] This test method is designed to quantify, in grams, the peak
dynamic shear strength of the ultrasonic point bonds holding the
front waist region of the absorbent article to the rear waist
region. The direction of force in this application is generally
perpendicular to the longitudinal centerline of the product.
[0129] Equipment
[0130] 1. Tensile tester capable of obtaining a peak load and
equipped with an appropriate load cell. A suitable tensile testing
system is a Sintech Tensile Tester, commercially available from MTS
Sintech, Research Triangle Park, N.C., under the trade designation
Instron Model 4201 Tensile Tester with Sintech QAD (Quality
Assurance Department) Software.
[0131] 2. Software commercially obtained from MTS Sintech under the
trade designation Sintech Testworks.TM..
[0132] 3. Pnuematic-action grips commercially available from
Instron Corporation, Canton, Mass., under the trade designation
"Instron Model 2712-004."
[0133] 4. 1 by 4 inch grip faces, serrated, commercially available
from Instron Corporation, Canton, Mass.
[0134] 5. Test facility having a temperature of 23.+-.1.degree. C.,
and a relative humidity of 50.+-.2 percent.
[0135] Test Procedure
[0136] 1. A sample to be tested is conditioned in the test facility
for at least 4 hours prior to testing.
[0137] 2. The load cell is calibrated and the software loaded.
[0138] 3. The grips are installed on the tensile tester with the
jaws closed.
[0139] 4. The test condition for the tensile tester are set as
follows:
2 Crosshead speed: 500 millimeters/minute Full-scale load: 5
kilograms Threshold: 5 percent Fail criterion: 95 percent Gage
length: 50 millimeters
[0140] 5. The weight of the clamp is tared out.
[0141] 6. The primary fastener tab of the fastening element on the
rear waist region of the article is inserted into the upper jaw
such that the edge of the grip face is flush with the inner edge of
the hook material.
[0142] 7. The front waist region of the article is inserted into
the lower jaw such that the inner surface of the rear waist region
and the inner surface of the front waist region are facing the same
direction and are parallel to one another. The lower jaw is
closed.
[0143] 8. The crosshead is started in motion.
[0144] 9. The peak load of failure is recorded. It is intended that
the mode of failure is that the rear waist region of the article
separates from the front waist region of the article. Results are
rejected if the place of failure is any location other than the
ultrasonic point bonds.
[0145] Having thus described the invention in rather full detail,
it will be readily apparent to a person of ordinary skill that
various changes and modifications can be made without departing
from the spirit of the invention. All of such changes and
modifications are contemplated as being within the scope of the
present invention as defined by the subjoined claims.
* * * * *