U.S. patent application number 10/038796 was filed with the patent office on 2003-07-03 for absorbent article with improved fastening system and method of fastening thereof.
This patent application is currently assigned to Kimberly-Clark Worldwide, Inc.. Invention is credited to Ratliff, Kathleen I., Ruman, Marcille F., Shelley, Lindsay C..
Application Number | 20030125705 10/038796 |
Document ID | / |
Family ID | 21901947 |
Filed Date | 2003-07-03 |
United States Patent
Application |
20030125705 |
Kind Code |
A1 |
Ruman, Marcille F. ; et
al. |
July 3, 2003 |
Absorbent article with improved fastening system and method of
fastening thereof
Abstract
An absorbent article such as infant training pants is provided
with a mechanical hook-and-loop type fastening system in which at
least the loop material is stretchable and in some embodiments is
elongated before it is brought into engagement with the hook
material and is then allowed to contract on the hook material while
in other embodiments the loop material is shrunk as it is placed in
engagement with the hook material.
Inventors: |
Ruman, Marcille F.;
(Oshkosh, WI) ; Shelley, Lindsay C.; (Appleton,
WI) ; Ratliff, Kathleen I.; (Neenah, WI) |
Correspondence
Address: |
SENNIGER POWERS LEAVITT AND ROEDEL
ONE METROPOLITAN SQUARE
16TH FLOOR
ST LOUIS
MO
63102
US
|
Assignee: |
Kimberly-Clark Worldwide,
Inc.
|
Family ID: |
21901947 |
Appl. No.: |
10/038796 |
Filed: |
December 31, 2001 |
Current U.S.
Class: |
604/391 |
Current CPC
Class: |
A61F 13/5633 20130101;
A61F 13/565 20130101; A61F 13/15756 20130101; A61F 13/622
20130101 |
Class at
Publication: |
604/391 |
International
Class: |
A61F 013/15 |
Claims
What is claimed is:
1. A disposable absorbent article comprising: a body having first
and second regions; a mechanical fastening system on the body, the
mechanical fastening system comprising a first fastening component
disposed on the body in the first region and a second fastening
component disposed on the body in the second region, at least a
portion of the first fastening component being a hook material, and
at least a portion of the second fastening component being a loop
material which is stretchable from a relaxed state to an elongated
state; whereby when the second fastening component is in an
elongated state and in juxtaposition and contact with the first
fastening component the loop material engages the hook material as
it moves from an elongated state to a relaxed state.
2. The article of claim 1 wherein the loop material is stretchable
by about 150 to 300 percent.
3. The article of claim 1 wherein the loop material is stretchable
by about 300 to 450 percent.
4. The article of claim 1 wherein the second fastening component is
elastomeric.
5. The article of claim 1 wherein the first fastening component is
stretchable.
6. A disposable absorbent article for personal wear, said
disposable article comprising: a body having first and second end
regions and comprising an inner layer for contact with the wearer's
skin, at least a portion of the inner layer being liquid permeable,
an outer layer in opposed relation with the inner layer, and an
absorbent layer disposed between the inner layer and the outer
layer; a mechanical fastening system positioned on the body
including: a first fastening component disposed on the body in the
first end region, at least a portion of the first fastening
component being a hook material, and a second fastening component
disposed on the body in the second end region, at least a portion
of the second fastening component being a loop material which is
stretchable and contractible; whereby when the second fastening
component is in an elongated state and in juxtaposition and contact
with the hook material it further engages the hook material as it
moves from an elongated state to a contracted state.
7. The article of claim 6 wherein the loop material is stretchably
mounted on the second end region.
8. The article of claim 6 wherein the loop material is stretchable
by about 150 to 300 percent.
9. The article of claim 6 wherein the loop material is stretchable
by about 300 to 450 percent.
10. The article of claim 6 wherein the loop material forms at least
a portion of the second end region.
11. The article of claim 10 wherein the loop material is
stretchable by about 150 to 300 percent.
12. The article of claim 10 wherein the loop material is
stretchable by about 300 to 450 percent.
13. The article of claim 6 wherein the second fastening component
is elastomeric.
14. The article of claim 6 wherein the first fastening component is
substantially stretchable.
15. A disposable absorbent article for personal wear, said
disposable article comprising: a body having first and second end
regions and comprising an inner layer for contact with the wearer's
skin, at least a portion of the inner layer being liquid permeable,
an outer layer in opposed relation with the inner layer, and an
absorbent layer disposed between the inner layer and the outer
layer; a mechanical fastening system positioned on the body
including: a first fastening component disposed on the body in the
first end region and at least a portion of the first fastening
component being a hook material, and a second fastening component
disposed on the body in the second end region, at least a portion
of the second fastening component being a loop material which is
contractible upon the application of heat; whereby when the second
fastening component is in juxtaposition and contact with the first
fastening component and then heated the second fastening component
further engages the hook material as it retracts.
16. A method of securing an absorbent article for personal wear,
comprising: providing an absorbent article having a body having
first and second end regions, the body comprising inner layer for
contact with the wearer's skin, at least a portion of the inner
layer being liquid permeable, an outer layer in opposed relation
with the inner layer, and an absorbent layer disposed between the
inner layer and the outer layer; providing a mechanical fastening
system positioned on the body including: a first fastening
component disposed on the body in the first end region, at least a
portion of the first fastening component being a hook material, and
a second fastening component disposed on the body in the second end
region, at least a portion of the second fastening component being
a loop material which is stretchable and contractible; and
stretching the loop material and then placing the stretched loop
material overlying and in engagement with the hook material and
then contracting the loop material.
17. The method of claim 16 wherein stretching the loop material is
done manually.
18. The method of claim 16 wherein the loop material is stretched
by about 150 to 300 percent.
19. The method of claim 16 wherein the loop material is stretched
by about 300 to 450 percent
20. A method of securing an absorbent article for personal wear,
comprising: providing an absorbent article having a body having
first and second end regions each having longitudinal edges, the
body also having an inner layer for contact with the wearer's skin,
at least a portion of the inner layer being liquid permeable, an
outer layer in opposed relation with the inner layer and an
absorbent layer disposed between the inner layer and the outer
layer; providing a mechanical fastening system positioned on the
body including: a first fastening component disposed on the body of
the first end region and at least a portion of the first fastening
component being a hook material, and a second fastening component
disposed on the body of the second end region, at least a portion
of the second fastening component being a loop material which is
retractable; and contacting the loop material in engagement with
the hook material and then contracting the loop material.
21. The method of claim 20 wherein contracting the loop material
comprises activating the loop material.
22. The method of claim 21 wherein activating the loop material
comprises heating the loop material.
23. The method of claim 20 wherein the loop material comprises a
stretched elastic member having its retraction temporarily
inhibited during engagement of the hook and loop materials.
24. A method of securing an absorbent article for personal wear,
comprising: providing an absorbent article comprising a body having
first and second end regions; providing a mechanical fastening
system on the body, the mechanical fastening system comprising a
first fastening component disposed on the body in the first end
region and a second fastening component disposed on the body in the
second end region, at least a portion of the first fastening
component being a hook material, and at least a portion of the
second fastening component being a loop material which is
stretchable from a relaxed state to an elongated state; stretching
the second fastening component to an elongated state; engaging the
first and second fastening component while the second fastening
component is in an elongate state; and allowing the second
fastening component to retract from the elongated state after the
first and second components are engaged.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention pertains to absorbent articles, such
as training pants, diapers, incontinence garments and the like, and
more particularly, to a mechanical fastening system for such
absorbent articles.
[0002] Such absorbent articles generally comprise a
liquid-impermeable barrier sheet, a liquid permeable body side
liner and an absorbent medium between them. They generally include
some type of attaching system for fitting the article to the
wearer. In many such applications, the fastening system is
preferably refastenable so that the article can be temporarily
removed and then refastened to the wearer.
[0003] One common form of mechanical attachment systems is the so
called hook-and-loop system which comes in various forms and has
both advantages and disadvantages in its application to such
absorbent articles. For example, particularly with disposable
diapers, the fasteners are secured to the garment in the front and
back, generally in such a manner that the hook portions of the
fasteners on each side are pulled over the loop portions to secure
the garment to the wearer. In typical such installations the loop
material is relatively unstretchable and either forms a portion of
the garment itself or is attached to the surface of the garment.
The hook panel is generally stretchable while the hook is generally
unstretchable so that it can be positioned on the loop material for
adjustment to the size and shape of the wearer of the garment.
[0004] A disadvantage of this type of hook-and-loop system is the
tendency of the hooks to separate from the loop material when the
wearer is active, such as when stooping or bending as is common
with a child in training pants. This disengagement failure can
result in requiring it to be refastened. This produces an
undesirable inconvenience and disadvantage of such a mechanical
fastening system for such applications. In an attempt to overcome
this disadvantage many systems have increased the force to
disengage through various enhancements to maximize the
hook-and-loop material interaction.
SUMMARY OF THE INVENTION
[0005] The present invention overcomes the above-described
difficulties and disadvantages associated with such prior art
mechanical fastening systems by providing, in particular
embodiments, a hook-and-loop fastening system in which the loop
material is a stretchable material that is in an elongated state
before contact is made with the hook material and is then
contracted on the hook material after contact.
[0006] One aspect of the present invention concerns a disposable
absorbent article. In one embodiment, the disposable absorbent
article comprises: a body having first and second regions; a
mechanical fastening system on the body, the mechanical fastening
system comprising a first fastening component disposed on the body
in the first region and a second fastening component disposed on
the body in the second region, at least a portion of the first
fastening component being a hook material, and at least a portion
of the second fastening component being a loop material which is
stretchable from a relaxed state to an elongated state; whereby
when the second fastening component is in an elongated state and in
juxtaposition and contact with the first fastening component the
loop material engages the hook material as it moves from an
elongated state to a relaxed state.
[0007] In another embodiment, a disposable absorbent article for
personal wear comprises: a body having first and second end regions
and comprising an inner layer for contact with the wearer's skin,
at least a portion of the inner layer being liquid permeable, an
outer layer in opposed relation with the inner layer, and an
absorbent layer disposed between the inner layer and the outer
layer; a mechanical fastening system positioned on the body
including: a first fastening component disposed on the body in the
first end region, at least a portion of the first fastening
component being a hook material, and a second fastening component
disposed on the body in the second end region, at least a portion
of the second fastening component being a loop material which is
stretchable and contractible; whereby when the second fastening
component is in an elongated state and in juxtaposition and contact
with the hook material it further engages the hook material as it
moves from an elongated state a contracted state.
[0008] In another embodiment, a disposable absorbent article for
personal wear comprises: a body having first and second end regions
and comprising an inner layer for contact with the wearer's skin,
at least a portion of the inner layer being liquid permeable, an
outer layer in opposed relation with the inner layer, and an
absorbent layer disposed between the inner layer and the outer
layer; a mechanical fastening system positioned on the body
including: a first fastening component disposed on the body in the
first end region and at least a portion of the first fastening
component being a hook material, and a second fastening component
disposed on the body in the second end region, at least a portion
of the second fastening component being a loop material which is
contractible upon the application of heat; whereby when the second
fastening component is in juxtaposition and contact with the first
fastening component and then heated the second fastening component
further engages the hook material as it retracts.
[0009] Another aspect of the present invention concerns methods for
secure an absorbent article for personal wear. In one embodiment,
the method comprises the steps of: providing an absorbent article
having a body having first and second end regions, the body
comprising inner layer for contact with the wearer's skin, at least
a portion of the inner layer being liquid permeable, an outer layer
in opposed relation with the inner layer, and an absorbent layer
disposed between the inner layer and the outer layer; providing a
mechanical fastening system positioned on the body including: a
first fastening component disposed on the body in the first end
region, at least a portion of the first fastening component being a
hook material, and a second fastening component disposed on the
body in the second end region, at least a portion of the second
fastening component being a loop material which is stretchable and
contractible; and stretching the loop material and then placing the
stretched loop material overlying and in engagement with the hook
material and then contracting the loop material.
[0010] In another embodiment, the method comprises the steps of:
providing an absorbent article having a body having first and
second end regions each having longitudinal edges, the body also
having an inner layer for contact with the wearer's skin, at least
a portion of the inner layer being liquid permeable, an outer layer
in opposed relation with the inner layer and an absorbent layer
disposed between the inner layer and the outer layer; providing a
mechanical fastening system positioned on the body including: a
first fastening component disposed on the body of the first end
region and at least a portion of the first fastening component
being a hook material, and a second fastening component disposed on
the body of the second end region, at least a portion of the second
fastening component being a loop material which is retractable; and
contacting the loop material in engagement with the hook material
and then contracting the loop material.
[0011] In another embodiment, the method comprises the steps of:
providing an absorbent article comprising a body having first and
second end regions; providing a mechanical fastening system on the
body, the mechanical fastening system comprising a first fastening
component disposed on the body in the first end region and a second
fastening component disposed on the body in the second end region,
at least a portion of the first fastening component being a hook
material, and at least a portion of the second fastening component
being a loop material which is stretchable from a relaxed state to
an elongated state; stretching the second fastening component to an
elongated state; engaging the first and second fastening component
while the second fastening component is in an elongate state; and
allowing the second fastening component to retract from the
elongated state after the first and second components are
engaged.
[0012] Definitions
[0013] Within the context of this specification, each term or
phrase below will include the following meaning or meanings.
[0014] "Bonded" refers to the joining, adhering, connecting,
attaching, or the like, of two elements. Two elements will be
considered to be bonded together when they are bonded directly to
one another or indirectly to one another, such as when each is
directly bonded to intermediate elements.
[0015] "Comprising" is inclusive or open-ended and does not exclude
additional, unrecited elements or method steps.
[0016] "Connected" refers to the joining, adhering, bonding,
attaching, or the like, of two elements. Two elements will be
considered to be connected together when they are connected
directly to one another or indirectly to one another, such as when
each is directly connected to intermediate elements.
[0017] "Disposable" refers to articles which are designed to be
discarded after a limited use rather than being laundered or
otherwise restored for reuse.
[0018] "Disposed," "disposed on," and variations thereof are
intended to mean that one element can be integral with another
element, or that one element can be a separate structure bonded to
or placed with or placed near another element.
[0019] "Elastic," "elasticized" and "elasticity" mean that property
of a material or composite by virtue of which it tends to recover
its original size and shape after removal of a force causing a
deformation.
[0020] "Elastomeric" refers to a material or composite which can be
elongated by at least 25 percent of its relaxed length and which
will recover, upon release of the applied force, at least 10
percent of its elongation. It is generally preferred that the
elastomeric material or composite be capable of being elongated by
at least 75 percent, particularly at least 150 percent, and more
particularly at least 350 percent, of its relaxed length and
recover, upon release of an applied force, at least 50 percent of
its elongation.
[0021] "Fabrics" is used to refer to all of the woven, knitted and
nonwoven fibrous webs.
[0022] "Flexible" refers to materials which are compliant and which
will readily conform to the general shape and contours of the
wearer's body.
[0023] "Force" includes a physical influence exerted by one body on
another which produces acceleration of bodies that are free to move
and deformation of bodies that are not free to move. Force is
expressed in grams per unit area.
[0024] "Graphic" refers to any design, pattern, or the like that is
visible on an absorbent article.
[0025] "Hydrophilic" describes fibers or the surfaces of fibers
which are wetted by the aqueous liquids in contact with the fibers.
The degree of wetting of the materials can, in turn, be described
in terms of the contact angles and the surface tensions of the
liquids and materials involved. Equipment and techniques suitable
for measuring the wettability of particular fiber materials or
blends of fiber materials can be provided by a Cahn SFA-222 Surface
Force Analyzer System, or a substantially equivalent system. When
measured with this system, fibers having contact angles less than
90.degree. are designated "wettable" or hydrophilic, while fibers
having contact angles greater than 90.degree. are designated
"nonwettable" or hydrophobic.
[0026] "Integral" is used to refer to various portions of a single
unitary element rather than separate structures bonded to or placed
with or placed near one another.
[0027] "Inward" and "outward" refer to positions relative to the
center of an absorbent article, and particularly transversely
and/or longitudinally closer to or away from the longitudinal and
transverse center of the absorbent article.
[0028] "Layer" when used in the singular can have the dual meaning
of a single element or a plurality of elements.
[0029] "Liquid impermeable", when used in describing a layer or
multi-layer laminate, means that a liquid, such as urine, will not
pass through the layer or laminate, under ordinary use conditions,
in a direction generally perpendicular to the plane of the layer or
laminate at the point of liquid contact. Liquid, or urine, may
spread or be transported parallel to the plane of the liquid
impermeable layer or laminate, but this is not considered to be
within the meaning of "liquid impermeable" when used herein.
[0030] "Longitudinal" and "transverse" have their customary
meaning, as indicated by the longitudinal and transverse axes
depicted in FIGS. 2 and 3. The longitudinal axis lies in the plane
of the article and is generally parallel to a vertical plane that
bisects a standing wearer into left and right body halves when the
article is worn. The transverse axis lies in the plane of the
article generally perpendicular to the longitudinal axis. The
article as illustrated is longer in the longitudinal direction than
in the transverse direction.
[0031] "Member" when used in the singular can have the dual meaning
of a single element or a plurality of elements.
[0032] "Nonwoven" and "nonwoven web" refer to materials and webs of
material which are formed without the aid of a textile weaving or
knitting process.
[0033] "Operatively joined," with reference to the attachment of an
elastic member to another element, means that the elastic member
when attached to or connected to the element, or treated with heat
or chemicals, by stretching, or the like, gives the element elastic
properties; and with reference to the attachment of a non-elastic
member to another element, means that the member and element can be
attached in any suitable manner that permits or allows them to
perform the intended or described function of the joinder. The
joining, attaching, connecting or the like can be either directly,
such as joining either member directly to an element, or can be
indirectly by means of another member disposed between the first
member and the first element.
[0034] "Outer cover graphic" refers to a graphic that is directly
visible upon inspection of the exterior surface of a garment, and
for a refastenable garment is in reference to inspection of the
exterior surface of the garment when the fastening system is
engaged as it would be during use.
[0035] "Permanently bonded" refers to the joining, adhering,
connecting, attaching, or the like, of two elements of an absorbent
garment such that the elements tend to be and remain bonded during
normal use conditions of the absorbent garment.
[0036] "Refastenable" refers to the property of two elements being
capable of releasable attachment, separation, and subsequent
releasable reattachment without substantial permanent deformation
or rupture.
[0037] "Releasably attached," "releasably engaged" and variations
thereof refer to two elements being connected or connectable such
that the elements tend to remain connected absent a separation
force applied to one or both of the elements, and the elements
being capable of separation without substantial permanent
deformation or rupture. The required separation force is typically
beyond that encountered while wearing the absorbent garment.
[0038] "Rupture" means the breaking or tearing apart of a material;
in tensile testing, the term refers to the total separation of a
material into two parts either all at once or in stages, or the
development of a hole in some materials.
[0039] "Stretch bonded" refers to an elastic member being bonded to
another member while the elastic member is extended at least about
25 percent of its relaxed length. Desirably, the term "stretch
bonded" refers to the situation wherein the elastic member is
extended at least about 100 percent, and more desirably at least
about 300 percent, of its relaxed length when it is bonded to the
other member.
[0040] "Stretch bonded laminate" refers to a composite material
having at least two layers in which one layer is a gatherable layer
and the other layer is an elastic layer. The layers are joined
together when the elastic layer is in an extended condition so that
upon relaxing the layers, the gatherable layer is gathered.
[0041] "Surface" includes any layer, film, woven, nonwoven,
laminate, composite, or the like, whether pervious or impervious to
air, gas, and/or liquids.
[0042] "Tension" includes a uniaxial force tending to cause the
extension of a body or the balancing force within that body
resisting the extension.
[0043] "Thermoplastic" describes a material that softens when
exposed to heat and which substantially returns to a nonsoftened
condition when cooled to room temperature.
[0044] These terms may be defined with additional language in the
remaining portions of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] The above-mentioned and other features of the present
invention and the manner of attaining them will become more
apparent, and the invention itself will be better understood by
reference to the following description and the accompanying
drawings, wherein similar features in different figures have been
given the same reference numeral.
[0046] FIG. 1 illustrates a side view of a training pant suitable
for use with the process and apparatus according to the present
invention, where the fastening system is shown engaged on one side
of the training pant and disengaged on the other side of the
training pant.
[0047] FIG. 2 illustrates a plan view of the training pant shown in
FIG. 1 in an unfastened, stretched and laid flat condition, and
showing the surface of the training pant that faces away from the
wearer.
[0048] FIG. 3 illustrates a plan view similar to FIG. 2, but
showing the surface of the training pant that faces the wearer when
the training pant is worn, and with portions cut away to show the
underlying features.
[0049] FIG. 4 illustrates an alternative embodiment of the present
invention in a side view similar to FIG. 1.
[0050] FIG. 5 is a plan view of the embodiment of FIG. 4 in a
similar position as FIG. 3.
[0051] FIG. 6 schematically illustrates a flow diagram for
manufacture of one embodiment of a pant according to the present
invention.
[0052] FIG. 7 illustrates a pant according to one embodiment of the
present invention at three stages during manufacture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0053] FIG. 1 representatively illustrates one embodiment of
training pant 20 in a partially fastened condition. The training
pant 20 comprises an absorbent body 32 and a fastening system 80.
The absorbent body 32 defines a front waist region 22, a back waist
region 24, a crotch region 26 interconnecting the front and back
waist regions, an inner surface 28 which is configured to contact
the wearer, and an outer surface 30 opposite the inner surface
which is configured to contact the wearer's clothing. With
additional reference to FIGS. 2 and 3, the absorbent body 32 also
defines a pair of transversely opposed side edges 36 and a pair of
longitudinally opposed waist edges, which are designated front
waist edge 38 and back waist edge 39. The front waist region 22 is
contiguous with the front waist edge 38, and the back waist region
24 is contiguous with the back waist edge 39.
[0054] The illustrated absorbent body 32 comprises a rectangular
composite structure 33, a pair of transversely opposed front side
panels 34, and a pair of transversely opposed back side panels 134.
The composite structure 33 and side panels 34 and 134 may be
integrally formed or comprise two or more separate elements, as
shown in FIG. 1. The illustrated composite structure 33 comprises
an outer cover 40, a bodyside liner 42 (FIG. 3) which is connected
to the outer cover in a superposed relation, an absorbent assembly
44 (FIG. 3) which is located between the outer cover and the
bodyside liner, and a pair of containment flaps 46 (FIG. 3). The
illustrated composite structure 33 has opposite linear end edges 45
that form portions of the front and back waist edges 38 and 39, and
opposite linear side edges 47 that form portions of the side edges
36 of the absorbent body 32 (FIGS. 2 and 3). For reference, arrows
48 and 49 depicting the orientation of the longitudinal axis and
the transverse axis, respectively, of the training pant 20 are
illustrated in FIGS. 2 and 3.
[0055] With the training pant 20 in the fastened position as
partially illustrated in FIG. 1, the front and back waist regions
22 and 24 are joined together to define a three-dimensional pant
configuration having a waist opening 50 and a pair of leg openings
52. The front waist region 22 comprises the portion of the training
pant 20 which, when worn, is positioned on the front of the wearer
while the back waist region 24 comprises the portion of the
training pant which, when worn, is positioned on the back of the
wearer. The crotch region 26 of the training pant 20 comprises the
portion of the training pant which, when worn, is positioned
between the legs of the wearer and covers the lower torso of the
wearer. The front and back side panels 34 and 134 comprise the
portions of the training pant 20 which, when worn, are positioned
on the hips of the wearer.
[0056] The front waist region 22 of the absorbent body 32 includes
the transversely opposed front side panels 34 and a front center
panel 35 (FIGS. 2 and 3) positioned between and interconnecting the
side panels. The back waist region 24 of the absorbent body 32
includes the transversely opposed back side panels 134 and a back
center panel 135 (FIGS. 2 and 3) positioned between and
interconnecting the side panels. The waist edges 38 and 39 of the
absorbent body 32 are configured to encircle the waist of the
wearer when worn and provide the waist opening 50 which defines a
waist perimeter dimension. Portions of the transversely opposed
side edges 36 in the crotch region 26 generally define the leg
openings 52. The waist regions 22 and 24 jointly define a waistband
75 (FIGS. 1, 4 and 7) that peripherally surrounds the waist opening
50 of the pant 20. The waist regions 22 and 24 also jointly define
a hip section 77 (FIGS. 1, 4 and 7) that encircles the pant 20 and
is disposed between the waistband 75 and the leg openings 52.
[0057] The absorbent body 32 is configured to contain and/or absorb
any body exudates discharged from the wearer. For example, the
absorbent body 32 desirably although not necessarily comprises the
pair of containment flaps 46 which are configured to provide a
barrier to the transverse flow of body exudates. A flap elastic
member 53 (FIG. 3) is operatively joined with each containment flap
46 in any suitable manner as is well known in the art. The
elasticized containment flaps 46 define an unattached edge which
assumes an upright configuration in at least the crotch region 26
of the training pant 20 to form a seal against the wearer's body.
The containment flaps 46 can be located along the transversely
opposed side edges of the absorbent body 32, and can extend
longitudinally along the entire length of the absorbent body or may
only extend partially along the length of the absorbent body.
Suitable constructions and arrangements for the containment flaps
46 are generally well known to those skilled in the art and are
described in U.S. Pat. No. 4,704,116 issued Nov. 3, 1987 to Enloe,
which is incorporated herein by reference.
[0058] To further enhance containment and/or absorption of body
exudates, the training pant 20 desirably although not necessarily
includes a front waist elastic member 54, a rear waist elastic
member 56, and leg elastic members 58, as are known to those
skilled in the art (FIG. 3). The waist elastic members 54 and 56
can be operatively joined to the outer cover 40 and/or bodyside
liner 42 along the opposite waist edges 38 and 39, and can extend
over part or all of the waist edges, such that the waist elastic
members are disposed in the waistband 75 in the fully assembled
pant. The leg elastic members 58 are desirably operatively joined
to the outer cover 40 and/or bodyside liner 42 along the opposite
side edges 36 and positioned in the crotch region 26 of the
training pant 20. The leg elastic members 58 can be longitudinally
aligned along each side edge 47 of the composite structure 33. Each
leg elastic member 58 has a front terminal point 63 and a back
terminal point 65, which points represent the longitudinal ends of
the elastic gathering caused by the leg elastic members. The front
terminal points 63 can be located adjacent the longitudinally
innermost parts of the front side panels 34, and the back terminal
points 65 can be located adjacent the longitudinally innermost
parts of the back side panels 134.
[0059] The flap elastic members 53, the waist elastic members 54
and 56, and the leg elastic members 58 can be formed of any
suitable elastic material. As is well known to those skilled in the
art, suitable elastic materials include sheets, strands or ribbons
of natural rubber, synthetic rubber, or thermoplastic elastomeric
polymers. The elastic materials can be stretched and adhered to a
substrate, adhered to a gathered substrate, or adhered to a
substrate and then elasticized or shrunk, for example with the
application of heat; such that elastic constrictive forces are
imparted to the substrate. In one particular embodiment, for
example, the leg elastic members 58 comprise a plurality of
dry-spun coalesced multifilament spandex elastomeric threads sold
under the trade name LYCRA.RTM. and available from E. I. Du Pont de
Nemours and Company, Wilmington, Del. U.S.A.
[0060] In particular embodiments, the waist elastic members 54 and
56 can be formed of retractive materials. For example, the waist
elastic members 54 and 56 can be formed of an elastomeric material
that is adapted to retract upon activation by a source of heat such
as disclosed in U.S. Pat. No. 4,640,726.
[0061] The outer cover 40 desirably comprises a material that is
substantially liquid impermeable, and can be elastic, stretchable
or nonstretchable. The outer cover 40 can be a single layer of
liquid impermeable material, but desirably comprises a
multi-layered laminate structure in which at least one of the
layers is liquid impermeable. For instance, the outer cover 40 can
include a liquid permeable outer layer and a liquid impermeable
inner layer that are suitably joined together by a laminate
adhesive, ultrasonic bonds, thermal bonds, or the like. Suitable
laminate adhesives, which can be applied continuously or
intermittently as beads, a spray, parallel swirls, or the like, can
be obtained from Findley Adhesives, Inc., of Wauwatosa, Wis.
U.S.A., or from National Starch and Chemical Company, Bridgewater,
N.J. U.S.A. The liquid permeable outer layer can be any suitable
material and desirably one that provides a generally cloth-like
texture. One example of such a material is a 20 gsm (grams per
square meter) spunbond polypropylene nonwoven web. The outer layer
may also be made of those materials of which liquid permeable
bodyside liner 42 is made. While it is not a necessity for outer
layer to be liquid permeable, it is desired that it provides a
relatively cloth-like texture to the wearer.
[0062] The inner layer of the outer cover 40 can be both liquid and
vapor impermeable, or can be liquid impermeable and vapor
permeable. The inner layer is desirably manufactured from a thin
plastic film, although other flexible liquid impermeable materials
may also be used. The inner layer, or the liquid impermeable outer
cover 40 when a single layer, prevents waste material from wetting
articles, such as bedsheets and clothing, as well as the wearer and
caregiver. A suitable liquid impermeable film for use as a liquid
impermeable inner layer, or a single layer liquid impermeable outer
cover 40, is a 0.02 millimeter polyethylene film commercially
available from Huntsman Packaging of Newport News, Va. U.S.A. If
the outer cover 40 is a single layer of material, it can be
embossed and/or matte finished to provide a more cloth-like
appearance. As earlier mentioned, the liquid impermeable material
can permit vapors to escape from the interior of the disposable
absorbent article, while still preventing liquids from passing
through the outer cover 40. A suitable "breathable" material is
composed of a microporous polymer film or a nonwoven fabric that
has been coated or otherwise treated to impart a desired level of
liquid impermeability. A suitable microporous film is a PMP-1 film
material commercially available from Mitsui Toatsu Chemicals, Inc.,
Tokyo, Japan, or an XKO-8044 polyolefin film commercially available
from 3M Company, Minneapolis, Minn. U.S.A.
[0063] As shown in FIGS. 1 and 2, the training pant 20 and in
particular the outer cover 40 desirably comprises one or more
appearance-related components. Examples of appearance-related
components include, but are not limited to, graphics; highlighting
or emphasizing leg and waist openings in order to make product
shaping more evident or visible to the user; highlighting or
emphasizing areas of the product to simulate functional components
such as elastic leg bands, elastic waistbands, simulated "fly
openings" for boys, ruffles for girls; highlighting areas of the
product to change the appearance of the size of the product;
registering wetness indicators, temperature indicators, and the
like in the product; registering a back label, or a front label, in
the product; and registering written instructions at a desired
location in the product.
[0064] The illustrated training pant 20, which is designed for use
by young girls, includes a registered outer cover graphic 60. In
this design, the registered graphic 60 includes a primary pictorial
image 61, simulated waist ruffles 62, and simulated leg ruffles 64.
The primary pictorial image 61 includes a rainbow, sun, clouds,
animal characters, wagon and balloons. Any suitable design can be
utilized for a training pant intended for use by young girls, so as
to be aesthetically and/or functionally pleasing to them and the
caregiver. The appearance-related components are desirably
positioned on the training pant 20 at selected locations, which can
be carried out using the methods disclosed in U.S. Pat. No.
5,766,389 issued Jun. 16, 1998 to Brandon et al., which is
incorporated herein by reference. The primary pictorial image 61 is
desirably positioned in the front waist region 22 along the
longitudinal centerline of the training pant 20.
[0065] The liquid permeable bodyside liner 42 is illustrated as
overlying the outer cover 40 and absorbent assembly 44, and may but
need not have the same dimensions as the outer cover 40. The
bodyside liner 42 is desirably compliant, soft feeling, and
non-irritating to the child's skin. Further, the bodyside liner 42
can be less hydrophilic than the absorbent assembly 44, to present
a relatively dry surface to the wearer and permit liquid to readily
penetrate through its thickness. Alternatively, the bodyside liner
42 can be more hydrophilic or can have essentially the same
affinity for moisture as the absorbent assembly 44 to present a
relatively wet surface to the wearer to increase the sensation of
being wet. This wet sensation can be useful as a training aid. The
hydrophilic/hydrophobic properties can be varied across the length,
width and depth of the bodyside liner 42 and absorbent assembly 44
to achieve the desired wetness sensation or leakage
performance.
[0066] The bodyside liner 42 can be manufactured from a wide
selection of web materials, such as synthetic fibers (for example,
polyester or polypropylene fibers), natural fibers (for example,
wood or cotton fibers), a combination of natural and synthetic
fibers, porous foams, reticulated foams, apertured plastic films,
or the like. Various woven and nonwoven fabrics can be used for the
bodyside liner 42. For example, the bodyside liner can be composed
of a meltblown or spunbonded web of polyolefin fibers. The bodyside
liner can also be a bondedcarded web composed of natural and/or
synthetic fibers. The bodyside liner can be composed of a
substantially hydrophobic material, and the hydrophobic material
can, optionally, be treated with a surfactant or otherwise
processed to impart a desired level of wettability and
hydrophilicity. For example, the material can be surface treated
with about 0.45 weight percent of a surfactant mixture comprising
Ahcovel N-62 from Hodgson Textile Chemicals of Mount Holly, N.C.
U.S.A. and Glucopan 220UP from Henkel Corporation of Ambler, Pa. in
an active ratio of 3:1. The surfactant can be applied by any
conventional means, such as spraying, printing, brush coating or
the like. The surfactant can be applied to the entire bodyside
liner 42 or can be selectively applied to particular sections of
the bodyside liner, such as the medial section along the
longitudinal centerline.
[0067] A suitable liquid permeable bodyside liner 42 is a nonwoven
bicomponent web having a basis weight of about 27 gsm. The nonwoven
bicomponent can be a spunbond bicomponent web, or a bonded carded
bicomponent web. Suitable bicomponent staple fibers include a
polyethylene/polypropylene bicomponent fiber available from CHISSO
Corporation, Osaka, Japan. In this particular bicomponent fiber,
the polypropylene forms the core and the polyethylene forms the
sheath of the fiber. Other fiber orientations are possible, such as
multi-lobe, side-by-side, end-to-end, or the like.
[0068] The absorbent assembly 44 (FIG. 3) is positioned between the
outer cover 40 and the bodyside liner 42, which components can be
joined together by any suitable means such as adhesives, ultrasonic
bonds, thermal bonds, or the like. The absorbent assembly 44 can be
any structure which is generally compressible, conformable,
non-irritating to the child's skin, and capable of absorbing and
retaining liquids and certain body wastes. The absorbent assembly
44 can be manufactured in a wide variety of sizes and shapes, and
from a wide variety of liquid absorbent materials commonly used in
the art. For example, the absorbent assembly 44 can 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 assembly 44 comprises a matrix of
cellulosic fluff, such as wood pulp fluff, and superabsorbent
hydrogel-forming particles. The wood pulp fluff can be exchanged
with synthetic, polymeric, meltblown fibers or short cut homofil
bicomponent synthetic fibers and natural fibers. The superabsorbent
particles can be substantially homogeneously mixed with the
hydrophilic fibers or can be nonuniformly mixed. The fluff and
superabsorbent particles can also be selectively placed into
desired zones of the absorbent assembly 44 to better contain and
absorb body exudates. The concentration of the superabsorbent
particles can also vary through the thickness of the absorbent
assembly 44. Alternatively, the absorbent assembly 44 can comprise
a laminate of fibrous webs and superabsorbent material or other
suitable means of maintaining a superabsorbent material in a
localized area.
[0069] Suitable superabsorbent materials can be selected from
natural, synthetic, and modified natural polymers and materials.
The superabsorbent materials can be inorganic materials, such as
silica gels, or organic compounds, such as crosslinked polymers,
for example, sodium neutralized polyacrylic acid. Suitable
superabsorbent materials are available from various commercial
vendors, such as Dow Chemical Company located in Midland, Mich.
U.S.A., and Stockhausen GmbH & Co. KG, D-47805 Krefeld, Federal
Republic of Germany. Typically, a superabsorbent material is
capable of absorbing at least about 15 times its weight in water,
and desirably is capable of absorbing more than about 25 times its
weight in water.
[0070] In one embodiment, the absorbent assembly 44 is generally
rectangular in shape, and comprises a blend of wood pulp fluff and
superabsorbent material. One preferred type of pulp is identified
with the trade designation CR1654, available from U.S. Alliance,
Childersburg, Ala. U.S.A., and is a bleached, highly absorbent
sulfate wood pulp containing primarily soft wood fibers and about
16 percent hardwood fibers. As a general rule, the superabsorbent
material is present in the absorbent assembly 44 in an amount of
from about 5 to about 90 weight percent based on total weight of
the absorbent assembly. The absorbent assembly 44 suitably has a
density within the range of about 0.10 to about 0.35 grams per
cubic centimeter. The absorbent assembly 44 may or may not be
wrapped or encompassed by a suitable tissue wrap that may help
maintain the integrity and/or shape of the absorbent assembly.
[0071] The absorbent body 32 can also incorporate other materials
that are designed primarily to receive, temporarily store, and/or
transport liquid along the mutually facing surface with absorbent
assembly 44, thereby maximizing the absorbent capacity of the
absorbent assembly. One suitable material is referred to as a surge
layer (not shown) and comprises a material having a basis weight of
about 50 to about 120 grams per square meter, and comprising a
through-air-bonded-carded web of a homogenous blend of 60 percent 3
denier type T-256 bicomponent fiber comprising a polyester
core/polyethylene sheath and 40 percent 6 denier type T-295
polyester fiber, both commercially available from Kosa Corporation
of Salisbury, N.C. U.S.A.
[0072] As noted previously, the illustrated training pant 20 has
front and back side panels 34 and 134 disposed on each side of the
absorbent body 32. These transversely opposed front side panels 34
and transversely opposed back side panels 134 can be permanently
bonded along attachment lines 66 to the composite structure 33 of
the absorbent body 32 in the respective front and back waist
regions 22 and 24. More particularly, as shown best in FIGS. 2 and
3, the front side panels 34 can be permanently bonded to and extend
transversely beyond the linear side edges 47 of the composite
structure 33 in the front waist region 22, and the back side panels
134 can be permanently bonded to and extend transversely beyond the
linear side edges of the composite structure in the back waist
region 24. The side panels 34 and 134 may be attached using
attachment means known to those skilled in the art such as
adhesive, thermal or ultrasonic bonding. Alternatively, the side
panels 34 and 134 can be formed as a portion of a component of the
composite structure 33. For example, the side panels can comprise a
generally wider portion of the outer cover, the bodyside liner,
and/or another component of the absorbent body. Thus, the pant 20
can include a one-piece chassis, such as an allover stretch outer
cover.
[0073] The illustrated side panels 34 and 134 each define a distal
edge 68 that is spaced from the attachment line 66, a leg end edge
70 disposed toward the longitudinal center of the training pant 20,
and a waist end edge 72 disposed toward a longitudinal end of the
training pant. The leg end edge 70 and waist end edge 72 extend
from the side edges 47 of the composite structure 33 to the distal
edges 68. The leg end edges 70 of the side panels 34 and 134 form
part of the side edges 36 of the absorbent body 32. In the back
waist region 24, the leg end edges 70 are desirably although not
necessarily curved and/or angled relative to the transverse axis 49
to provide greater coverage toward the back of the pant as compared
to the front of the pant. The waist end edges 72 are desirably
parallel to the transverse axis 49. The waist end edges 72 of the
front side panels 34 form part of the front waist edge 38 of the
absorbent body 32, and the waist end edges 72 of the back side
panels 134 form part of the back waist edge 39 of the absorbent
body.
[0074] In particular embodiments for improved fit and appearance,
the side panels 34 and 134 desirably have an average length
dimension measured parallel to the longitudinal axis 48 that is
about 20 percent or greater, and particularly about 25 percent or
greater, of the overall length dimension of the absorbent article,
also measured parallel to the longitudinal axis 48. For example, in
training pants having an overall length dimension of about 54
centimeters, the side panels 34 and 134 desirably have an average
length dimension of about 10 centimeters or greater, such as about
15 centimeters. While each of the side panels 34 and 134 extend
from the waist opening 50 to one of the leg openings 52, the back
side panels 134 have a continually decreasing length dimension
moving from the attachment line 66 to the distal edge 68, as is
best shown in FIGS. 2 and 3.
[0075] Each of the side panels 34 and 134 can include one or more
individual, distinct pieces of material. In particular embodiments,
for example, each side panel 34 and 134 can include first and
second side panel portions that are joined at a seam, or can
include a single piece of material which is folded over upon itself
(not shown). The side panels 34 and 134 desirably although not
necessarily comprise an elastic material capable of stretching in a
direction generally parallel to the transverse axis 49 of the
training pant 20. Solely by way of illustration, suitable elastic
side panels 34 and 134 can be stretchable from about 150 percent to
about 450 percent. This means that a panel having a relaxed length
of 10 millimeters (mm) when stretched 5 mm would have been
stretched 150 percent of its original length. Elastic materials if
provided over the entire front and/or back region of pant 20 could
fit well with lower stretch, for example from about 150 percent to
about 250 percent. In embodiments where the entire front and/or
back region panel is not stretchable, then higher levels of
stretch, for example, about 250 percent to about 450 percent may be
preferred.
[0076] Suitable elastic materials, as well as one process of
incorporating elastic side panels into a training pant, are
described in the following U.S. Pat. No. 4,940,464 issued Jul. 10,
1990 to Van Gompel et al.; U.S. Pat. No. 5,224,405 issued Jul. 6,
1993 to Pohjola; U.S. Pat. No. 5,104,116 issued Apr. 14, 1992 to
Pohjola; and U.S. Pat. No. 5,046,272 issued Sep. 10, 1991 to Vogt
et al.; all of which are incorporated herein by reference. In
particular embodiments, the elastic material comprises a
stretch-thermal laminate, a neck-bonded laminate, a reversibly
necked laminate, or a stretch-bonded laminate material. 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.; all of which are
incorporated herein by reference. Alternatively, the side panel
material may comprise other woven or nonwoven materials, such as
those described above as being suitable for the outer cover 40 or
bodyside liner 42; mechanically prestrained materials; and/or
stretchable but inelastic materials.
[0077] In particular embodiments, one or more of the side panels 34
and 134 can be formed of retractive materials. For example, the
side panels 34 and 134 can be formed of an elastomeric material
that is adapted to retract upon activation by a source of heat,
such as disclosed in U.S. Pat. No. 4,640,726.
[0078] The illustrated training pant 20 includes a fastening system
80 for refastenably securing the training pant about the waist of
the wearer. The illustrated fastening system 80 includes first
fastening components 82 and 83 that are adapted to refastenably
connect to mating second fastening components 84 and 85. In one
embodiment, one surface of each of the first fastening components
82 and 83 comprises a plurality of engaging elements that project
from that surface. The engaging elements of the first fastening
components 82 and 83 are adapted to repeatedly engage and disengage
engaging elements of the second fastening components 84 and 85.
[0079] In one particular embodiment, the first fastening components
82 and 83 each comprise hook type fasteners and the second
fastening components 84 and 85 each comprise complementary loop
type fasteners. In another particular embodiment, the first
fastening components 82 and 83 each comprise loop type fasteners
and the second fastening components 84 and 85 each comprise
complementary hook type fasteners. Although the illustrated
embodiments show the back waist region 24 overlapping the front
waist region 22, which is convenient, the training pant 20 can also
be configured so that the front waist region overlaps the back
waist region.
[0080] Hook type fasteners typically comprise a fabric or material
having a base or backing structure and a plurality of hook members
extending upwardly from at least one surface of the backing
structure. The hook material advantageously comprises a resilient
material to minimize unintentional disengagement of the fastener
components as a result of the hook material becoming deformed and
catching on clothing or other items. The term "resilient" as used
herein refers to an interlocking material having a predetermined
shape and the property of the interlocking material to resume the
predetermined shape after being engaged and disengaged from a
mating, complementary interlocking material. Suitable hook material
can be molded or extruded of nylon, polypropylene or another
suitable material. Suitable single-sided hook materials for the
fastening components 82-85 are available from commercial vendors
such as Velcro Industries B.V., Amsterdam, Netherlands or
affiliates thereof, and are identified as Velcro HTH829 with a
uni-directional hook pattern and having a thickness of about 0.9
millimeters (35 mils) and HTH-851 with a uni-directional hook
pattern and having a thickness of about 0.5 millimeters (20 mils);
and Minnesota Mining & Manufacturing Co., St. Paul, Minn.
U.S.A., including specific materials identified as CS-600. Hook
materials could be made with elastic material with base polymer
such as urethane, KRAYTON or PEBAX.
[0081] In accordance with the present invention, the loop type
fastener is preferably made of a stretchable or extensible material
which may include a stretch bonded laminate, and which may be
elastomeric. In particular embodiments, the loop material can be
mounted to a base of stretchable material so the assembly is
stretchable. Alternatively, the loop material may be a retractable
material which retracts on application of heat as described more
fully below in connection with one particular embodiment.
[0082] With particular reference to FIG. 3, the first fastening
components 82 and 83 are desirably although not necessarily
disposed on the inner surface 28 of the training pant 20 in the
back waist region 24. The first fastening components 82 and 83 are
desirably positioned along the distal edges 68 of the back side
panels 134, and abutting or adjacent to the waist end edge 72. In
certain embodiments, for example, the first fastening components 82
and 83 can be located within about 2 centimeters, and more
particularly within about 1 centimeter, of the distal edges 68, the
waist end edges 72, and the leg end edges 70.
[0083] With particular reference to FIG. 2, the second fastening
components 84 and 85 are desirably although not necessarily
disposed on the outer surface 30 of the training pant 20 in the
front waist region 22, although it is contemplated that the
fastening components can be placed anywhere on the pant so long as
they help to hold the pant on the wearer. The second fastening
components 84 and 85 are sized to receive the first fastening
components 82 and 83 and are desirably positioned along the distal
edges 68 of the front side panels 34, and abutting or adjacent to
the waist end edge 72. In certain embodiments, for example, the
second fastening components 84 and 85 can be located within about 2
centimeters, and more particularly within about 1 centimeter, of
the distal edges 68, the waist end edges 72, and the leg end edges
70. Where the first fastening components 82 and 83 comprise loop
type fasteners disposed on the inner surface 28 and the second
fastening components 84 and 85 comprise hook type fasteners
disposed on the outer surface 30, the first fastening components
can be sized larger than the second fastening components to ensure
coverage of the rigid, outwardly-directed hooks. The loop fastening
components can be integral with the side panels or adhered to the
side panels 34 and 134 by any means known to those skilled in the
art such as adhesive bonds, sonic bonds or thermal bonds. The loop
fastening components can be extensible and bonded to components of
the body 32 in a manner that retains extension and retraction
characteristics of the loop fastening components.
[0084] The fastening components are desirably rectangular, although
they may alternatively be square, round, oval, curved or otherwise
non-rectangularly shaped. In particular embodiments, each of the
fastening components 82-85 defines a length dimension aligned
generally parallel with the longitudinal axis 48 of the training
pant 20 and a width dimension aligned generally parallel with the
transverse axis 49 of the training pant. For a child of about 9 to
about 15 kilograms (20-30 pounds), for example, the length
dimension of the fastening components is desirably from about 5 to
about 13 centimeters, such as about 10 centimeters, and the width
dimension is desirably from about 0.5 to about 3 centimeters, such
as about 1 centimeter. With particular embodiments, the fastening
components can have a length-to-width ratio of about 2 or greater,
such as about 2 to about 25, and particularly about 5 or greater,
such as about 5 to about 8. For other embodiments such as for adult
products, it may be desirable for one or more of the fastening
components to comprise a plurality of relatively smaller fastening
elements. In that case, a fastening component or individual
fastening elements may have an even smaller length-to-width ratio,
for example, of about 2 or less, and even about 1 or less.
[0085] When the fastening components 82-85 are releasably engaged,
the side edges 36 of the absorbent body 32 in the crotch region 26
define the leg openings 52, the waist edges 38 and 39 of the
absorbent body, including the waist end edges 72 of the side
panels, define the waist opening 50, and the waist regions 22 and
24 jointly define a waistband 75 and hip section 77. For improved
formation of the leg openings 52, it can be desirable in some
embodiments for the front side panels 34 to be longitudinally
spaced from the back side panels 134 (see FIGS. 2 and 3). For
example, the front side panels 34 can be longitudinally spaced from
the back side panels 134 by a distance equal to about 20 percent or
greater, particularly from about 20 to about 60 percent, and more
particularly from about 35 to about 50 percent, of the overall
length dimension of the absorbent article.
[0086] When connected, the fastening components 82-85 form
refastenable seams 88 (FIG. 1) that desirably although not
necessarily extend substantially the entire distance between the
waist opening 50 and the leg openings 52. More specifically, the
refastenable seams 88 can cover about 80 to 100 percent, and
particularly about 90 to about 98 percent, of the distance between
the waist opening 50 and each leg opening 52, which distance is
measured parallel to the longitudinal axis 48. To construct the
seams 88 to extend substantially the entire distance between the
waist and leg openings 50 and 52, the fastening components 82-85
can be formed to cover about 80 to 100 percent, and more
particularly about 90 to about 98 percent, of the distance between
the waist end edge 70 and the leg end edge 72 of the side panels 34
and 134. In other embodiments, the fastening components can
comprise a plurality of smaller fastening elements covering a
smaller portion of the distance between the waist opening 50 and
the leg openings 52, for example, about 20 to about 70 percent, but
spaced apart to span a larger percentage of the distance between
the waist opening and the leg openings.
[0087] For the refastenable seams 88 to be located at the sides of
the wearer, it can be particularly desirable for the transverse
distance between the first fastening components 82 and 83 to be
substantially equal to the transverse distance between the second
fastening components 84 and 85. The transverse distance between a
set of fasteners is the distance measured parallel to the
transverse axis 49 between the longitudinal centerlines of the
fasteners, measured with the side panels 34 and 134 in an
unstretched condition. In an alternative embodiment, the training
pant 20 includes only a single second fastening component disposed
in the front waist region 22 for refastenably connecting the first
fastening components 82 and 83 (not shown).
[0088] In a further alternative embodiment illustrated in FIGS. 4
and 5, one or both of the fastening components can comprise
integral portions of the waist regions. For instance, one of the
elastomeric front or back side panels 34 and 134, respectively, can
function as second fastening components in that they can comprise a
material that is releasably engageable with fastening components
disposed in the opposite waist region. As illustrated in FIGS. 4
and 5, the side panels 134 are made completely of stretchable loop
material although, alternatively, these side panels could be made
of loop material only at there outer ends where they will engage
the hook material and the remainder of the side panels can be made
of some other, preferably stretchable, material and joined along
abutting edges thereof.
[0089] FIG. 6 schematically illustrates a flow diagram for
manufacture of one embodiment of a pant according to the present
invention. The components of the pants 20 can be provided and
bonded together in an assembly section 200, typically in the form
of a continuous web of interconnected and partially assembled
pants. The assembly section 200 can include a cutting mechanism
which selectively cuts the web into discrete, partially assembled
training pants.
[0090] The discrete training pants can then be folded at a folding
station 202 using any suitable folding mechanism. The training
pants 102 can be folded about a fold line generally bisecting the
training pants. As such, the waist regions 22 and 24 of each
training pant can be positioned in facing relationship with the
side panels 34 and 134 extending laterally outward relative to the
longitudinal axis 48 of the training pant. The fold line can extend
in a lateral direction through the crotch region 26 of the training
pant. Desirably, the discrete training pants are consistently
folded about the fold line such that the front and back waist edges
38 and 39 of the training pants align with each other.
[0091] The opposed side panels 34 and 134 can also be folded in the
folding section 202. The side panels 34 and 134 can desirably be
folded parallel to the longitudinal centerline of the training
pants so that at least portions of the first and second fastening
components overlap with one another. The side panels 34 and 134 can
alternatively be folded together in conjunction with engagement of
the first and second fastening components 82-85 in a seaming
section 204. The seaming section 204 forms the refastenable seams
88 of the pants 20. Suitable devices to inwardly fold the side
panels 34 and 134 parallel to the longitudinal centerline can
include folding boards, folding skis, paddles, fingers, vacuum
devices, air blasts, mechanical devices with reciprocating motion
such as tuckers, four-bar linkages, slide-crank mechanisms, or the
like and combinations thereof which are preferably adapted to
stretch or extend the fastening component formed of loop material
prior to its being placed on the fastening component formed of hook
material.
[0092] The training pants 20 can be transported to an activation
station 206, which can but need not necessarily follow the seaming
section 204 as illustrated. The activation station 206 can comprise
an activation source such as a heating unit to instigate retraction
of the retractive material in those constructions which use a heat
activated retractive material in any components of the pants 20,
including the loop-type fastening material. It is contemplated that
materials which shrink or contract through other means can also be
utilized in the present invention, such as disclosed in U.S. Pat.
No. 4,883,549, incorporated herein by reference, or simply by slow
responding material. The activation station 206 can comprise a
separate stage of the manufacturing operation or can be
incorporated into another stage. In particular embodiments, the
activation station 206 can be combined with devices such as product
stackers for packaging the pants 20. Suitable devices incorporating
activation mechanisms are disclosed in U.S. Pat. No. 4,640,726
issued Feb. 3, 1987 to Sallee et al. and U.S. Pat. No. 4,663,106
issued May 5, 1987 to Pomplun et al., which are incorporated herein
by reference. In the illustrated embodiment, at least a portion of
the retractive material is activated and caused to retract
subsequent to engagement of the fastening components 82-85. While
the loop-type fastening material was described in particular
embodiments as comprising a retractive material, other components
of the training pant such as distinct elements or portions of the
outer cover, bodyside liner, absorbent assembly, waist elastics,
side panels or fastening components can alternatively or
additionally comprise retractive materials.
[0093] FIG. 7 illustrates a training pant 300 at three stages
during manufacture, denoted with reference numerals 301, 302 and
303. The training pant 300 is similar to the training pant 20 shown
in FIG. 1, although the front side panels 34 are narrower than the
back side panels 134. The training pant 300 at stage 301 has been
folded through the crotch region 26 to overlap the waist regions 22
and 24 and the hip regions. At stage 302, one or both pairs of side
panels 34 and 134 of the training pant 300 can be folded along fold
lines 306 which are parallel to the longitudinal centerline 308 of
the training pant. With the fastening components 82-85 engaged, the
waist regions 22 and 24 define the waistband 75 and hip section 77,
both of which encircle the pant 300 between the crotch region 26
and the waist opening. The waistband 75 is contiguous with the
waist opening 50 (FIG. 1) while the hip section 77 is disposed
between the waistband and the leg openings 52 (FIG. 1). At stage
303, the retractive materials forming the waist elastic members 54
and 56, the side panels 34 and 134, and/or other components, such
as loop-type fastening material, can be activated and the
retractive materials allowed to retract.
[0094] When the training pants 20, or other garment formed in
accordance with the present invention, are manually formed into a
three dimensional garment to fit a wearer, as illustrated in FIG.
1, by manual manipulation as the garment is being placed on the
wearer the fastening components 82 and 83 that contain the loop
material and rear side panels 134 are stretched toward the front
side panels 34 and then applied to the respective hook material 84
and 85 on the front side panels 34. The loop material and side
panels are then released and allowed to contract on the hook
material to produce a mechanical fastener system which exhibits
greater engagement strength than conventional mechanical fastening
systems. Alternatively, it is contemplated that the loop material
can be held under tension and the hook material applied to it or
any other means for causing engagement between the hook and loop
material while the loop material is in an extended or stretched
state and then allowed to retract.
[0095] As discussed above, it is also contemplated that when the
training pants or the like garment are being initially constructed
and folded by machine, the loop material and/or its underlying
support material of the various embodiments described above can be
extended and placed in engagement with the hook material and then
pressed thereon to give an initial construction that is stronger in
the mechanical fastener system than conventional mechanical
fastening systems. Also as mentioned above, in an alternative
embodiment where the garment is constructed and assembled by
machine the loop material may be a retractive material that is
simply placed on the hook material during making of the garment and
then the hook material can be shrunk by an application of heat to
embed the hooks into the loop material. Alternatively, as mentioned
above, the loop material can retract in other ways, such as
temporarily inhibiting retraction of a stretched elastic member as
described in U.S. Pat. No. 4,883,549, or other means such as light
motion, pressure exerted, etc.
[0096] It is believed that the stretch in the loop material
increases the amount of engagement such a fastening system obtains,
reduceing the occurrence of "pop opens" (refastenable side panels
with hook-and-loop disengaging) over conventional hook-and-loop
fasteners.
[0097] It is believed that a wide range of hook-and-loop materials
would be suitable for use in the present invention, so long as the
loop material is sufficiently stretchable to exhibit the desired
enhanced engagement capabilities that produce the desired reduction
in "pop opens" over conventional hook-and-loop fasteners. For
example, in the embodiment of FIGS. 3 and 4, it is desirable that
the loop material side panels exhibit a high stretchability of
approximately 150 to 300 percent although greater stretchability
such as from 300 to 450 percent of at least the loop portion of the
side panel, can be exhibited by the material. In its preferred form
it is desirable that the loop material be constructed of a
extensible material such as but not limited to a stretch bonded
material.
[0098] While the mechanical fastening means of the present
invention are shown and described herein in connection with
children's toilet training pants, it is understood that such
fastening means may be incorporated into various other disposable
absorbent articles, such as diapers, adult incontinence garments,
sanitary napkins and the like, as well as surgical bandages and
sponges, without departing from the scope of the present
invention.
[0099] As various changes could be made in the above constructions
and methods, without departing from the scope of the invention, it
is intended that all matter contained in the above description and
shown in the accompanying drawings shall be interpreted as
illustrative and not in a limiting sense.
[0100] When introducing elements of the present invention or the
preferred embodiment(s) thereof, the articles "a", "an", "the" and
"said" are intended to mean that there are one or more of the
elements. The terms "comprising", "including" and "having" are
intended to be inclusive and mean that there may be additional
elements other than the listed elements.
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