U.S. patent application number 10/750505 was filed with the patent office on 2004-08-26 for methods of folding disposable absorbent articles.
Invention is credited to Nelson, Denise J., Winkel, Paula C..
Application Number | 20040167490 10/750505 |
Document ID | / |
Family ID | 32868005 |
Filed Date | 2004-08-26 |
United States Patent
Application |
20040167490 |
Kind Code |
A1 |
Nelson, Denise J. ; et
al. |
August 26, 2004 |
Methods of folding disposable absorbent articles
Abstract
Methods of folding a protective cover article are described. The
methods described result in a compact protective cover article that
is relatively easy to unfold.
Inventors: |
Nelson, Denise J.;
(Greenville, WI) ; Winkel, Paula C.; (Chilton,
WI) |
Correspondence
Address: |
KIMBERLY-CLARK WORLDWIDE, INC.
401 NORTH LAKE STREET
NEENAH
WI
54956
|
Family ID: |
32868005 |
Appl. No.: |
10/750505 |
Filed: |
December 31, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10750505 |
Dec 31, 2003 |
|
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10366872 |
Feb 14, 2003 |
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Current U.S.
Class: |
604/385.01 |
Current CPC
Class: |
B65D 81/2007 20130101;
B65D 75/30 20130101; B65H 45/04 20130101; A61F 2013/8497 20130101;
B65H 2801/57 20130101; B65D 85/07 20180101; A61F 13/55115 20130101;
B65D 75/58 20130101; A61F 13/15747 20130101; A61F 13/5511
20130101 |
Class at
Publication: |
604/385.01 |
International
Class: |
A61F 013/15; A61F
013/20 |
Claims
What is claimed is:
1. A method of folding a disposable absorbent article, the article
having an initial upper surface, an initial lower surface, a
longitudinal centerline, a transverse centerline, opposing first
longitudinal side edges, opposing first transverse end edges and an
unfolded configuration, the method of folding comprising: forming
one fold extending in a transverse direction by bringing a portion
of the initial upper surface into a facing relationship with
another portion of the initial upper surface, the one fold being
spaced between opposing first transverse end edges, the resulting
partially-folded article having an intermediate first surface, an
intermediate second surface and opposing second transverse end
edges, and thereafter forming a number, greater than one, of
transversely extending folds in an accordion-like manner, the
transversely extending accordion-like folds being spaced between
opposing second transverse end edges.
2. The method described in claim 1, wherein the number of
accordion-like transverse extending folds is an even number.
3. The method described in claim 2, wherein the number of
accordion-like transverse extending folds is 2.
4. The method described in claim 2, wherein the one fold extending
in a transverse direction is located substantially adjacent the
transverse centerline.
5. The method described in claim 4, wherein the accordion-like
transversely extending folds are spaced substantially equally
between opposing second transverse end edges.
6. A disposable absorbent article folded according to the method
described in claim 5 and having a folded configuration, wherein the
folded article has a ratio between the folded configuration and the
unfolded configuration of no more than 0.08.
7. The disposable absorbent article of claim 6, wherein the folded
article is an infant diaper.
8. The method described in claim 1, wherein the accordion-like
transversely extending folds are spaced substantially equally
between opposing second transverse end edges.
9. A disposable absorbent article folded according to the method
described in claim 8 and having a folded configuration, wherein the
folded article has a ratio between the folded configuration and the
unfolded configuration of no more than 0.15.
10. The disposable absorbent article of claim 9, wherein the folded
article has a ratio between the folded configuration and the
unfolded configuration of no less than 0.04.
11. The disposable absorbent article of claim 10, wherein the
folded article is an infant diaper.
12. A method of folding a disposable absorbent article, the article
having an initial upper surface, an initial lower surface, a
longitudinal centerline, a transverse centerline, opposing first
longitudinal side edges, opposing first transverse end edges, side
margins, opposing terminal side edges and an unfolded
configuration, the method of folding comprising: forming at least
one longitudinally extending fold in each side margin by folding
each first longitudinal side edge inward toward the initial upper
surface and thus bringing at least a portion of the initial upper
surface into facing relationship with another portion of the
initial upper surface, then forming one fold extending in a
transverse direction by bringing a portion of the initial upper
surface into a facing relationship with another portion of the
initial upper surface, the one fold being spaced between opposing
first transverse end edges, the resulting partially-folded article
having an intermediate first surface, an intermediate second
surface, opposing second longitudinal side edges and opposing
second transverse end edges, and thereafter forming a number,
greater than one, of transversely extending folds in an
accordion-like manner, the transversely extending accordion-like
folds being spaced between opposing second transverse end
edges.
13. The method described in claim 12, wherein the number of
accordion-like transverse extending folds is an even number.
14. The method described in claim 13, wherein the number of
accordion-like transverse extending folds is 2.
15. The method described in claim 13, wherein the one fold
extending in a transverse direction is located substantially
adjacent the transverse centerline.
16. The method described in claim 15, wherein the accordion-like
transversely extending folds are spaced substantially equally
between opposing second transverse end edges.
17. A disposable absorbent article folded according to the method
described in claim 16 and having a folded configuration, wherein
the folded article has a ratio between the folded configuration and
the unfolded configuration of no more than 0.08.
18. The disposable absorbent article of claim 17, wherein the
folded article is an infant diaper.
19. The method described in claim 12, wherein the accordion-like
transversely extending folds are spaced substantially equally
between opposing second transverse end edges.
20. A disposable absorbent article folded according to the method
described in claim 19 and having a folded configuration, wherein
the folded article has a ratio between the folded configuration and
the unfolded configuration of no more than 0.15.
21. The disposable absorbent article of claim 20, wherein the
folded article has a ratio between the folded configuration and the
unfolded configuration of no less than 0.04.
22. The disposable absorbent article of claim 21, wherein the
folded article is an infant diaper.
23. A disposable absorbent article comprising a topsheet, a
backsheet and an absorbent core situated between the topsheet and
the backsheet, the article having a folded configuration and an
unfolded configuration, the article in the unfolded configuration
having an initial upper surface, an initial, lower surface, a
longitudinal centerline, a transverse centerline, opposing first
longitudinal side edges and opposing first transverse end edges,
the article having a ratio between the folded configuration and the
unfolded configuration of no more than 0.15.
24. The disposable absorbent article of claim 23, wherein the
article has a ratio between the folded configuration and the
unfolded configuration of no less than 0.04
25. The disposable absorbent article of claim 24, wherein the
article is folded according the method comprising: forming one fold
extending in a transverse direction by bringing a portion of the
initial upper surface into a facing relationship with another
portion of the initial upper surface, the one fold being spaced
between opposing first transverse end edges, the resulting
partially-folded article having an intermediate first surface, an
intermediate second surface and opposing second transverse end
edges, and thereafter forming a number, greater than one, of
transversely extending folds in an accordion-like manner, the
transversely extending folds being spaced between opposing second
transverse end edges.
26. The method described in claim 25, wherein the number of
accordion-like transverse extending folds is 2.
27. The method described in claim 26, wherein the one fold
extending in a transverse direction is located substantially
adjacent the transverse centerline.
28. The method described in claim 27, wherein the accordion-like
transversely extending folds are spaced substantially equally
between opposing second transverse end edges.
29. The disposable absorbent article of claim 28, wherein the
folded article is an infant diaper.
30. The disposable absorbent article of claim 23, wherein the
article is folded according the method comprising: forming a
number, greater than two, of transversely extending folds in an
accordion-like manner, the transversely extending folds being
spaced between opposing first transverse end edges.
31. The method described in claim 30, wherein the number of
transversely extending accordion-like folds is 5.
32. The method described in claim 31, wherein the
transversely-extending accordion-like folds are spaced
substantially equally between opposing first transverse end
edges.
33. The disposable absorbent article of claim 32, wherein the
folded article is an infant diaper.
34. The disposable absorbent article of claim 23, wherein the
folded article is an infant diaper having a ratio between the
folded configuration and the unfolded configuration of no more than
0.09.
35. A method of folding a disposable absorbent article, the article
having an initial upper surface, an initial lower surface, a
longitudinal centerline, a transverse centerline, opposing first
longitudinal side edges, opposing first transverse end edges and an
unfolded configuration, the method of folding comprising: forming a
number, greater than two, of transversely extending folds in an
accordion-like manner, the transversely extending folds being
spaced between opposing first transverse end edges.
36. The method described in claim 35, wherein the number of
transversely extending accordion-like folds is an odd number.
37. The method described in claim 35, wherein the number of
transversely extending accordion-like folds is an odd number
greater than 4.
38. The method described in claim 37, wherein the number of
transversely extending accordion-like folds is 5.
39. The method described in claim 38, wherein the
transversely-extending accordion-like folds are spaced
substantially equally between opposing first transverse end
edges.
40. A disposable absorbent article folded according to the method
described in claim 39.
41. The disposable absorbent article of claim 40, wherein the
folded article is an infant diaper.
42. A method of folding a disposable absorbent article, the article
having an initial upper surface, an initial lower surface, a
longitudinal centerline, a transverse centerline, opposing first
longitudinal side edges, opposing first transverse end edges, side
margins, opposing terminal side edges and an unfolded
configuration, the method of folding comprising: forming at least
one longitudinally extending fold in each side margin by folding
each first longitudinal side edge inward toward the initial upper
surface and thus bringing at least a portion of the initial upper
surface into facing relationship with another portion of the
initial upper surface, then forming a number, greater than two, of
transversely extending folds in an accordion-like manner, the
transversely extending folds being spaced between opposing first
transverse end edges.
43. The method described in claim 42, wherein the number of
transversely extending accordion-like folds is an odd number.
44. The method described in claim 42, wherein the number of
transversely extending accordion-like folds is an odd number
greater than 4.
45. The method described in claim 44, wherein the number of
transversely extending accordion-like folds is 5.
46. The method described in claim 45, wherein the
transversely-extending accordion-like folds are spaced
substantially equally between opposing first transverse end
edges.
47. A disposable absorbent article folded according to the method
described in claim 46.
48. The disposable absorbent article of claim 47, wherein the
folded article is an infant diaper.
Description
REFERENCE TO PRIOR APPLICATION
[0001] This is a continuation-in-part of U.S. patent application
Ser. No. 10/366,872, filed Feb. 14, 2003, hereby incorporated
herein by reference.
BACKGROUND
[0002] The present invention relates to methods of folding. More
particularly, the present invention relates to methods of folding
disposable absorbent articles, the methods resulting in folded
disposable absorbent articles that are relatively compact.
[0003] Absorbent articles such as, for example, diapers, training
pants and adult incontinence garments are generally available to
users in packages which include multiple articles therein.
Frequently, these users often encounter situations away from home
which would be satisfied with a single disposable absorbent
article. Users therefore often carry single disposable absorbent
articles about in purses, backpacks, briefcases and other similar
containers until needed. Unfortunately, these containers do not
always provide a hygienic environment for the disposable absorbent
articles, and thus the articles can become dirty and/or damaged.
Another situation arises when users are away from home and forget
to pack even a single disposable absorbent article. These users
typically have no alternative but to purchase multiple disposable
absorbent articles in a single package.
[0004] In view of the foregoing, the manufacturers of disposable
absorbent articles have attempted to enclose a smaller number of
disposable absorbent articles in relatively compact packaging. Many
of these attempts do not address reducing the configuration or
footprint of the disposable absorbent articles, but are instead
limited to reducing only the number of disposable absorbent
articles in a single package. Consequently, there remains a need to
reduce the configuration or footprint of individual disposable
absorbent articles.
SUMMARY
[0005] The present inventors undertook intensive research and
development efforts concerning reducing the configuration or
footprint of individual disposable absorbent articles. While
conducting their research, the present inventors discovered unique
methods of folding disposable absorbent articles that resulted in
folded disposable articles that are more compact and thus well
suited for enclosing in compact packaging. One version of the
present invention involves a disposable absorbent article having an
initial upper surface, an initial lower surface, a longitudinal
centerline, a transverse centerline, opposing first longitudinal
side edges, opposing first transverse end edges and an unfolded
configuration. The article is folded by forming one fold extending
in a transverse direction by bringing a portion of the initial
upper surface into facing relationship with another portion of the
initial upper surface. The one fold so formed is spaced between
opposing first transverse end edges. The resulting partially-folded
article has an intermediate first surface, an intermediate second
surface and opposing second transverse end edges. Thereafter, a
number, greater than one, of transversely extending folds are
formed in an accordion-like manner. The transversely extending
accordion-like folds are spaced between opposing second transverse
end edges.
[0006] Another version of the present invention relates to a
disposable absorbent article having an initial upper surface, an
initial lower surface, a longitudinal centerline, a transverse
centerline, opposing first longitudinal side edges, opposing first
transverse end edges, side margins, opposing terminal side edges
and an unfolded configuration. The article is folded by forming at
least one longitudinally extending fold in each side margin by
folding each first longitudinal side edge inward toward the initial
upper surface and thus bringing at least a portion of the initial
upper surface into facing relationship with another portion of the
initial upper surface. One fold is then formed extending in a
transverse direction by bringing a portion of the initial upper
surface into a facing relationship with another portion of the
initial upper surface. The one fold so formed is spaced between
opposing first transverse end edges. The resulting partially-folded
article has an intermediate first surface, an intermediate second
surface and opposing second transverse end edges. Thereafter, a
number, greater than one, of transversely extending folds are
formed in an accordion-like manner. The transversely extending
accordion-like folds are spaced between opposing second transverse
end edges.
[0007] Yet another version of the present invention involves a
disposable absorbent article having an initial upper surface, an
initial lower surface, a longitudinal centerline, a transverse
centerline, opposing first longitudinal side edges, opposing first
transverse end edges and an unfolded configuration. The article is
folded by forming a number, greater than two, of transversely
extending folds in an accordion-like manner. The transversely
extending accordion-like folds are spaced between opposing first
transverse end edges.
[0008] Still another version of the present invention relates to a
disposable absorbent article having an initial upper surface, an
initial lower surface, a longitudinal centerline, a transverse
centerline, opposing first longitudinal side edges, opposing first
transverse end edges, side margins, opposing terminal side edges
and an unfolded configuration. The article is folded by forming at
least one longitudinally extending fold in each side margin by
folding each first longitudinal side edge inward toward the initial
upper surface and thus bringing at least a portion of the initial
upper surface into facing relationship with another portion of the
initial upper surface. The article is then folded by forming a
number, greater than two, of transversely extending folds in an
accordion-like manner. The transversely extending accordion-like
folds are spaced between opposing first transverse end edges.
[0009] Also disclosed is a disposable absorbent article having a
relatively compact configuration. The disposable absorbent article
has a topsheet, a backsheet and an absorbent core situated between
the topsheet and the backsheet. The article has a folded
configuration and an unfolded configuration. The article in its
unfolded configuration has an initial upper surface, an initial
lower surface, a longitudinal centerline, a transverse centerline,
opposing first longitudinal side edges and opposing first
transverse end edges. The article also has a ratio between its
folded configuration and its unfolded configuration of no more than
0.15.
DRAWINGS
[0010] The foregoing and other features, aspects and advantages of
the present invention will become better understood with regard to
the following description, appended claims and accompanying
drawings where:
[0011] FIG. 1 illustrates a plan view of a disposable absorbent
article in an unfolded, flat-out, uncontracted state (i.e., with
all elastic induced gathering and contraction removed), with the
bodyfacing surface of the article facing the viewer and with
portions of the article partially cut away to illustrate underlying
features;
[0012] FIG. 2 illustrates a plan view of a disposable absorbent
article in an unfolded, flat-out, uncontracted state, with the
garment facing surface of the article facing the viewer and with
portions of the article partially cut away to illustrate underlying
features;
[0013] FIG. 3 illustrates a plan view of a disposable absorbent
article in an unfolded, flat-out, uncontracted state, with the
bodyfacing surface of the article facing the viewer;
[0014] FIG. 4 illustrates a plan view of a disposable absorbent
article with the first longitudinal side edges being folded in
toward the longitudinal centerline;
[0015] FIG. 5 illustrates a plan view of a disposable absorbent
article in an unfolded, flat-out, uncontracted stated, with the
bodyfacing surface of the article facing the viewer;
[0016] FIG. 6 illustrates a side view of the disposable absorbent
article of FIG. 5, when viewed from a transverse end edge;
[0017] FIG. 7 illustrates a perspective view of a partially-folded
disposable absorbent article;
[0018] FIG. 8 illustrates a side view of a partially-folded
disposable absorbent article;
[0019] FIG. 9 illustrates a top plan view of an intermediate first
surface of a partially-folded disposable absorbent article;
[0020] FIG. 10 illustrates a further folding of a partially-folded
disposable absorbent article;
[0021] FIG. 11 illustrates a disposable absorbent article having a
number of folds in an accordion-like manner;
[0022] FIG. 12 illustrates the disposable absorbent article of FIG.
10 in a folded configuration;
[0023] FIG. 13 illustrates the disposable absorbent article of FIG.
10 in a folded configuration;
[0024] FIG. 14 illustrates a top plan view of an outer panel of a
folded disposable absorbent article;
[0025] FIG. 15 illustrates a folding of a disposable absorbent
article;
[0026] FIG. 16 illustrates the disposable absorbent article of FIG.
15 in a folded configuration; and
[0027] FIG. 17 illustrates the disposable absorbent article of FIG.
15 in a folded configuration.
DESCRIPTION
[0028] The present invention relates to methods of folding
disposable absorbent articles. While the various versions of the
present invention are described in terms of a disposable absorbent
article such as an infant diaper, the invention is equally
applicable to other disposable absorbent articles such as
children's training pants, adult incontinence garments and the
like.
[0029] Referring now to the drawings, FIG. 1 illustrates a
disposable absorbent article such as a disposable diaper (30) in an
unfolded, flat-out, uncontracted state (i.e., with all elastic
induced gathering and contraction removed). Portions of the
structure are partially cut away to more clearly show the interior
construction of the diaper (30), with the surface of the diaper
which contacts the wearer facing the viewer. FIGS. 1 and 2
illustrate a disposable diaper (30) as having a front portion (32),
a rear portion (34) and a crotch portion (36) located between the
front and rear portions. The diaper (30) includes a backsheet (38),
a topsheet (40), and an absorbent core (42) situated between the
backsheet and the topsheet. The outer edges of the diaper (30)
define a periphery (44) with transversely opposed, longitudinally
extending first side edges (46); longitudinally opposed,
transversely extending first end edges (48); and a system of
elastomeric gathering members, such as a system including leg
elastics (50) and waist elastics (52). The longitudinal side edges
(46) define the leg openings (54) for the diaper (30), and
optionally, are curvilinear and contoured. The first transverse end
edges (48) are illustrated as straight, but optionally, may be
curvilinear. The diaper (30) may also include additional components
to assist in the acquisition, distribution and storage of bodily
waste. For example, the diaper (30) may include a transport layer,
such as described in U.S. Pat. No. 4,798,603, issued to Meyer et
al. (attorney docket number 8,263), or a surge management layer,
such as described in European Patent Application Publication No. 0
539 703 (attorney docket number 9,922), published May 5, 1993.
[0030] With regard to the designated surfaces of a disposable
absorbent article and its components, the various upper or
bodyfacing surfaces are configured to face toward the body of the
wearer when the absorbent article is worn by the wearer for
ordinary use. The various opposing or lower surfaces are configured
to face away from the wearer's body when the absorbent article is
worn by the wearer.
[0031] The diaper (30) generally defines a longitudinally extending
length dimension (56), and a laterally extending width dimension
(58), as representatively illustrated in FIG. 1. The diaper may
have any desired shape, such as rectangular, I-shaped, a generally
hourglass shape, or a T-shape.
[0032] The backsheet (38) defines a length and a width which, in
the illustrated version, coincide with the length and width of the
diaper (30). The absorbent core (42) generally defines a length and
width which are less than the length and width of the backsheet
(38), respectively. Thus, marginal portions of the diaper (30),
such as marginal sections of the backsheet (38), may extend past
the transversely opposed, longitudinally extending terminal side
edges (60) and/or the longitudinally opposed, transversely
extending terminal end edges (62) of the absorbent core (42) to
form side margins (64) and end margins (66) of the diaper. The
topsheet (40) is generally coextensive with the backsheet (38), but
may optionally cover an area which is larger or smaller than the
area of the backsheet, as desired. The backsheet (38) and topsheet
(40) are intended to face the garment and body of the wearer,
respectively, while in use. As used herein when describing the
topsheet (40) in relation to the backsheet (38) and vice versa, the
term "associated" encompasses configurations in which the topsheet
is directly joined to the backsheet, and configurations where the
topsheet is indirectly joined to the backsheet by affixing portions
of the topsheet to intermediate members which in turn are affixed
to at least portions of the backsheet. The topsheet (40) and the
backsheet (38) can, for example, be joined to each other in at
least a portion of the diaper periphery (44) by attachment
mechanisms (not shown) such as adhesive bonds, sonic bonds, thermal
bonds, pinning, stitching, or a variety of other attachment
techniques known in the art, as well as combinations thereof.
[0033] The topsheet (40) suitably presents a bodyfacing surface
which is compliant, soft feeling, and non-irritating to the
wearer's skin. Further, the topsheet (40) may be less hydrophilic
than the absorbent core (42), to present a relatively dry surface
to the wearer, and is sufficiently porous to be liquid permeable,
permitting liquid to readily penetrate through its thickness. A
suitable topsheet (40) may be manufactured from a wide selection of
web materials, such as porous foams, reticulated foams, apertured
plastic films, natural fibers (for example, polyester or
polypropylene fibers), or a combination of natural and synthetic
fibers. The topsheet (40) is suitably employed to help isolate the
wearer's skin from liquids held in the absorbent core (42).
[0034] Various woven and nonwoven fabrics may be used for the
topsheet (40). For example, the topsheet (40) may be composed of a
meltblown or spunbonded web of polyolefin fibers. The topsheet (40)
may also be a bonded-carded web composed of natural and/or
synthetic fibers. The topsheet (40) 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. Specifically, the topsheet (40) may be a nonwoven,
spunbond, polypropylene fabric composed of about 2.8 to about 3.2
denier fibers formed into a web having a basis weight of about 22
gsm and a density of about 0.06 g/cc.
[0035] The topsheet (40) may also be surface treated with about 0.3
weight percent of a surfactant mixture that contains a mixture of
AHCOVEL Base N-62 surfactant and GLUCOPON 220UP surfactant in about
a 3:1 ratio based on a total weight of the surfactant mixture. The
AHCOVEL Base N-62 surfactant is purchased from Hodgson Textile
Chemicals Inc., a business having offices in Mount Holly, N.C., and
includes a blend of hydrogenated ethoxylated castor oil and
sorbitan monooleate in a 55:45 weight ratio. The GLUCOPON 220UP
surfactant is purchased from Henkel Corporation, Gulph Mills, Pa.,
and includes alkyl polyglycoside. The surfactant may also include
additional ingredients such as aloe. The surfactant may be applied
by any conventional means, such as spraying, printing, brush
coating, foam or the like. The surfactant may be applied to the
entire topsheet (40) or may be selectively applied to particular
sections of the topsheet, such as the medial section along the
longitudinal centerline of a diaper, to provide greater wettability
of such sections.
[0036] The backsheet (38) may suitably be composed of a material
which is either liquid permeable or liquid impermeable. It is
generally desirable that the backsheet (38) be formed from a
material which is substantially liquid impermeable. For example, a
typical backsheet (38) can be manufactured from a thin plastic film
or other flexible liquid impermeable material. Moreover, the
backsheet (38) may be formed from a polyethylene film having a
thickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0
mils). If desirous of presenting the backsheet (38) with a more
cloth-like feel, the backsheet may include a polyethylene film
having laminated to the lower or opposing surface thereof a
nonwoven web, such as a spunbond web of polyolefin fibers. For
example, a polyethylene film having a thickness of about 0.015 mm
(0.6 mil) may have thermally laminated thereto a spunbond web of
polyolefin fibers, which fibers have a thickness of about 1.5 to
about 2.5 denier per filament, which nonwoven web has a basis
weight of about 24 gsm (0.7 osy). Methods of forming such
cloth-like outer covers are known to those skilled in the art.
[0037] Further, the backsheet (38) 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 (42). Still further, the backsheet (38) may
optionally be composed of micro-porous "breathable" material which
permits vapors to escape from the absorbent core (42) while still
preventing liquid exudates from passing through the backsheet.
[0038] The absorbent core (42) may include 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 version, the absorbent core (42) includes
a mixture of superabsorbent hydrogel-forming particles and wood
pulp fluff. 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 non-uniformly mixed.
[0039] The absorbent core (42) may have any of a number of shapes.
For example, the absorbent core (42) may be rectangular, I-shaped
or T-shaped. It is often considered as desirable for the absorbent
core (42) to be narrower in the crotch portion than the rear or
front portion(s).
[0040] 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.
[0041] 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. Processes for preparing synthetic, absorbent
gelling polymers are disclosed in U.S. Pat. No. 4,076,663, issued
to Masuda et al., and U.S. Pat. No. 4,286,082, issued to
Tsubakimoto et al.
[0042] The high-absorbency material may be in a variety of
geometric forms. It is desired 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. Often, the high-absorbency material is
present in the absorbent core (42) in an amount of from about 5 to
about 100 weight percent based on total weight of the absorbent
core.
[0043] Referring now to FIGS. 3-6, in its unfolded condition a
disposable absorbent article, in this instance a diaper (30), has
an initial upper surface (70), an initial lower surface (72), a
longitudinal centerline (74), a transverse centerline (76),
opposing first longitudinal side edges (46), opposing first
transverse end edges (48), opposing longitudinal terminal side
edges (60), and opposing transverse terminal end edges (62).
[0044] The diaper (30) may be suitably folded by forming one fold
extending in a transverse direction. The one fold is formed by
bringing a portion of the initial upper surface (70) into facing
relationship with another portion of the initial upper surface, an
example of which is illustrated in FIG. 7. The one fold extends in
a transverse direction and runs generally parallel to the
transverse centerline (76) of the diaper (30). Moreover, the one
fold extending in the transverse direction may be spaced
substantially equally between the first transverse end edges (48)
or unequally between the first transverse end edges. Typically, the
initial upper surface (70) is the topsheet (40); however, one of
skill in the art will readily appreciate that the initial upper
surface may alternatively be the backsheet (38). The formation of
the one fold extending in the transverse direction results in a
partially-folded diaper (78). As illustrated in FIGS. 7-10, the
partially-folded diaper (78) has an intermediate first surface
(80), an intermediate second surface (82), opposing first
longitudinal side edges (46) and opposing second transverse end
edges (84). The partially-folded diaper (78) is thereafter further
folded by forming a number, greater than one, of transversely
extending folds in an accordion-like manner. The accordion-like
folds extend in a transverse direction and run generally parallel
to the transverse centerline (76) of the diaper (30). The
transversely extending accordion-like folds are spaced between
opposing second transverse end edges (84). The accordion-like folds
extending in the transverse direction may be spaced substantially
equally between the second transverse end edges (84) or unequally
between the second transverse end edges. For clarification
purposes, FIG. 11 illustrates an article having five accordion-like
folds. The number of transversely extending accordion-like folds is
typically greater than one. Desirably, the number of transversely
extending accordion-like folds is an even number greater than one.
Even more desirably, the number of transversely extending
accordion-like folds is 2. As illustrated in FIGS. 12 and 13, the
diaper (88) has a folded configuration (similar in shape to the
letter "S" and thus also referred to herein as the "S" folded
configuration), a first outer panel (90) and a second outer panel
(92). Referring to FIGS. 13 and 14, each outer panel (90, 92)
typically has a major surface (94), a minor surface (96), and a
periphery (98). Desirably, the backsheet (38) comprises a
substantial portion of the major surface (94) of each outer panel
(90, 92) of the disposable absorbent article folded according to
this version. However, one of skill in the art will readily
appreciate that the topsheet (40) may comprise a substantial
portion of the major surface (94) of each outer panel (90, 92) of
the disposable absorbent article folded according to this
version.
[0045] Another version of the present invention provides for a
diaper (30) to be folded by forming at least one longitudinally
extending fold in each of the side margins (64), an example of
which is illustrated in FIG. 4. The longitudinally extending folds
are usually formed by folding the first longitudinal side edges
(46) inward toward the initial upper surface (70) and thus bringing
at least a portion of the initial upper surface into facing
relationship with another portion of the initial upper surface.
Each longitudinally extending fold so formed is typically inboard
of the original positioning of the respective first longitudinal
side edge (46) and either on or outboard of the respective
longitudinal terminal side edge (60) of the absorbent core (42).
The diaper (30) is further folded by forming one fold extending in
a transverse direction. The one fold is formed by bringing a
portion of the initial upper surface (70) into facing relationship
with another portion of the initial upper surface, an example of
which is illustrated in FIG. 7. The one fold extends in a
transverse direction and runs generally parallel to the transverse
centerline (76) of the diaper (30). Moreover, the one fold
extending in the transverse direction may be spaced substantially
equally between the first transverse end edges (48) or unequally
between the first transverse end edges. Typically, the initial
surface (70) is the topsheet (40); however, one of skill in the art
will readily appreciate that the initial upper surface may
alternatively be the backsheet (38). The formation of the one fold
extending in the transverse direction results in a partially-folded
diaper (78). As illustrated in FIGS. 7-10, the partially-folded
diaper (78) has an intermediate first surface (80), an intermediate
second surface (82), opposing second longitudinal side edges (47)
and opposing second transverse end edges (84). The partially-folded
diaper (78) is thereafter further folded by forming a number,
greater than one, of transversely extending folds in an
accordion-like manner. The accordion-like folds extend in a
transverse direction and run generally parallel to the transverse
centerline (76) of the diaper (30). The transversely extending
accordion-like folds are spaced between opposing second transverse
end edges (84). Moreover, the accordion-like folds extending in the
transverse direction may be spaced substantially equally between
the second transverse end edges (84) or unequally between the
second transverse end edges. For clarification purposes, FIG. 11
illustrates an article having five accordion-like folds. The number
of transversely extending accordion-like folds is typically greater
than one. Desirably, the number of transversely extending
accordion-like folds is an even number greater than one. Even more
desirably, the number of transversely extending accordion-like
folds is 2. As illustrated in FIGS. 12 and 13, the diaper (88) has
a folded configuration (similar in shape to the letter "S" and thus
also referred to herein as the "S" folded configuration), a first
outer panel (90) and a second outer panel (92). Referring to FIGS.
13 and 14, each outer panel (90, 92) typically has a major surface
(94), a minor surface (96), and a periphery (98). Desirably, the
backsheet (38) comprises a substantial portion of the major surface
(94) of each outer panel (90, 92) of the disposable absorbent
article folded according to this version. However, one of skill in
the art will readily appreciate that the topsheet (40) may comprise
a substantial portion of the major surface (94) of each outer panel
(90, 92) of the disposable absorbent article folded according to
this version.
[0046] Still another version of the present invention provides for
a diaper (30) to be folded by forming a number of transversely
extending folds in an accordion-like manner. For clarification
purposes, FIG. 15 illustrates a disposable absorbent article having
a number of folds in an accordion-like manner. The number of
transversely extending accordion-like folds is typically greater
than two. Desirably, the number of transversely extending
accordion-like folds is an odd number greater than four.
Alternatively, the number of transversely extending accordion-like
folds is five. The transversely extending accordion-like folds run
in a direction generally parallel to the transverse centerline (76)
of the diaper (30). Moreover, the transversely extending folds may
be spaced substantially equally between the opposing first
transverse end edges (48) or unequally between the transverse end
edges. As illustrated in FIGS. 16 and 17, the folded diaper has a
first outer panel (90) and a second outer panel (92). Referring to
FIGS. 14 and 17, each outer panel (90, 92) typically has a major
surface (94), a minor surface (96) and a periphery (98). Desirably,
the backsheet (38) comprises a substantial portion of the major
surface (94) of each outer panel (90, 92) of the disposable
absorbent article folded according to this version. However, one of
skill in the art will readily appreciate that the topsheet (40) may
comprise a substantial portion of the major surface (94) of each
outer panel (90, 94) of the disposable absorbent article folded
according to this version.
[0047] In yet another version of the present invention, a diaper
(30) is folded by forming at least one longitudinally extending
fold in each of the side margins (64), an example of which is
illustrated in FIG. 4. The longitudinally extending folds are
usually formed by folding the first longitudinal side edges (46)
inward toward the initial upper surface (70) and thus bringing at
least a portion of the initial upper surface into facing
relationship with another portion of the initial upper surface.
Each longitudinally extending fold so formed is typically inboard
of the original positioning of the respective first longitudinal
side edge (46) and either on or outboard of the respective
longitudinal terminal side edge (60) of the absorbent core (42).
Typically, the initial surface (70) is the topsheet (40); however,
one of skill in the art will readily appreciate that the initial
upper surface may alternatively be the backsheet (38). The diaper
(30) is further folded by forming a number of transversely
extending folds in an accordion-like manner. For clarification
purposes, FIG. 15 illustrates a disposable absorbent article having
a number of folds in an accordion-like manner. The number of
transversely extending accordion-like folds is typically greater
than two. Desirably, the number of transversely extending
accordion-like folds is an odd number greater than four.
Alternatively, the number of transversely extending accordion-like
folds is five. The transversely extending accordion-like folds run
in a direction generally parallel to the transverse centerline (76)
of the diaper (30). Moreover, the transversely extending
accordion-like folds may be spaced substantially equally between
the opposing first transverse end edges (48) or unequally between
the transverse end edges. As illustrated in FIGS. 16 and 17, the
folded diaper has a first outer panel (90) and a second outer panel
(92). Referring to FIGS. 14 and 17, each outer panel (90, 92)
typically has a major surface (94), a minor surface (96) and a
periphery (98). Desirably, the backsheet (38) comprises a
substantial portion of the major surface (94) of each outer panel
(90, 92) of the disposable absorbent article folded according to
this version. However, one of skill in the art will readily
appreciate that the topsheet (40) may comprise a substantial
portion of the major surface (94) of each outer panel (90, 92) of
the disposable absorbent article folded according to this
version.
[0048] The term "inboard" is intended to refer to the direction
from a periphery or an edge toward a respective centerline. The
term "outboard" is intended to refer to a direction away from a
respective centerline.
[0049] The disposable absorbent articles folded according to the
present invention will desirably have a relatively compact
configuration. Specifically, the area or footprint of a folded
disposable absorbent article is compared to the area or footprint
of the unfolded disposable absorbent in its flat-out, uncontracted
state (i.e., with all elastic induced gathering and contraction
removed). The method of comparing the folded footprint to the
unfolded footprint is described in the Examples that follow. Table
1 summarizes the results obtained from this comparison. Desirably,
the ratio between the folded configuration and the unfolded
configuration is no more than 0.15; alternatively, no more than
0.14; alternatively, no more than 0.13; alternatively, no more than
0.12; alternatively, no more than 0.11; alternatively, no more than
0.10; alternatively, no more than 0.09; alternatively, no more than
0.08; alternatively, no more than 0.07; alternatively, no more than
0.06; and finally, alternatively, no more than 0.05. Desirably, the
ratio between the folded configuration and the unfolded
configuration is no less than 0.04; alternatively, no less than
0.05; alternatively, no less than 0.06; alternatively, no less than
0.07; alternatively, no less than 0.08; alternatively, no less than
0.09; alternatively, no less than 0.10; alternatively, no less than
0.11; alternatively, no less than 0.12; alternatively, no less than
0.13; and finally, alternatively, no less than 0.14. Thus, the
ratio between the folded and unfolded configuration of a disposable
absorbent article typically is no less than 0.04 and no more than
0.15; although the approximate ratio may vary according to, inter
alia, the general design and intended use of the disposable
absorbent article.
[0050] Disposable absorbent articles folded according to any of the
methods of the present invention are relatively compact.
Consequently, these compact folded articles are well suited for
incorporation into a variety of packaging, including compact
packaging that is suitable for use by consumers in purses,
backpacks, briefcases and other similar containers until
needed.
EXAMPLES
[0051] The following Examples describe various versions of the
invention. Other versions within the scope of the claims herein
will be apparent to one skilled in the art from consideration of
the specification or practice of the invention as disclosed herein.
It is intended that the specification, together with the Examples,
be considered exemplary only, with the scope and spirit of the
invention being indicated by the claims which follow the
Examples.
Example 1
[0052] A diaper (HUGGIES.RTM. ULTRATRIM.RTM. Step 3 diaper,
available from Kimberly-Clark Corporation, Neenah, Wis.) was
produced which is similar to the disposable absorbent articles
described in detail herein. The diaper was configured to fit an
infant weighing about 16 to about 28 pounds. The diaper was folded
by hand as illustrated in FIG. 12 and described previously in
detail herein, in the "S" fold configuration, and positioned in a
cavity formed from a material, namely, 611K-3 mil nylon with LLDPE
coextrusion, available from Curwood, New London, Wis., having at
least one layer of a substantially low gas permeability or one
layer of a substantially gas impermeable material, which was formed
and positioned in a horizontal form/fill/seal packaging machine, in
this instance, a RapidPak RP-55, manufactured by Alkar-Rapidpak,
Inc., Lodi, Wis. The top material, that is, the sealing cover, also
having at least one substantially gas impermeable layer, was a 48
gauge polyester film with 2 mils HDPE peel seal (coextrusion),
available from Curwood, New London, Wis. The top material was
provided as a "peel back" material for a caregiver's convenience,
and it was thermally sealed over the cavity while the cavity with
the folded diaper therein was positioned in the vacuum chamber and
a vacuum pressure in a range of about 20 to about 25 inches of
Mercury relative to the existing atmospheric pressure was removed
from the chamber. The chamber was then returned to existing
atmospheric pressure, which resulted in compression of the package
and the folded absorbent article therein. The packaged article was
then removed from the chamber.
[0053] The dimensions of the S-folded diaper in its package were
then compared to the unfolded dimensions of the Step 3 diaper
disclosed in Example 4, which was measured as described in detail
in Example 1A. The dimensions of the S-folded diaper in its package
were then measured. The width was 4.250 inches and the length was
2.500 inches. The area of the perimeter or "footprint" was 10.625
inches.sup.2. The depth was 0.750 inches. The volume was 7.969
inches.sup.3. The ratio of the footprint of the S folded vacuum
packaged diaper compared to its unfolded footprint was 0.06. The
measurement did not include any portion of the package which
extended beyond the perimeter of the diaper, but only the diaper
contained within. As compared to the S folded but un-packaged
diaper of Example 4B, the present vacuum packaging diaper only had
about 78 percent of the area of the unpackaged S folded diaper of
Example 4B (an about 22 percent reduction in area), and only had
about 55 percent of the volume of the unpackaged S folded diaper of
Example 4B (an about 45 percent reduction in volume).
1TABLE 1 Diaper Dimensions Dimensions (in.) Area Volume Width
Length Depth (in..sup.2) (in..sup.3) Ratio* HUGGIES .RTM. ULTRATRIM
.RTM. PREEMIE Flat/Unfolded 99.59 Bifold (Example 1A) 3.750 5.750
0.329 21.56 7.094 0.217 S-Fold (Example 1B) 3.750 2.000 0.988 7.50
7.410 0.075 HUGGIES .RTM. ULTRATRIM .RTM. STEP 1 Flat/Unfolded
128.61 Bifold (Example 2A) 4.000 6.625 0.343 26.50 9.100 0.206
S-Fold (Example 2B) 4.000 2.500 1.028 10.00 10.280 0.078 HUGGIES
.RTM. ULTRATRIM .RTM. STEP 2 Flat/Unfolded 153.36 Bifold (Example
3A) 4.125 7.500 0.350 30.94 10.828 0.202 S-Fold (Example 3B) 4.125
2.750 1.050 11.34 11.910 0.074 HUGGIES .RTM. ULTRATRIM .RTM. STEP 3
Flat/Unfolded 172.6 Bifold (Example 4A) 4.500 8.250 0.354 37.13
13.142 0.215 S-Fold (Example 4B) 4.500 3.000 1.063 13.50 14.351
0.078 HUGGIES .RTM. ULTRATRIM .RTM. STEP 4 Flat/Unfolded 208.41
Bifold (Example 5A) 4.0625 9.375 0.375 38.09 14.282 0.183 S-Fold
(Example 5B) 4.0625 3.375 1.125 13.71 14.425 0.066 HUGGIES .RTM.
ULTRATRIM .RTM. STEP 5 Flat/Unfolded 231.59 Bifold (Example 6A)
4.375 9.625 0.383 42.11 16.128 0.182 S-Fold (Example 6B) 4.375
3.250 1.150 14.22 16.352 0.061 HUGGIES .RTM. ULTRATRIM .RTM. STEP 6
Flat/Unfolded 265.52 Bifold (Example 7A) 4.500 10.375 0.399 46.69
18.628 0.176 S-Fold (Example 7B) 4.500 3.750 1.197 16.88 20.199
0.064 *Folded to Unfolded Area
Example 1A
[0054] A diaper (HUGGIES.RTM. ULTRATRIM.RTM. diaper, available from
Kimberly-Clark Corporation, Neenah, Wis.) which is similar to the
disposable absorbent article described herein was utilized in this
Example. The diaper was a "preemie" size, configured to fit a
premature infant. The diaper was positioned in its unfolded
configuration, i.e., it's laid flat with unretracted elastics and
extended to ungathered length configuration, and, as disclosed in
Table 1, the diaper was measured to have an area or "footprint" of
99.59 inches.sup.2. The area was determined as described below.
[0055] A rectangular sheet of translucent paper large enough to
cover the absorbent article was obtained and utilized. The length
and width of the sheet was measured to the nearest 0.01 inch. The
paper was then weighed to the nearest 0.001 gram. The weight
measurement was divided by the area measurement to determine the
basis weight of the paper. The article, in this instance, the
diaper, was opened completely, including any fasteners, and
positioned in the laid flat configuration described above, on a
planar surface. The article was taped to the surface using masking
tape. For other disposable absorbent articles, such as training
pants and adult incontinence pants, the articles were cut on each
side between the leg openings and the waist opening prior to being
positioned and taped to the planar surface. The sheet was
positioned over and upon the disposable absorbent article, and a
tracing of the outer perimeter, including fasteners, was made on
the sheet. The paper was then cut along the traced line and
weighed. The weight of the paper was multiplied by the inverse of
the basis weight obtained previously. The result was an estimate of
the total square inches of the absorbent article, which was
reported to the nearest 0.01 in.sup.2.
[0056] The diaper was then folded into the bifolded configuration
illustrated in FIG. 7 by hand. The dimensions of the bifolded
diaper were then measured. That is, the diaper was positioned on a
planar surface and restrained by hand, if necessary, in the folded
position, while the length measurement 138 and the width
measurement 140 were obtained and recorded.
[0057] The depth measurement 142 was obtained by measuring a
standard packaged bag of articles, that is, in this instance, a bag
containing bifolded diapers. The height of the bag was divided by
the total number of panels (for example, in a bag of 24 bifolded
diapers, there are 48 panels; diapers in the bag were packaged in
the bag horizontally relative to the top height of the bag). These
numbers were recorded. All measurements relating to diapers are in
Tables 1 and 4.
[0058] As disclosed in Table 1, the width was 3.750 inches and the
length was 5.750 inches. The area or "footprint" was 21.56
inches.sup.2. The calculated depth was 0.329 inches.sup.2. The
volume was 7.094 inches.sup.3. The ratio of the footprint of the
bifolded diaper compared to its unfolded footprint was 0.217.
Example 1B
[0059] A diaper (HUGGIES.RTM. ULTRATRIM.RTM.) which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "preemie" size, configured for a
premature infant. The diaper was positioned in its completely
unfolded configuration, and as disclosed in Example 1A. As
disclosed in Table 1, the diaper was measured to have an area or
"footprint" of 99.59 inches.sup.2. The diaper was folded into the
"S" folded configuration illustrated in FIG. 12 by hand, and was
measured in the same manner as described in Example 1A.
[0060] As disclosed in Table 1, the width was 3.75 inches and the
length was 2.000 inches. The area or "footprint" was 7.50
inches.sup.2. The calculated depth was 0.988 inches. The volume was
7.410 inches.sup.3. The ratio of the footprint of the "S" folded
diaper compared to its unfolded footprint was 0.075.
Example 2A
[0061] A diaper (HUGGIES.RTM. ULTRATRIM.RTM.) which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 1" size, configured to fit an
infant having a weight of about 8 to about 14 pounds. The diaper
was positioned in its completely unfolded configuration, as
described in Example 1A. As disclosed in Table 1, the diaper was
measured to have an area or "footprint" of 128.61 inches.sup.2. The
diaper was folded into the bifolded configuration illustrated in
FIG. 7 by hand, and it was measured in the same manner as described
in Example 1A.
[0062] As disclosed in Table 1, the width was 4.000 inches and the
length was 6.625 inches. The area or "footprint" was 26.50
inches.sup.2. The calculated depth was 0.343 inches. The volume was
9.100 inches.sup.3. The ratio of the footprint of the bifolded
diaper compared to its unfolded footprint was 0.206.
Example 2B
[0063] A diaper (HUGGIES.RTM. ULTRATRIM.RTM.) which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 1" size, configured to fit an
infant having a weight of about 8 to about 14 pounds. The diaper
was positioned in its completely unfolded configuration, described
in Example 1A. As disclosed in Table 1, the diaper was measured to
have an area or "footprint" of 128.61 inches.sup.2. The diaper was
folded into the "S" folded configuration illustrated in FIG. 12 by
hand, and it was measured in the same manner as described in
Example 1A.
[0064] As disclosed in Table 1, the width was 4.000 inches and the
length was 2.500 inches. The area or "footprint" was 10.000
inches.sup.2. The calculated depth was 1.028 inches. The volume was
10.280 inches.sup.3. The ratio of the footprint of the "S" folded
diaper compared to its unfolded footprint was 0.078.
Example 3A
[0065] A diaper (HUGGIES.RTM. ULTRATRIM.RTM.) which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 2" size, configured to fit an
infant having a weight of about 12 to about 18 pounds. The diaper
was positioned in its completely unfolded configuration, as
described in Example 1A. As disclosed in Table 1, the diaper was
measured to have an area or "footprint" of 153.36 inches.sup.2. The
diaper was folded into the bifolded configuration illustrated in
FIG. 7 by hand, and it was measured in the same manner as described
in Example 1A.
[0066] As disclosed in Table 1, the width was 4.125 inches and the
length was 7.500 inches. The area or "footprint" was 30.94
inches.sup.2. The calculated depth was 0.350 inches. The volume was
10.828 inches.sup.3. The ratio of the footprint of the bifolded
diaper compared to its unfolded footprint was 0.202.
Example 3B
[0067] A diaper (HUGGIES.RTM. ULTRATRIM.RTM.) which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 2" size, configured to fit an
infant having a weight of about 12 to about 18 pounds. The diaper
was positioned in its completely unfolded configuration, as
described in Example 1A. As disclosed in Table 1, the diaper was
measured to have an area or "footprint" of 153.36 inches.sup.2. The
diaper was folded into the "S" folded configuration illustrated in
FIG. 12 by hand, and it was measured in the same manner as
described in Example 1A.
[0068] As disclosed in Table 1, the width was 4.125 inches and the
length was 2.750 inches. The area or "footprint" was 11.34
inches.sup.2. The calculated depth was 1.050 inches. The volume was
11.910 inches.sup.3. The ratio of the footprint of the "S" folded
diaper compared to its unfolded footprint was 0.074.
Example 4A
[0069] A diaper (HUGGIES.RTM. ULTRATRIM.RTM.) which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 3" size, configured to fit an
infant having a weight of about 16 to about 28 pounds. The diaper
was positioned in its completely unfolded configuration, as
described in Example 1A. As disclosed in Table 1, the diaper was
measured to have an area or "footprint" of 172.6 inches.sup.2. The
diaper was folded into the bifolded configuration illustrated in
FIG. 7 by hand, and it was measured in the same manner as described
in Example 1A.
[0070] As disclosed in Table 1, the width was 4.500 inches and the
length was 8.250 inches. The area or "footprint" was 37.13
inches.sup.2. The calculated depth was 0.354 inches. The volume was
13.142 inches.sup.3. The ratio of the footprint of the bifolded
diaper compared to its unfolded footprint was 0.215.
Example 4B
[0071] A diaper (HUGGIES.RTM. ULTRATRIM.RTM.) which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 3" size, configured to fit an
infant having a weight of about 16 to about 28 pounds. The diaper
was positioned in its completely unfolded configuration, as
described in Example 1A. As disclosed in Table 1, the diaper was
measured to have an area or "footprint" of 172.6 inches.sup.2. The
diaper was folded into the "S" folded configuration illustrated in
FIG. 12 by hand, and it was measured in the same manner as
described in Example 1A.
[0072] As disclosed in Table 1, the width was 4.500 inches and the
length was 3.000 inches. The area or "footprint" was 13.50
inches.sup.2. The calculated depth was 1.063 inches. The volume was
14.351 inches.sup.3. The ratio of the footprint of the "S" folded
diaper compared to its unfolded footprint was 0.078.
Example 5A
[0073] A diaper (HUGGIES.RTM. ULTRATRIM.RTM.) which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 4" size, configured to fit an
infant having a weight of about 22 to about 37 pounds. The diaper
was positioned in its completely unfolded configuration, as
described in Example 1A. As disclosed in Table 1, the diaper was
measured to have an area or "footprint" of 208.41 inches.sup.2. The
diaper was folded into the bifolded configuration illustrated in
FIG. 7 by hand, and it was measured in the same manner as described
in Example 1A.
[0074] As disclosed in Table 1, the width was 4.0625 inches and the
length was 9.375 inches. The area or "footprint" was 38.09
inches.sup.2. The calculated depth was 0.375 inches. The volume was
14.282 inches.sup.3. The ratio of the footprint of the bifolded
diaper compared to its unfolded footprint was 0.183.
Example 5B
[0075] A diaper (HUGGIES.RTM. ULTRATRIM.RTM.) which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 4" size, configured to fit an
infant having a weight of about 22 to about 37 pounds. The diaper
was positioned in its completely unfolded configuration, as
described in Example 1A. As disclosed in Table 1, the diaper was
measured to have an area or "footprint" of 208.41 inches.sup.2. The
diaper was folded into the "S" folded configuration illustrated in
FIG. 12 by hand, and it was measured in the same manner as
described in Example 1A.
[0076] As disclosed in Table 1, the width was 4.0625 inches and the
length was 3.375 inches. The area or "footprint" was 13.71
inches.sup.2. The calculated depth was 1.125 inches. The volume was
14.425 inches.sup.3. The ratio of the footprint of the "S" folded
diaper compared to its unfolded footprint was 0.066.
Example 6A
[0077] A diaper (HUGGIES.degree. ULTRATRIM.RTM.) which is similar
to the disposable absorbent article described herein was utilized
in this Example. The diaper was a "Step 5" size, configured to fit
an infant having a weight of over 27 pounds. The diaper was
positioned in its completely unfolded configuration, as described
in Example 1A. As disclosed in Table 1, the diaper was measured to
have an area or "footprint" of 231.59 inches.sup.2. The diaper was
folded into the bifolded configuration illustrated in FIG. 7 by
hand, and it was measured in the same manner as described in
Example 1A.
[0078] As disclosed in Table 1, the width was 4.375 inches and the
length was 9.625 inches. The area or "footprint" was 42.11
inches.sup.2. The calculated depth was 0.383 inches. The volume was
16.128 inches.sup.3. The ratio of the footprint of the bifolded
diaper compared to its unfolded footprint was 0.182.
Example 6B
[0079] A diaper (HUGGIES.RTM. ULTRATRIM.RTM. which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 5" size, configured to fit an
infant having a weight of over 27 pounds. The diaper was positioned
in its completely unfolded configuration, as described in Example
1A. As disclosed in Table 1, the diaper was measured to have an
area or "footprint" of 231.59 inches.sup.2. The diaper was folded
into the "S" folded configuration illustrated in FIG. 12 by hand,
and it was measured in the same manner as described in Example
1A.
[0080] As disclosed in Table 1, the width was 4.375 inches and the
length was 3.250 inches. The area of the perimeter or "footprint"
was 14.22 inches.sup.2. The calculated depth was 1.150 inches. The
volume was 16.352 inches.sup.3. The ratio of the footprint of the
"S" folded diaper compared to its unfolded footprint was 0.061.
Example 7A
[0081] A diaper (HUGGIES.RTM. ULTRATRIM.RTM. which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 6" size, configured to fit an
infant having a weight of over 35 pounds. The diaper was positioned
in its completely unfolded configuration, as described in Example
1A. As disclosed in Table 1, the diaper was measured to have an
area or "footprint" of 265.52 inches.sup.2. The diaper was folded
into the bifolded configuration illustrated in FIG. 7 by hand, and
it was measured in the same manner as described in Example 1A.
[0082] As disclosed in Table 1, the width was 4.500 inches and the
length was 10.375 inches. The area or "footprint" was 46.69
inches.sup.2. The calculated depth was 0.399 inches. The volume was
18.628 inches.sup.3. The ratio of the footprint of the bifolded
diaper compared to its unfolded footprint was 0.176.
Example 7B
[0083] A diaper (HUGGIES.RTM. ULTRATRIM.RTM. which is similar to
the disposable absorbent article described herein was utilized in
this Example. The diaper was a "Step 6" size, configured to fit an
infant having a weight of over 35 pounds. The diaper was positioned
in its completely unfolded configuration, as described in Example
1A. As disclosed in Table 1, the diaper was measured to have an
area or "footprint" of 265.52 inches.sup.2. The diaper was folded
into the "S" folded configuration illustrated in FIG. 12 by hand,
and it was measured in the same manner as described in Example
1A.
[0084] As disclosed in Table 1, the width was 4.500 inches and the
length was 3.750 inches. The area or "footprint" was 16.88
inches.sup.2. The calculated depth was 1.197 inches. The volume was
20.199 inches.sup.3. The ratio of the footprint of the "S" folded
diaper compared to its unfolded footprint was 0.064.
2TABLE 2 Training Pant Dimensions HUGGIES .RTM. PULL-UPS .RTM.
Dimensions Training Pants (in.) Area Volume (large size) Width
Length Depth (in..sup.2) (in..sup.3) Ratio* Flat/Unfolded 182.375
Bifold (Example 8A) 4.375 10.100 0.532 44.19 23.508 0.242 S-Fold
(Example 8B) 4.375 3.250 1.595 14.22 22.679 0.078 *Folded to
Unfolded Area
Example 8A
[0085] A training pant (HUGGIES.RTM. PULL-UPS.RTM., available from
Kimberly-Clark Corporation, Neenah, Wis.), which was similar to the
disposable absorbent articles described herein, was utilized in
this Example, except that it is an underwear-type of garment for a
young child. The training pant was a "large" size. The training
pant was positioned in its unfolded configuration. That is, the
training pant was cut on each side from leg opening to waist
opening, and laid flat with unretracted elastics and extended to
ungathered length configuration, and measured as described
previously in detail in Example 1A. As disclosed in Table 2, the
training pant was measured to have an area or "footprint" of
182.375 inches.sup.2. The area was determined as described
previously in Example 1A
[0086] An identical uncut training pant, which in its configuration
as underwear has a pre-existing bifold (front and back panel seamed
on each side) configuration was measured. That is the training pant
was positioned on a planar surface and restrained by hand, if
necessary, in the position, while the length measurement 138 and
the width measurement 140 were obtained and recorded.
[0087] The depth measurement 142 was obtained by measuring a
standard packaged bag of articles, that is, in this instance, a bag
containing training pants. The height of the bag was divided by the
total number of panels in a manner substantially similar that that
described previously in Example 1A for diapers (training pants in
the bag were packaged in the bag horizontally relative to the top
height of the bag). These numbers were recorded. All measurements
relating to training pants are in Tables 2 and 4.
[0088] As disclosed in Table 2, the width was 4.375 inches and the
length was 10.100 inches. The area or "footprint" was 44.19
inches.sup.2. The calculated depth was 0.532 inches. The volume was
23.508 inches.sup.3. The ratio of the footprint of the folded
training pant compared to its unfolded footprint was 0.242.
Example 8B
[0089] A training pant diaper (HUGGIES.RTM. PULL-UPS.RTM. "large"
size available from Kimberly-Clark Corporation, Neenah, Wis.),
which was similar to the disposable absorbent articles described
herein, was utilized in this Example, except that the article is an
underwear-type garment for a young child. The training pant was
positioned in its cut-open laid flat configuration, as described in
Example 1A. As disclosed in Table 2, the training pant was measured
to have an area or "footprint" of 182.375 inches.sup.2. The
training pant was folded into the "S" configuration illustrated in
FIG. 12 by hand, and was measured in the same manner as described
in Example 1A.
[0090] As disclosed in Table 2, the width was 4.375 inches and the
length was 3.250 inches. The area or "footprint" was 14.22
inches.sup.2. The calculated depth was 1.595 inches. The volume was
22.679 inches.sup.3. The ratio of the footprint of the folded
training pant compared to its unfolded footprint was 0.078.
3TABLE 3 Adult Incontinence Pant Dimensions DEPEND .RTM. Dimensions
Refastenable Under Wear (in.) Area Volume (large size) Width Length
Depth (in..sup.2) (in..sup.3) Ratio* Flat/Unfolded 562.08 Bifold
(Example 9A) 7.125 15.125 0.499 107.77 53.775 0.192 S-Fold (Example
9D) 7.125 5.275 1.497 37.58 56.264 0.068 *Folded to Unfolded
Area
[0091]
4TABLE 4 Depth Measurement of Panel(s) of Product Product
Mechanical Compression.sup.1,2,3 HUGGIES .RTM. ULTRATRIM .RTM.
Preemie 0.1656 HUGGIES .RTM. ULTRATRIM .RTM. Step 1 0.1714 HUGGIES
.RTM. ULTRATRIM .RTM. Step 2 0.1750 HUGGIES .RTM. ULTRATRIM .RTM.
Step 3 0.1771 HUGGIES .RTM. ULTRATRIM .RTM. Step 4 0.1875 HUGGIES
.RTM. ULTRATRIM .RTM. Step 5 0.1917 HUGGIES .RTM. ULTRATRIM .RTM.
Step 6 0.1955 HUGGIES .RTM. PULL-UPS .RTM. 0.2658 Training Pants
(large size) DEPEND .RTM. Refastenable 0.2495 Under Wear (large
size) .sup.1This panel dimension was determined by measuring a
standard bag of diapers HUGGIES .RTM. ULTRATRIM .RTM. diapers
containing bifolded diapers and dividing the height of the bag by
the total number of panels (diapers positioned horizontally
relative to the top height of the bag). # Using this average per
panel thickness, the thickness of several fold configurations were
calculated by multiplying the average per panel thickness by the
number of panels in the given fold configuration. .sup.2This panel
dimension was determined by measuring a standard bag of HUGGIES
.RTM. PULL-UPS .RTM. training pants containing bifolded constructed
pants and dividing the height of the bag by the total number of
panels (training pants positioned horizontally relative to the top
height # of the bag). Using this average per panel thickness, the
thickness of several fold configurations were calculated by
multiplying the average per panel thickness by the number of panels
in the given fold configur .sup.3This panel dimension was determine
by measuring a standard bag of DEPEND .RTM. Refastenable Under Wear
containing bifolded constructed garments and dividing the height of
the bag by the total number of panels (garments positioned
horizontally relative to the top height of the bag). # Using this
average per panel thickness, the thickness of several fold
configurations were calculated by multiplying the average per panel
thickness by the number of panels in the given fold
configuration.
Example 9A
[0092] An adult incontinence garment "pant" (DEPEND.RTM.
Refastenable Disposable Underwear, size "large", available from
Kimberly-Clark Corporation, Neenah, Wis.), which was similar to the
disposable absorbent articles described herein, was utilized in
this Example, except that it is an underwear-type of garment for an
adult. The garment was positioned in its unfolded configuration.
That is, the underwear garment was cut on each side from leg
opening to waist opening, and laid flat with unretracted elastics
and extended to ungathered length configuration, and measured as
described previously in detail in Example 1A. As disclosed in Table
3, the garment was measured to have an area or "footprint" of
562.08 inches.sup.2. The area was determined as described
previously in Example 1A.
[0093] An identical uncut garment, which in its configuration as
underwear has a pre-existing bifold (front and back panel formed on
each anterior and posterior side) configuration was measured. That
is the garment was positioned on a planar surface and restrained by
hand, if necessary, in the position, while the length measurement
138 and the width measurement 140 were obtained and recorded. The
depth measurement 142 was obtained by measuring a standard packaged
bag of articles, that is, in this instance, a bag containing the
adult garment described herein. The height of the bag was divided
by the total number of panels in a manner substantially similar
that that described previously in Example 1A for diapers (the
garments in the bag were packaged in the bag horizontally relative
to the top height of the bag). These numbers were recorded. All
measurements relating to the adult garment are in Tables 3 and
4.
[0094] As disclosed in Table 3, the width was 7.125 inches and the
length was 15.125 inches. The area or "footprint" was 107.77
inches.sup.2. The calculated depth was 0.499 inches. The volume was
53.775 inches.sup.3. The ratio of the footprint of the bifolded
garment compared to its unfolded footprint was 0.192.
Example 9B
[0095] An adult incontinence garment "pant" (DEPEND.RTM.
Refastenable Disposable Underwear, size "large", available from
Kimberly-Clark Corporation, Neenah, Wis.), which was similar to the
disposable absorbent articles described herein, was utilized in
this Example, except that it is an underwear-type of garment for an
adult. The garment was positioned in its cut-open laid flat
configuration, as described in Example 1A. As disclosed in Table 3,
the garment was measured to have an area or "footprint" of 562.08
inches.sup.2. The garment was folded into the "S" folded
configuration illustrated in FIG. 12 by hand, and was measured in
the same manner as described in Example 1A.
[0096] As disclosed in Table 3, the width was 7.125 inches and the
length was 5.275 inches. The area or "footprint" was 38.30
inches.sup.2. The calculated depth was 1.497 inches. The volume was
56.264 inches.sup.3. The ratio of the footprint of the "S" folded
garment compared to its unfolded footprint was 0.068.
[0097] Having described the invention in rather full detail, it
will be readily apparent that various changes and modifications can
be made without departing from the spirit of the invention. All of
such changes and modifications are contemplated as being within the
scope of the invention as defined by the appended claims and any
equivalents thereto.
* * * * *