U.S. patent application number 10/821223 was filed with the patent office on 2004-09-30 for refastenable absorbent garment.
This patent application is currently assigned to Kimberly-Clark Worldwide, Inc.. Invention is credited to Van Gompel, Paul T..
Application Number | 20040193135 10/821223 |
Document ID | / |
Family ID | 25495422 |
Filed Date | 2004-09-30 |
United States Patent
Application |
20040193135 |
Kind Code |
A1 |
Van Gompel, Paul T. |
September 30, 2004 |
Refastenable absorbent garment
Abstract
A refastenable absorbent garment includes a first body panel
having first and second opposite side edges, a second body panel
having first and second opposite side edges and a crotch portion
extending between the first and second body panels. At least a
first fastener member and a second fastener member are fixedly
secured to and extend outboard from the first and second opposite
side edges of the first body panel respectively. Each of the first
and second fastener members includes a refastenable portion. First
and second extension members are fixedly secured to and extend
outboard from the first and second opposite side edges of the
second body panel respectively. The refastenable portion of the
first fastener member releasably engages the first extension member
and the refastenable portion of the second fastener member
releasably engages the second extension member.
Inventors: |
Van Gompel, Paul T.;
(Hortonville, WI) |
Correspondence
Address: |
Andrew D. Stover
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Assignee: |
Kimberly-Clark Worldwide,
Inc.
|
Family ID: |
25495422 |
Appl. No.: |
10/821223 |
Filed: |
April 8, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10821223 |
Apr 8, 2004 |
|
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09954444 |
Sep 14, 2001 |
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6743321 |
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Current U.S.
Class: |
604/391 |
Current CPC
Class: |
A61F 13/15747 20130101;
Y10T 156/1052 20150115; Y10T 428/237 20150115; Y10T 156/1056
20150115; Y10T 428/298 20150115; Y10T 156/1084 20150115; A61F
13/15756 20130101; Y10T 156/1015 20150115; Y10T 156/1036 20150115;
Y10T 156/1075 20150115; A61F 13/15593 20130101 |
Class at
Publication: |
604/391 |
International
Class: |
A61F 013/15; A61F
013/20 |
Claims
What is claimed is:
1. A refastenable absorbent garment comprising: a first body panel
having first and second opposite side edges; a second body panel
having first and second opposite side edges; a crotch portion
extending between said first and second body panels; at least a
first fastener member and a second fastener member fixedly secured
to and extending outboard from said first and second opposite side
edges of said first body panel respectively, wherein each of said
first and second fastener members comprises a refastenable portion;
and first and second extension members fixedly secured to and
extending outboard from said first and second opposite side edges
of said second body panel respectively, wherein said refastenable
portion of said first fastener member releasably engages said first
extension member and wherein said refastenable portion of said
second fastener member releasably engages said second extension
member.
2. The refastenable absorbent garment of claim 1 wherein said
refastenable portion comprises a hook material.
3. The refastenable absorbent garment of claim 2 wherein said first
and second extension portions comprise a loop material configured
to releasably engage said hook material.
4. The refastenable absorbent garment of claim 1 wherein said first
and second extension members have an outboard curved edge.
5. The refastenable absorbent garment of claim 1 wherein said first
and second extension members are elasticized.
6. The refastenable absorbent garment of claim 1 wherein at least a
portion of said first and second fastener members are
elasticized.
7. The refastenable absorbent garment of claim 1 wherein said first
and second extension members are secured to a bodyside surface of
said second body panel member.
8. The refastenable absorbent garment of claim 1 wherein said first
and second extension members are bonded to said first and second
opposite side edges of said second body panel respectively.
9. The refastenable absorbent garment of claim 8 wherein said
wherein said first and second extension members are adhesively
bonded to said first and second opposite side edges of said second
body panel respectively.
10. The refastenable absorbent garment of claim 8 wherein said
wherein said first and second extension members are sonically
bonded to said first and second opposite side edges of said second
body panel respectively.
11. The refastenable absorbent garment of claim 1 wherein said
first and second fastener members are bonded to said first and
second opposite side edges of said first body panel
respectively.
12. The refastenable absorbent garment of claim 1 wherein said
first and second fastener members each comprise a carrier member
supporting said refastenable portion.
13. The refastenable absorbent garment of claim 10 wherein said
carrier member comprises a pair of tabs supporting first and second
refastenable portions respectively.
14. A refastenable absorbent garment comprising: a first body panel
having first and second opposite side edges; a second body panel
having first and second opposite side edges; a crotch portion
extending between said first and second body panels; at least a
first fastener member and a second fastener member extending
outboard from said first and second opposite side edges of said
first body panel respectively, wherein each of said first and
second fastener members comprises a carrier portion bonded to said
first and second opposite side edges respectively and a
refastenable portion supported by said carrier portion; and first
and second extension members fixedly secured to and extending
outboard from said first and second opposite side edges of said
second body panel respectively, wherein said refastenable portion
of said first fastener member releasably engages said first
extension member and wherein said refastenable portion of said
second fastener member releasably engages said second extension
member.
15. The refastenable absorbent garment of claim 14 wherein said
refastenable portion comprises a hook material.
16. The refastenable absorbent garment of claim 15 wherein said
first and second extension portions comprise a loop material
configured to releasably engage said hook material.
17. The refastenable absorbent garment of claim 14 wherein said
first and second extension members have an outboard curved
edge.
18. The refastenable absorbent garment of claim 14 wherein said
first and second extension members are elasticized.
19. The refastenable absorbent garment of claim 14 wherein said
first and second extension members are secured to a bodyside
surface of said second body panel member.
20. The refastenable absorbent garment of claim 14 wherein said
carrier member comprises a pair of tabs supporting first and second
refastenable portions respectively.
Description
[0001] This application is a divisional of U.S. patent application
Ser. No. 09/954,444, filed Sep. 14, 2001, the entire disclosure of
which is hereby incorporated herein by reference.
BACKGROUND
[0002] The present invention relates generally to a refastenable
absorbent garment, and in particular, to a method for fabricating
refastenable absorbent garments.
[0003] Absorbent garments can be configured in many different
forms. For example, absorbent garments can be configured as a
pant-type, pull-on garment, or as a diaper-type product that is
drawn up between the legs and fastened about the waist with various
fastening systems. Pant-type, pull-on garments are often provided
with various elastic elements that can conform to the body of the
user and provide a comfortable, snug fit. Such garments, however,
often do not have a refastenable mechanism that allows the garment
to be easily removed after use or to be adjusted during use.
[0004] On the other hand, diaper-type products, which can be
configured with fastening systems that allow the user to detach and
reattach various fasteners so as to provide a refastenable
absorbent garment, often are not configured with various elastic
elements, for example around the waist, and may not conform well to
the body of the user and/or may provide a bulky appearance beneath
the user's garments. Moreover, such garments are typically produced
as an "open" product, which is open at the sides and which cannot
be pulled on like a pant-type garment. Some consumers prefer a
pull-on type garment, since the garment is appled to the user like
conventional underwear. Therefore, there remains a need for an
improved absorbent garment, and in particular a pant-type garment,
that is refastenable and provides a snug fit with a non-bulky
appearance.
[0005] In addition, manufacturing facilities are often configured
to fabricate one particular type of product. As such, these
facilities may not provide the flexibility to transition between
fabricating a conventional pull-on type garment and fabricating a
refastenable garment using a single manufacturing line or asset.
Therefore the need also remains for improved methods and assemblies
for manufacturing refastenable absorbent garments.
SUMMARY
[0006] Briefly stated, in one aspect, the invention is directed to
a method for assembling a refastenable absorbent garment. In one
preferred embodiment, the method includes moving a continuous body
panel web in a machine direction and successively fixedly securing
a plurality of discrete fastener pieces, spaced along the machine
direction, to the body panel web. Each of the fastener pieces
includes a first and second end also spaced along the machine
direction. The method further includes successively cutting the
body panel web and each of the fastener pieces along a cross
direction at a location between the first and second ends of each
of the fastener pieces and thereby forming a plurality of discrete
body panels each comprising opposite side edges and a plurality of
pairs of fastener members fixedly secured to one of the plurality
of body panels and a next successive body panel.
[0007] In one preferred embodiment, each of said fastener pieces
includes a refastenable portion formed proximate at least both of
the first and second ends thereof. In one preferred embodiment, the
method further includes releasably engaging the body panel web with
the refastenable portions of each of the plurality of discrete
fastener pieces.
[0008] In another aspect, the method further includes successively
cutting, and preferably perforating, the body panel web along a
cross direction at plurality of locations between the location
where the base web and fastener pieces are fixedly secured and the
location where the refastenable portions releasably engage the body
panel web. Preferably, the successive perforations are made prior
to fixedly securing the plurality of discrete fastener pieces to
the body panel web.
[0009] In another aspect, the fastener pieces each include a first
and second side. In one preferred embodiment, the first side is
fixedly secured to the body panel web. The second side includes the
refastenable portion, which preferably faces away from the body
panel web. In an alternative preferred embodiment, the first side
also includes the refastenable portion, which faces, and is
preferably releasably engaged with, the body panel web.
[0010] In yet another aspect, the refastenable garment includes a
first and second body panel and a crotch portion extending
therebetween. In one preferred embodiment, the crotch portion is
folded such that the first and second body panel webs face each
other. In one preferred embodiment, the first and second body panel
webs are attached at a plurality of cross direction attachment
locations spaced along the machine direction to form a plurality of
side seams. Also in one preferred embodiment, the first and second
body panel webs are cut along the cross direction at the side seams
to form the discrete absorbent garments. In one preferred
embodiment, the side seams are formed simultaneously with the fixed
securement of the fastener pieces to the body panel web.
[0011] In another aspect, the method further comprises successively
fixedly securing a plurality of discrete extension panels to the
second body panel web at an attachment location and successively
cutting the second body panel web and extension panels along a
cross direction at the attachment location.
[0012] In yet another aspect, a refastenable absorbent garment
includes a first body panel having first and second opposite side
edges, a second body panel having first and second opposite side
edges and a crotch portion extending between the first and second
body panels. At least a first and second fastener member are
secured to and extend outboard from the first and second opposite
side edges of the first body panel respectively. Each of the first
and second fastener members comprises a refastenable portion. A
first and second extension member are secured to and extend
outboard from the first and second opposite side edges of the
second body panel respectively. The refastenable portion of the
first fastener member releasably engages the first extension member
and the refastenable portion of the second fastener member
releasably engages the second extension member. In one preferred
embodiment, the refastenable portion comprises a hook material.
[0013] The present invention provides significant advantages over
other absorbent garments and methods and apparatus for the
manufacture thereof. For example, in one embodiment of a pant-type
garment, the user can pull the garment on or off like underwear.
However, by making the absorbent garment refastenable, it can be
applied without needing to pull the garment on or off like a
pant-like garment, if desired. For example, the garment can be
pulled on like a pant-type garment, and removed like a diaper-type
product by disengaging the fastener members and breaking the lines
of weakness. Alternatively, the garment can be pulled on and off
like a pant-like garment, and can thereafter be converted to a
refastenable garment, if desired. For example, the garment can be
made bigger or smaller simply by adjusting the positioning of the
fasteners. Moreover, in one particular application, wherein the
garment is used by adults, for example with occasional incontinence
problems, the garment can be pulled up or down by the user, or the
fastening system may be disengaged and engaged repeatedly by the
user while the garment remains unsoiled over an extended period of
time.
[0014] In one preferred embodiment, the absorbent garment includes
elastic elements extending along the waist region. The elastic
elements provide a snug, comfortable fit that does not create a
bulky appearance beneath the user's outer garments. The combination
of the refastenable fasteners with the elastic elements further
enhances the fit and appearance of the garment.
[0015] The process and apparatus also provide significant
advantages. For example, the manufacturer can easily switch between
the manufacture of a non-refastenable, pant-type product and a
refastenable product simply by introducing a plurality of fastener
pieces, and applying those fastener pieces to one or both of the
front and rear body panels. Other modules may be added or omitted
as desired. For example, a cutter may be introduced to make various
cross direction cuts, for example perforations, in the front or
rear body panel, and various bonders and rotators can be introduced
to align and apply the fastener pieces. In this way, the machinery
and equipment used to fabricate the body panels and crotch portion
can be integrated into both processes, thereby maximizing the use
of the assets and reducing the costs and space needed for the
manufacturing facility.
[0016] In addition, the size of the absorbent garment can be easily
changed, simply by increasing or decreasing the length of the
fastener pieces, without changing the machine pitch of the stream
of products. In particular, the distance between the side edges of
the body panel(s), otherwise defined as the lateral width of the
absorbent garment, can be maintained as a constant, while at the
same time lengthening or shortening the fastener members such that
they can accommodate larger or smaller users respectively. In this
way, the process can be quickly modified to manufacture different
size products without having to reconfigure various machines and
apparatus. For example, the distance between the cuts made by
various dies and cutters doesn't have to be altered, which greatly
reduces the amount of down time when making product changes.
[0017] The present invention, together with further objects and
advantages, will be best understood by reference to the following
detailed description taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a front view of one embodiment of a refastenable
absorbent garment in a fastened configuration.
[0019] FIG. 2 is plan view of the refastenable absorbent garment
shown in FIG. 1 in an unfastened configuration prior to side seams
being formed.
[0020] FIG. 3 is plan view of an alternative embodiment of a
refastenable absorbent garment in an unfastened configuration.
[0021] FIG. 4 is plan view of an alternative embodiment of a
refastenable absorbent garment in an unfastened configuration.
[0022] FIG. 5 is a partial schematic top view representation of one
preferred method of fabricating a portion of one embodiment of a
refastenable absorbent garment.
[0023] FIG. 6 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0024] FIG. 7 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0025] FIG. 8 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0026] FIG. 9 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0027] FIG. 10 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0028] FIG. 11 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0029] FIG. 12 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0030] FIG. 13 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0031] FIG. 14 is an enlarged portion of the absorbent garment
subsassembly shown in FIG. 13.
[0032] FIG. 15 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0033] FIG. 16 is a plan view of one embodiment of a body
panel.
[0034] FIG. 17 is a plan view of one alternative embodiment of a
body panel.
[0035] FIG. 18 is a plan view of one alternative embodiment of a
body panel.
[0036] FIG. 19 is a partial schematic top view representation of an
alternative preferred method of fabricating a portion of one
embodiment of a refastenable absorbent garment.
[0037] FIG. 20 is a perspective view of one embodiment of a
refastenable absorbent garment.
[0038] FIG. 21 is a plan view of a portion of one embodiment of a
refastenable absorbent garment.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
[0039] Referring to FIG. 1, it should be understood that the term
"longitudinal," as used herein, means of or relating to length or
the lengthwise direction 502, and in particular, the direction
running between the front and back of the user. The term
"laterally," as used herein means situated on, directed toward or
running from side to side, and in particular, a direction 500
running from the left to the right of a user, and vice versa. The
terms "upper," "lower," "inner," and "outer" as used herein are
intended to indicate the direction relative to the user wearing an
absorbent garment over the crotch region, while the terms "inboard"
and "outboard" refer to the directions relative to a centerline 8
of the garment. For example, the terms "inner" and "upper" refer to
a "bodyside," which means the side closest to the body of the user,
while the terms "outer" and "lower" refer to a "garment side."
[0040] The term "bodyside" should not be interpreted to mean in
contact with the body of the user, but rather simply means the side
that would face toward the body of the user, regardless of whether
the absorbent garment is actually being worn by the user and
regardless of whether there are or may be intervening layers
between the component and the body of the user. Likewise, the term
"garment side" should not be interpreted to mean in contact with
the garments of the user, but rather simply means the side that
faces away from the body of the user, and therefore toward any
outer garments that may be worn by the user, regardless of whether
the absorbent garment is actually being worn by a user, regardless
of whether any such outer garments are actually worn and regardless
of whether there may be intervening layers between the component
and any outer garment.
[0041] The term "machine direction" means the direction of flow as
the various members and webs progress along the fabrication line
and process. It should be understood that various separate members
or webs can each be traveling in a machine direction, but with the
various machine directions not necessarily being parallel or
oriented in the same direction. For example, one web may be
traveling along a first machine direction, which is substantially
perpendicular to the travel of another web in a second machine
direction.
[0042] The term "cross direction" means the direction substantially
perpendicular to the machine direction.
[0043] The term "downstream" means that one item is positioned more
closely to the output or finished product end of the machine and/or
process relative to another item. Conversely, the term "upstream"
means that an item is positioned more closely to the input end of
the machine or process relative to another item. For example, the
output end is downstream of the input end, and vice versa, the
input end is upstream of the output end.
[0044] The phrases "removeably attached," "removeably attaching,"
"removeably connected," "removeably engaged," "releasably
attached," "releasably connected," or "releasably engaged," and
variations thereof, refers to two or more elements being connected
or connectable such that the elements tend to remain connected
absent a separation force applied to one, both or all of the
elements, and where the elements are capable of being separated
upon the application of a separation force. The required separation
force is typically beyond that encountered while wearing the
absorbent garment.
[0045] The phrases "fixedly secured," "fixedly engaged," "fixedly
attached," "fixedly connected," and variations thereof, refers to
two or more elements being connected or connectable such that they
are not disconnected or otherwise separated, and are not intended
to be separated or disconnected, during the normal operation and
use of the absorbent garment.
[0046] The term "web" refers to a continuous stream of material,
whether made from one or more layers or substrates, and regardless
of whether it may have non-continuous, discrete items disposed
thereon.
[0047] Referring to FIGS. 1 and 2, an absorbent garment 2 includes
a first, front body panel 4 and a second, rear body panel 6. The
term "body panel" refers to the portion(s) of the absorbent
garment, whether made of one or more layers or substrates or of one
or more pieces or components, that is/are fitted circumferentially
around at least the waist region of the user, including for example
the user's lower back, buttock, hips and/or abdomen. The first and
second body panels each have an inner, bodyside surface 10 and an
outer, garment side surface 12. The first, front body panel 4 has a
length, which is measured between opposed first and second terminal
edges 16 and 20, and which is less than the overall length of the
absorbent garment. Likewise, the second, rear body panel 6 has an
overall length, which is measured between opposed first and second
terminal edges 14 and 18, and which is also less than the overall
length of the absorbent garment. Each of the first and second body
panels has an outboard edge 24, 28 formed along the outer periphery
of laterally opposed side portions of the first and second body
panel. It should be understood that the outboard edges of the front
and rear body panels can be different lengths.
[0048] In one preferred embodiment, each of the first and second
body panels includes a tapered edge 26 on each side thereof that
forms in part the leg opening, along with the side edges of the
absorbent composite. The tapered edge can be straight, as shown in
FIGS. 1 and 2, or curved, as shown in FIGS. 16 and 17. It should be
understood that the first and second body panels can be configured
without tapered side edges, such that the terminal edge of one or
both of the first and second body panels extends across the entire
lateral width of the body panel and forms part of the leg
opening.
[0049] Referring to FIGS. 1 and 2, one or more, and preferably a
plurality, meaning two or more, laterally extending elastic
elements 36 are secured to each of the first and second body
panels. Preferably, a plurality of laterally extending elastic
elements are longitudinally spaced across substantially the entire
length of a waist portion of the rear body panel 6.
[0050] In one alternative embodiment, the front body panel has a
"non-elasticized" area wherein there are no laterally extending
elastic elements, or other elastic or elastomeric backing members,
incorporated therein or making up any portion of the thickness or
cross-section of the body panel at that area, such that the
material can be gathered.
[0051] Alternatively, as shown in FIGS. 1-4, the front body panel 4
can have a plurality of laterally extending elastic elements 36
spaced longitudinally along a portion thereof. The elastic elements
can be spaced longitudinally along the entire length of the body
panels, or along lesser lengths. For example elastic elements can
extend along an upper waist portion and along the lower terminal
edge defining the leg opening. It should be understood, that in an
alternative embodiment, one or more separate waist bands, with or
without elastic elements, can be secured to one or both of the rear
and front body panels, preferably along the upper terminal edges
thereof. Similarly, separate leg bands can be secured along the
edges of the body panels and absorbent composite that define the
leg openings. Alternatively, one or both of the body panels can be
formed without any elastic elements.
[0052] In an alternative embodiment, shown in FIG. 20, the
absorbent garment includes a chassis 400 having a T-shape, with a
laterally extending rear body panel 402 and a crotch portion 404
extending longitudinally therefrom. An end portion 406 of the
crotch portion forms a portion of a front body panel, together with
a pair of fastener members 408 that are secured to the rear body
panel and wrap around the user and are engaged with the end portion
406.
[0053] In another alternative embodiment, the front body panel
includes a "deactivated" area wherein the elastic elements are
severed, chopped or otherwise deactivated, for example by using a
rotary die cutter, by melt-breaking (e.g. with a heated or
ultrasonic function roll) or by any other means known to those
skilled in the art. In one preferred embodiment, the deactivated
area or landing zone is formed along a center portion of the front
body panel and underlies a landing member and a pair of fastener
members.
[0054] Referring to FIGS. 1-4, one or more leg elastic elements 38
can be secured along the inner terminal edges of the body panels 4,
6 and an absorbent composite 50 to form a gasket with the leg of
the user at the leg opening 125 formed by the absorbent garment.
The various waist and leg elastic elements can be formed from
rubber or other elastomeric materials. One suitable material is a
LYCRA.RTM. elastic material. For example, the various elastic
elements can be formed of LYCRA.RTM. XA Spandex 540, 740 or 940
detex T-127 or T-128 elastics available from E.I. duPont De Nemours
and Company, having an office in Wilmington, Del.
[0055] Each body panel, or chassis, is preferably formed as a
composite, or laminate material, otherwise referred to as
substrates or laminates, with the plurality of elastic strands
sandwiched therebetween. Preferably two or more layers are bonded
with various adhesives, such as hot melt, or by other techniques,
including for example and without limitation ultrasonic bonding and
heat pressure sealing. In one embodiment, the two layers are made
of a non-woven material. It should be understood that the body
panels or chassis can be made of a single layer or substrate of
non-woven material, or can be comprised of more than two layers or
substrates. Of course, it should be understood that other knitted
or woven fabrics, elastomeric materials, non-woven fabrics, polymer
films, laminates and the like can be used to form one or more of
the body panel layers. The term "non-woven" web or material, as
used herein, means a web having a structure of individual fibers or
filaments that are interlaid, but not in an identifiable manner and
without the aid of textile weaving or knitting, as in a knitted or
woven fabric.
[0056] In one embodiment, the non-woven layers or substrates, and
also a landing material, can be made by spunbonding. Spunbond
nonwoven webs or materials are made from melt-spun filaments or
spunbonded fibers which refers to small diameter fibers that are
formed by extruding molten thermoplastic material as filaments from
a plurality of fine, usually circular capillaries of a spinneret
with the diameter of the extruded filaments then being rapidly
reduced, for example, by non-eductive or eductive fluid-drawing or
other well known spunbonding mechanisms. The production of
spunbound nonwoven webs is described in U.S. Pat. No. 4,340,563 to
Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al., U.S.
Pat. No. 3,802,817 to Matsuki et al, U.S. Pat. No. 3,502,763 to
Hartmann, U.S. Pat. No. 3,276,944 to Levy, U.S. Pat. No. 3,502,538
to Peterson, and U.S. Pat. No. 3,542,615 to Dodo et al, all of
which are incorporated herein by reference.
[0057] The melt-spun filaments formed by the spunbond process are
generally continuous and have diameters larger than 7 microns, more
particularly, between about 10 and 30 microns. Another frequently
used expression of fiber or filament diameter is denier, which is
defined as grams per 9000 meters of a fiber or filament. The fibers
may also have shapes such as those described in U.S. Pat. No.
5,277,976 to Hogle, et al, U.S. Pat. No. 5,466,410 to Hills and
U.S. Pat. Nos. 5,069,970 and 5,057,368 to Largman et al., all of
which are incorporated herein by reference. The spunbond filaments
usually are deposited, by one or more banks, onto a moving
foraminous belt or forming wire where they form a web. Spunbonded
filaments generally are not tacky when they are deposited onto the
collecting surface.
[0058] Spunbond fabrics typically are stabilized or consolidated
(pre-bonded) in some manner immediately as they are produced in
order to give the web sufficient integrity to withstand the rigors
of further processing into a finished product. This stabilization
(prebonding) step may be accomplished through the use of an
adhesive applied to the filaments as a liquid or powder which may
be heat activated, or more commonly, by compaction rolls. As used
herein, the term "compaction rolls" means a set of rollers above
and below the web used to compact the web as a way of treating a
just produced, melt-spun filament, particularly spunbond, web, in
order to give the web sufficient integrity for further processing,
but not the relatively strong bonding of secondary bonding
processes, such as through-air bonding, thermal bonding, ultrasonic
bonding and the like. Compaction rolls slightly squeeze the web in
order to increase its self-adherence and thereby its integrity.
[0059] An alternative means for performing the pre-bonding step
employs a hot air knife, as described in U.S. Pat. No. 5,707,468,
which is hereby incorporated herein by reference in its entirety.
Briefly, the term "hot air knife" means a process of pre-bonding a
just produced melt-spun filament, particularly spunbond, web, in
order to impart the web with sufficient integrity, i.e., increase
the stiffness of the web, for further processing. A hot air knife
is a device that focuses a stream of heated air at a very high flow
rate, generally from about 300 to about 3000 meters per minute
(m/min.), or more particularly from about 900 to about 1500 m/min.,
directed at the nonwoven web immediately after its formation. The
air temperature usually is in the range of the melting point of at
least one of the polymers used in the web, generally between about
90.degree. C. and about 290.degree. C. for the thermoplastic
polymers commonly used in spunbonding. The control of air
temperature, velocity, pressure, volume and other factors helps
avoid damage to the web while increasing its integrity.
[0060] The hot air knife's focused stream of air is arranged and
directed by at least one slot of about 3 to about 25 millimeters
(mm) in width, particularly about 9.4 mm, serving as the exit for
the heated air towards the web, with the slot running in a
substantially cross-machine direction over substantially the entire
width of the web. In other embodiments, there may be a plurality of
slots arranged next to each other or separated by a slight gap. The
at least one slot usually, but not necessarily, is continuous, and
may be comprised of, for example, closely spaced holes. The hot air
knife has a plenum to distribute and contain the heated air prior
to its exiting the slot. The plenum pressure of the hot air knife
usually is between about 2 to about 22 mmHg, and the hot air knife
is positioned between about 6.35 mm and about 254 mm, and more
particularly from about 19.05 to about 76.20 mm above the forming
surface. In a particular embodiment, the hot air knife plenum's
cross-sectional area for cross-directional flow (i.e., the plenum
cross-sectional area in the machine direction) is at least twice
the total slot exit area.
[0061] Since the foraminous wire onto which the spunbond polymer is
formed generally moves at a high rate of speed, the time of
exposure of any particular part of the web to the air discharge
from the hot air knife typically is less than a tenth of a second
and generally about one hundredth of a second, in contrast with the
through-air bonding process, which has a much longer dwell time.
The hot air knife process has a great range of variability and
control over many factors, including air temperature, velocity,
pressure, and volume, slot or hole arrangement, density and size,
and the distance separating the hot air knife plenum and the
web.
[0062] The spunbond process also can be used to form bicomponent
spunbond nonwoven webs as, for example, from side-by-side (or
sheath/core) linear low density polyethylene/polypropylene spunbond
bicomponent filaments. A suitable process for forming such
bicomponent spunbond nonwoven webs is described in U.S. Pat. No.
5,418,045 to Pike et al., which is incorporated herein by reference
in its entirety.
[0063] Commercially available thermoplastic polymeric materials can
be advantageously employed in making the fibers or filaments from
which pattern-unbonded nonwoven material is formed. As used herein,
the term "polymer" shall include, but is not limited to,
homopolymers, copolymers, such as, for example, block, graft,
random and alternating copolymers, terpolymers, etc., and blends
and modifications thereof. Moreover, unless otherwise specially
limited, the term "polymer" shall include all possible geometrical
configurations of the material, including, without limitation,
isotactic, syndiotactic and random symmetries. As used herein, the
terms "thermoplastic polymer" or "thermoplastic polymeric material"
refer to a long-chain polymer that softens when exposed to heat and
returns to its original state when cooled to ambient temperature.
Preferably, the spunbond fibers are made of a polypropylene. Other
alternative thermoplastic materials include, without limitation,
poly(vinyl chloride)s, polyesters, polyamides, polyfluorocarbons,
polyolefins, polyurethanes, polystyrenes, polyethylenes, poly(vinyl
alcohol)s, caprolactams, and copolymers of the foregoing. The
fibers or filaments used in making the nonwoven material may have
any suitable morphology and may include hollow or solid, straight
or crimped, single component, bicomponent or multicomponent,
biconstituent or multiconstituent fibers or filaments, and blends
or mixes of such fibers and/or filaments, as are well known in the
art.
[0064] After the nonwoven web is formed, the pre-bonded or unbonded
web is passed through a suitable process or apparatus, including
for example a calendar roll, to form a pattern of discrete bonded
areas. The term "discrete" as used herein means individual or
disconnected, and is contrasted with the term "continuous" as used
in U.S. Pat. No. 5,858,515 to Stokes et al, which is hereby
incorporated herein by reference, and which describes
pattern-unbonded, or point un-bonded nonwoven fabrics having
continuous bonded areas defining a plurality of discrete unbonded
areas. In one embodiment, the calendar stack (not shown) includes
an anvil roll and a pattern roll, which is heated and includes
various raised landing portions. The raised portions of the pattern
roll thermally bond the fibers to form the bonded areas. The bonds
can made of any shape and size. Preferably, the percent bonded area
of the web is between about 5% and 25% of the area of the web, and
is more preferably between about 10% and 15%. Thereafter, the
bonded substrate can be bonded to another substrate with the
elastic members disposed therebetween.
[0065] In one alternative preferred embodiment, the landing
material is made of the point-unbonded nonwoven material, for
example, a 2.0 osy point-unbonded material. One exemplary material
of this type has been used in a HUGGIES.RTM. Ultratrim Disposable
Diaper, which is commercially available from Kimberly-Clark
Corporation. In another preferred embodiment, the landing material,
which can be comprised of a portion of one of the body panel
substrates, e.g., a body panel liner, is made of a non-woven
spunbond material, for example, a spunbond material having a basis
weight of preferably about 0.6 osy. In other preferred embodiments,
the basis weight of each substrate can be between at least about
0.3 and about 2.0 osy, and preferably between about 0.5 osy and
about 1.5 osy, and more preferably between about 0.5 osy and about
1.0 osy. Even with a relatively low percent area bonding, the
relatively low basis weight non-woven spunbond material exhibits
strength and tear characteristics allowing it to be used as a body
panel. Other materials that may be used as the non-woven material
include various meltblown materials, and also bonded-carded
materials.
[0066] In other alternative embodiments, the landing material can
be made of a loop material, which typically includes a backing
structure and a plurality of loop members extending upwardly
therefrom. The loop material can be formed by any suitable
material, such as acrylic, nylon or polyester, and can be formed
from such methods as warp knitting, stitch bonding or needle
punching. Suitable loop materials are available from Guilford
Mills, Inc., Greensboro, N.C., U.S.A. under the trade designation
No. 36549.
[0067] The body panel 4, 6 non-woven material is preferably
substantially hydrophobic, which may optionally be treated with a
surfactant or otherwise process to impart a desired level of
wettability and hydrophilicity. In one particular embodiment of the
invention, the body panel is a nonwoven, wire-weave spunbond
polypropylene fabric composed of about 1.6 denier fibers formed
into a web having a basis weight of about 0.6 osy. One suitable
non-woven material is the Corinth 0.60 osy, 1.6 dpf wireweave,
nonwettable Metallocene (EXXON ACHIEVE 2854 PP) spunbond material
manufactured by Kimberly-Clark Corporation, the assignee of the
present application.
[0068] Referring to FIGS. 1 and 2, fastening members 42 are
preferably attached to the front body panel and extend laterally
inboard relative to the outboard side edge 24 of the front body
panel 4 from an attachment location 45, which is preferably located
at the side edge, but which can be spaced inboard from the side
edge. In the embodiment shown in FIG. 1, the front body panel 4
includes a middle portion 33, which can have a landing member
secured thereto, and opposite side portions 35. Opposite
longitudinally extending lines of weakness 37 separate the middle
portion 33, which can include a landing member attached thereto,
from the opposite side portions 35, such that the side portions 35
are initially breakably attached to opposite sides of the middle
portion 33. The lines of weakness 37 can comprise a perforation or
other series of cuts, a thinning, breakage or separation of
material, or a strip of a different kind of material bridging
between the middle portion and the side portions that is more
easily torn or broken than the material of the middle portion and
side portions, and which allow a user or the manufacturer to
separate the side portions from the middle portion. For example,
the absorbent garment can be broken after the garment is applied to
a user, or beforehand. Preferably, the fastening members 42 are
secured to the garment-side surface 12 of the side portions 35,
preferably in a portion of a deactivacted area or zone, between the
side edge 24 of the front body panel and the line of weakness 37.
The elastic elements in the side portions that are not deactivated
allow the side portions to be stretched to provide a snug fit
around the user. It should be understood that none of the elastic
elements need be deactivated. In other embodiments, the front body
panel, including the side portions, may not incorporate any elastic
elements, or may incorporate a limited number spaced across various
portions of the length thereof, as explained herein.
[0069] Referring to the embodiments illustrated in FIGS. 3 and 20,
the fastening members 42, 408 are secured to the rear body panel 6,
402 and releasably engage the front body panel 4, or the end
portion 406. In an alternative embodiment, the fastener members can
be secured to the front body panel and engage the rear body panel.
In the embodiments of FIGS. 3, 4 and 20, the side edges 24, 28 of
the front and rear body panels, or the side edges 410 of the body
panel 402 and the end portion 406, are not fixedly secured to one
another to form a side seam, such that the product remains "open,"
and is not initially pulled on like a pant-type product, unless the
fastener members are first joined with the opposite body panel to
form and define the leg openings. Preferably, in such an
embodiment, there are no lines of weakness.
[0070] In another alternative embodiment, the fastening members can
be secured to the rear body panel and can include a portion
crossing over a line of weakness formed along the front body panel,
or alternatively along the rear body panel, and can refastenably
engage a portion of one or both of the front and rear body panels
on the other side of the line of weakness. In one embodiment, the
fastening members engage the body panel along at least a portion
that is not elasticized. It should be understood that the line of
weakness could be formed at the side seam separating the front and
rear body panels. Preferably, the fastening members are fixedly
secured to the outer, garment-side surface of the front and/or rear
body panels, and releasably engage the outer, garment-side surface
of the front and/or rear body panels, although it should be
understood that the fastening members could be fixedly secured to
an inner, body-side surface of front and/or rear body panels and
releasably engage an inner, body-side surface of the front and/or
rear body panels. For example, in FIGS. 3, 4 and 13-18, the
fastener members 42 are fixedly secured to an inner, bodyside
surface of the rear body panel web, which is cut to form the rear
body panels.
[0071] Referring to the embodiments of FIGS. 1-3, the middle
portion 33 does not include a separate landing member secured
thereto. Instead, the front body panel itself serves as a landing
material. Again, opposite longitudinally extending lines of
weakness 37 separate the middle portion 33 from the opposite side
portions 35, such that the side portions 35 are initially breakably
attached to opposite sides of the middle portion 33. Preferably,
the fastening members 42 are secured to the garment-side surface of
the side portions 35 between the side edge 24 of the front body
panel and the line of weakness 37.
[0072] In an alternative embodiment, shown in FIG. 4, the fastening
members 42 are secured to the rear body panel 6, preferably a body
side surface 10 thereof, and releasably engage a pair of extension
members 414 or panels fixedly secured to the side edges 24 of the
front body panel 4. The extension panels have a curved, outboard
edge 416 and are preferably made of one or more of the
above-referenced body panel materials. It should be understood that
the extension panels can be made of a landing material, including
for example a loop material, or may include a landing member
secured thereto for engagement with the fastener members 42 secured
to the rear body panel. The extension members can also be
elasticized, for example by way of incorporation of elastic
elements across various portions thereof.
[0073] Referring to the embodiments of FIGS. 1 and 2, the opposite
side edges 24 of the front body panel 4 are joined to the opposite
side edges 28 of the rear body panel 6 to form a seam 39. The seam
39 is formed by bonding, sewing or otherwise attaching the side
edges. For example, in one preferred embodiment, the side seams are
formed by ultrasonic bonds. In this way, prior to the breaking of
the line of weakness 37, the absorbent garment can be configured as
a pant-like garment, which can be pulled over the legs of the user.
After the garment is applied to the user, the lines of weakness can
be broken, if desired, or left intact, as the fasteners are
adjusted to fit the garment to the user. If desired, the lines of
weakness can be broken prior to securing the garment to the user,
for example when the user is bed-ridden. In this configuration, the
garment is laid beneath the user and is secured to the user with
the fastening tabs. By providing the side portions, and by
connecting the fastening tabs to the front body panel, instead of
the rear body panel, the tabs are located at the front of the user
so as to not provide discomfort to the user when lying on their
backs and to allow the fasteners to be more easily seen and
adjusted by the user or caretaker.
[0074] It should be understood that the lines of weaknesses and the
fasteners can be moved laterally inboard and outboard to provide
more or less adjustment capability. In addition, the elasticized
side portions or fastener members can provide further adjustment
capability.
[0075] In the embodiments shown in FIGS. 3, 4, 13 and 20, the lines
of weakness are omitted altogether, and the side edges 24, 28, 410
of the front and/or rear body panels are not fixedly joined to form
a side seam. Instead, the fastener members fixedly secured to one
of the front and rear body panels releasably engage the other of
the front and rear body panels to thereby join the front and rear
body panels and define the leg openings for the user.
[0076] It should be understood that the front and rear body panels
can be made as an integral unitary member that extends along the
crotch from the front to back and with the sides thereof connected
to form side seams. Alternatively, the front and rear body panels
can be formed integrally as a ring-like member, for example as one
body panel extending around the waist and hips of the user, that is
attached to a crotch portion that forms leg openings.
[0077] In one alternative embodiment, an outer cover is disposed
over the entire garment and forms the outer garment side layer or
substrate of the front and rear body panels, with the various
elastic elements 36, 38 disposed between a bodyside liner on each
of the front and rear body panels, which liner preferably is
configured as a single substrate, and the outer cover, which is
also preferably configured as single substrate. In this way, the
portion of the outer cover that overlies the front body panel liner
and is fitted around the front of the user forms part of the front
body panel, while the portion of the outer cover that overlies the
rear body panel liner and is fitted around the rear of the user
forms part of the rear body panel. The front and rear body panels,
with the liners and with the outer cover forming portions thereof
and preferably extending therebetween, forms a chassis. The outer
cover is preferably made of a non-woven material, similar to that
of the other body panel materials described herein. It should be
understood that the body panels, including the outer cover, can be
configured with any number of a plurality of substrates, and that
the body panels can include other layers and substrates.
[0078] Preferably, as shown in FIGS. 1-4, the fastening members 42
comprise a carrier member 43 that is formed in a generally
side-ways, "U" shape, with a vertical extending base member 55 and
a pair of laterally extending and longitudinally spaced tab members
47. The tabs can have curved edges, or can be linear. The carrier
member can also include a single tab member, or more than two tab
members.
[0079] Alternatively, as shown in FIGS. 7, 8 and 10-12, the carrier
member 424 has a square or rectangular shape, with straight side
edges 422. In one embodiment, a refastenable material can extend
beyond the edges of the carrier member to form tabs. In the
embodiment shown in FIG. 12, a laterally extending slit 423 is
formed in the carrier member 424. The slit 423 extends laterally
inboard from a free edge of the carrier member. The slit 423 forms
a pair of tab members on each fastener member. It should be
understood that additional slits can be formed in the carrier
member to thereby define additional tab members.
[0080] As shown in FIGS. 1-2, the carrier members are preferably
fixedly secured to the side portions of the front body panel 4 with
adhesive bonds 49, sonic bonds, thermal bonds, pinning, stitching
or other known types of attachment. In alternative embodiments, the
fastening members 42 can be fixedly secured to the rear body panel
6, as shown in FIGS. 3 and 4, or to one or both of the front and
rear body panels, e.g., at the seam.
[0081] In a preferred embodiment, the pair of fastener members 42
used to releasably secure the front and rear body panels define a
"fastening system," which refers to the grouping of fastener
members used to releasably secure two or more portions of an
absorbent garment. Although the fastening system is shown as being
configured with two fastener members, it should be understood that
it could include additional fastener members, and that the
two-fastener member fastening system shown in the Figures is meant
to be illustrative rather than limiting. For example, the fastening
system could include three, four or even more fastener members.
[0082] The tab members 47 are preferably oriented toward each other
on either of the front and rear body panels when in use, although
it should be understood that they can extend away from each other.
Referring to FIGS. 3 and 4, one of the fastener members 42 is shown
as being folded down over and releasably engaged with the body side
surface of the rear body panel, which is the configuration of the
fastener members when packaged. The other fastener member 42 is
shown as being disengaged from the rear body panel in an unfolded
configuration wherein it is ready for releasable engagement with
the front body panel 4, or landing member secured thereto. In such
an embodiment, the fastener member 42 and tab members 47 are
rotated about the attachment location 45 so that they can engage
the front body panel.
[0083] Each carrier member 43 has a longitudinal length and each of
the tab members 47 comprises a refastenable portion or an
engagement portion having a longitudinal length. The refastenable
portion 51 preferably comprises an array of hooks, as explained
below, but alternatively can comprise various adhesives, such as
pressure sensitive adhesives, buttons, zippers, snaps and other
releasable and reattachable fastening devices known to those
skilled in the art. Referring to the embodiment of FIG. 3, the
refastenable portion 51 extends along the entire length of the tab
members. Alternatively, as shown in FIGS. 1, 2, 4, 11 and 12, the
refastenable portion is configured as a patch member 430 secured to
the carrier member. Alternatively, as shown in FIGS. 9 and 10, the
refastenable portion, preferably configured as a strip 420, extends
laterally beyond and outboard of the side edges 422 of the carrier
member 424. As shown for example in FIG. 20, the carrier member 424
can include various laterally extending elastic elements 36 spaced
longitudinally therealong to provide the fastener member with
various elastic properties such that it can be extended to provide
additional adjustment capabilities. The elastic elements can be
deactivated beneath the refastenable portion if desired.
[0084] In yet another alternative embodiment, shown in FIGS. 19 and
20, the refastenable member 432, or portion, extends longitudinally
along substantially the entire length of the carrier member 424,
although it should be understood that the refastenable portion can
be configured as one or more separate discrete patch members, or
can extend along the entire length of the carrier member, or some
lesser length thereof.
[0085] In the embodiment shown in FIGS. 1-3, each fastening member
42 is comprised of two separate, longitudinally spaced tab members
47. In any of the embodiments, the two or more tab members provides
a pant-like fit that controls the waist and leg openings in the
front and back of the garment, and also allows the user to adjust
the fit of the garment without totally undoing the garment. For
example, the user can release one of the tab members and refasten
it without undoing the other tab member.
[0086] In an alternative embodiment, shown in FIG. 9, a pair of
fastener members are secured to each side of the body panel. The
fastener members are preferably configured as a laterally extending
strip 420 of refastenable material. The pair of strips 420 on each
side of the body panel again provide the user with the ability to
adjust the fit of the garment without undoing one or both sides
thereof. The strips can be secured directly to the body panel, or
alternatively the strips 420 can be secured to a carrier member
424, as shown in FIG. 10. It should be understood that a single
strip, or more than two strips, with or without a carrier member,
can be secured to the front or rear body panels.
[0087] It should be understood that any of the various fastener
member configurations, and refastenable configurations, described
herein can be used interchangeably.
[0088] In the embodiment of FIGS. 1-13 and 20, the fastener member
42, 408, whether configured with a carrier member and a
refastenable portion or with a refastenable member alone, has a
first side 440 and a second side 442, as shown in FIGS. 3 and 4.
Preferably, the first side of the fastener member is fixedly
secured to either the garment side surface 12 of the front body
panel or the body side surface 10 of the rear body panel. In
addition, the first side 440 further includes the refastenable
portion, which faces and is releasably engaged with either the
bodyside surface 10 of the rear body panel, when the fastener
member is in the folded, packaged configuration prior to use, or
with the garment side surface 12 of the front body panel 4 when in
use.
[0089] Alternatively, as shown in the embodiments of FIGS. 13-18
and 21, the fastener member 420 does not include any carrier
member, but rather has a first side fixedly attached to the body
side surface 10 of the rear body panel and a second side, which is
configured as the refastenable portion and which faces away from
the body side surface. As shown in the embodiments of FIGS. 16-18,
one, two or three fastener members 420 are secured to the rear body
panel, although it should be understood that additional fastener
members, or other configurations thereof, could be used. As shown
in FIG. 21, the fastener member 420 is elongated along the
longitudinal direction, and, in one embodiment, can extend
substantially the entire length of the waist portion of the rear
body panel. In addition, it should be understood that the fastener
member could include a carrier member having a first side secured
to the garment side surface of the body panel and a second side
supporting the refastenable portion, which faces away
therefrom.
[0090] In one preferred embodiment, the refastenable portion 51
comprises a hook-type fastener member, or hook strip, which is
secured to the carrier member 43, 424 with adhesive, ultrasonic
bonding, stitching or other known attachment devices. In one
embodiment, shown for example in FIG. 3, the end portion 53 or tip
of the carrier member can be left uncovered by the refastenable
portion 51, such that it can be lifted or flexed and grasped by a
user as they disengage or peel back the fastener member. In another
embodiment, shown in FIGS. 9 and 13-18, the entire fastener member
420 is configured as a hook strip, with the hooks arranged on the
first side of the strip and facing away from the second side of the
strip. In one embodiment, the hooks can be deadened along a portion
of the first side of the strip in the attachment location, such
that the first side can be fixedly secured to the body panel.
[0091] It should be understood that the term "hook" as used herein
means any element capable of engaging another element, and is not
intended to limit the fonn of the engaging elements, for example to
include only "hooks," but rather encompasses any form or shape of
engaging element, whether unidirectional or bi-directional. Various
hook configurations are described in U.S. Pat. No. 5,845,375 to
Miller et al., U.S. Pat. No. 6,132,660 to Kampfer, U.S. Pat. No.
6,000,106 to Kampfer, U.S. Pat. No. 5,868,987 to Kampfer, U.S. Pat.
No. 4,894,060 to Nestegard, and U.S. Pat. No. 6,190,594 B1 to
Gorman, the entire disclosures of which are incorporated by
reference herein. Some examples of hook fasteners are the various
CS600 hook fasteners, including the XKH-01-002 CS600, 2300 Pin
Density hook fastener (Part No. XKH-01-002/60MM/SP#2628),
manufactured by Minnesota Mining and Manufacturing Co., St. Paul
Minn. Another example of a hook fastener are the Velcro.RTM.
HTH-851 and HTH-829 hook fasteners available from Velcro USA,
Inc.
[0092] In one preferred embodiment, a mushroom-type hook strip
comprises a homogeneous backing of thermoplastic resin and,
integral with backing, an array of upstanding stems distributed
across at least one face of the backing, each having a mushroom
head. The array of hooks on each strip comprise an engagement
portion having a longitudinal length. The stems can have a
molecular orientation as evidenced by a birefringence value of at
least 0.001, and the mushroom heads having circular disc shapes
with generally planar end surfaces opposite the backing, which disc
shaped heads preferably have diameter to thickness ratios of
greater than about 1.5 to 1.
[0093] The stems of the hook strip can be molecularly orientated as
evidenced by a birefringence value of at least 0.001. As such, they
have significantly greater stiffness and durability, as well as
greater tensile and flexural strength, than would be achievable
without such orientation. Because of these qualities, the portions
of the stems not heated by a heating surface during the forming
process remain resiliently flexible during a deforming step, which
preferably involves the application of heat to the stem tips by
contact with the heated surface of a metal roller. Such contact
forms the tip of each stem into a circular disc shaped mushroom
head at the tip of each stem, which head has a substantially flat
inner surface that enhances its holding power when engaged with a
loop.
[0094] As compared to hook strips that have unoriented stems, the
enhanced strength of the hooks of the hook strip makes them less
likely to break during disengagement. When the hook strip is used
with the non-woven material herein described, the enhanced strength
of the hooks makes them less likely to break under disengagement
forces than the fibers of the material, a beneficial attribute for
at least two reasons. First, broken hooks can create debris whereas
a broken fiber typically does not. Furthermore, the non-woven
material typically contains many more engageable fibers than there
are hooks per unit area, thus allowing a greater number of
disengagements before a hook-and-loop fastener becomes useless.
[0095] Although the stems of the hook strip preferably are
generally circular in cross section, other suitable cross sections
include rectangular and hexagonal. The stems preferably have
fillets at their bases, both to enhance strength and stiffness and
for easy release from a mold in which they are formed. In addition,
the stems can be tapered, preferably from a larger to a smaller
cross-section as one moves from the base to the head.
[0096] The stem portions are preferably at an angle of about 90
degrees from the backing substrate, however, this angle can range
from about 80 to about 100 degrees, preferably 85 to about 95
degrees. The hook head portion is formed on the distal end of the
stem. The hook head can be elongated in on or more directions
forming the fiber engaging portions. These fiber engaging portions
extend outward from the stem portion at any angle so that they can
project upwardly away from the film backing, parallel with the film
backing or even downward toward the film backing.
[0097] For example, the hook head portion has a deformed fiber
engaging portion that projects downward. Preferably, the lower
surface of the fiber engaging portion also projects downward form a
crook between the lower face of the fiber engaging portion and the
stem base portion. In one preferred embodiment, the heads of the
hooks generally project at a downward angle from the hook head top
portions toward the base. This downward angle (measured from a
reference line taken from the top of the hook head and parallel
with the backing) is generally from about 0 to about 70 degrees,
preferably from about 5 to about 60 degrees and most preferably
from about 5 to about 35 degrees (defined by a linear extent
running from a center region of the hook head top portion to an end
of the hook head fiber engaging portion).
[0098] The head shape with its high diameter to thickness ratio,
and the small size and close spacing or high density of individual
hooks that are provided by the hook strip according to the present
invention makes it able to easily firmly releasably engage
non-woven materials in shear, possibly because the many thin heads
can easily move radially into engagement with rather small fibers.
Thus the hook strip is particularly useful for hook-and-loop
fastening when the "loops" are provided by non-woven materials
which are not particularly adapted for use as the loop portions of
hook and loop fasteners, and which are not as well engaged by known
prior art hook strips. For example, the hook strip is particularly
well-suited for engaging the topographically flatter non-woven
materials described above, including the non-woven spunbond
material, which has relatively fewer loose, outwardly extending,
free fibers than conventional loop materials, but still provides a
relatively high number of pores, of sufficient size, such that the
material can be engaged by the hooks. Indeed, once the hooks are
received in the pores, or embedded in the non-woven material, the
fastening tabs provide excellent shear characteristics, such that
the garment is securely fastened during normal wearing
conditions.
[0099] In general, the hooks are of uniform height, preferably of
from about 0.10 to 1.30 mm in height, and more preferably from
about 0.18 to 0.51 mm in height; have a density on the backing
preferably of from 60 to 1,600 hooks per square centimeter, and
more preferably from 125 to 690 hooks per square centimeter, and
preferably greater than about 150 hooks per square centimeter; have
a stem diameter adjacent the heads of the hooks preferably of from
0.07 to 0.7 mm, and more preferably from about 0.1 to 0.3 mm. The
deformed hook heads project radially past the stems on at least one
side preferably by an average of about 0.01 to 0.3 mm, and more
preferably by an average of about 0.02 to 0.25 mm and have average
thicknesses between their outer and inner surfaces (i.e., measured
in a direction parallel to the axis of the stems) preferably of
from about 0.01 to 0.3 mm and more preferably of from about 0.02 mm
to 0.1 mm. The hook heads have average head diameter (i.e.,
measured radially of the axis of the heads and stems) to average
head thickness ratio preferably of from 1.5:1 to 12:1, and more
preferably from 2.5:1 to 6:1.
[0100] For most hook-and-loop uses, the hooks of the hook strip
should be distributed substantially uniformly over the entire area
of the hook strip, usually in a square or hexagonal array.
[0101] To have both good flexibility and strength, the backing of
the hook strip preferably is from 0.02 to 0.5 mm thick, and more
preferably is from 0.06 to 0.3 mm in thick, especially when the
hook strip is made of polypropylene or a copolymer of polypropylene
and polyethylene. For some uses, a stiffer backing could be used,
or the backing can be coated with a layer of pressure sensitive
adhesive on its surfaces opposite the hooks by which the backing
could be adhered to a substrate, such as the carrier member 43, so
that the backing could then rely on the strength of the substrate
to help anchor the hooks.
[0102] Virtually any orientable thermoplastic resin that is
suitable for extrusion molding may be used to produce the hook
strip. Thermoplastic resins that can be extrusion molded and should
be useful include polyesters such as poly(ethylene terephthalate),
polyamides such as nylon, poly(styrene-acrylonitrile),
poly(acrylonitrile-butadiene-styrene)- , polyolefins such as
polypropylene, and plasticized polyvinyl chloride. One preferred
thermoplastic resin is a random copolymer of polypropylene and
polyethylene containing 17.5% polyethylene and having a melt flow
index of 30, that is available as SRD7-463 from Shell Oil Company,
Houston, Tex.
[0103] The hook strip has preferably substantially continuous
planar backing of thermoplastic resin. Integral with the backing is
the array of hooks projecting generally at right angles to one
major surface of the backing. Each of the hooks has a stem, and, at
the end of the stem opposite the backing, a generally circular
plate-like cap or head projecting radially past or overhanging the
stem so as to form a fiber engaging portion that projects downward.
Preferably, the lower surface of the fiber engaging portion also
projects downward form a crook between the lower face of the fiber
engaging portion and the stem base portion. The stem can also have
a fillet around its base.
[0104] When the absorbent garment is secured to the user, the
fastening members 42, 408 secured to the side portions of the front
body panels 4 or rear body panels 6, or elsewhere as described
above, releasably engage or are otherwise connected to the front
body panel, or a landing member secured thereto. In particular, the
heads on the hooks engage the fibers of the front body panel, or of
the landing material. In particular, the heads on the hooks engage
the fibers of the body panel, whether elasticized or not, or
alternatively the landing material making up the landing member.
The refastenable portions 51 can be initially engaged with the
fibers to form a mechanical bond with the body panel or landing
member during the manufacturing process so as to help maintain the
connection between the side and middle portions. In the embodiments
of FIGS. 3, 4 and 20, where the absorbent garment is preferably
sold to the user as an "open product," the refastenable portions
51, 432 are initially engaged with body side surface 10 of the rear
body panel, preferably with a mechanical bond, during the
manufacturing process so as to maintain the fastener member flat
against the body panel such that it does not interfere with the
folding and packaging process. When the user desires to put on the
absorbent garment, the fastener members 42, 408 are peeled back so
as to disengage the refastenable portion 51, 432 from the rear body
panel, preferably the body side surface thereof. The fastener
members 42, 408 are rotated about the attachment location 45,
wherein the tab members 47 extend laterally outward and preferably
outboard from the side edges 28. The user then reapplies the
refastenable portion 51, 432 to the front body panel so as to
releasably secure the front and rear body panels to one another
about the user.
[0105] Referring to FIGS. 1-12 and 19-21, the absorbent garment
includes an absorbent composite 50 having first and second
longitudinally opposed terminal end edges 60, 62. Referring to
FIGS. 2-4, the absorbent composite preferably includes a
substantially liquid permeable topsheet 64, or liner, and a
substantially liquid impermeable backsheet 68, or outer cover. A
retention portion 70 is disposed or sandwiched between the topsheet
and the backsheet, which are connected. The topsheet, backsheet and
other components of the absorbent composite 50 can be joined for
example with adhesive bonds, sonic bonds, thermal bonds, pinning,
stitching or any other attachment techniques known in the art, as
well as combinations thereof. For example, a uniform continuous
layer of adhesive, a patterned layer of adhesive, a sprayed pattern
of adhesive or any array of lines, swirls or spots of construction
bonds may be used to join the topsheet and backsheet, or any of the
other components described herein. It should be understood that the
term "absorbent composite" refers to any material or assembly
capable of absorbing liquids or bodily exudates, and may be
comprised of a single material or component, for example a
retention portion.
[0106] Additional layers, including for example, a surge layer 72,
are also preferably incorporated into the absorbent composite.
Preferably, the surge layer does not run the entire length of the
absorbent composite and is shorter than the retention portion. The
topsheet can be indirectly joined to the backsheet by affixing the
topsheet to intermediate layers, such as the surge layer or
retention portion, which in turn is affixed to the backsheet. The
absorbent composite can further include one or more longitudinally
extending barrier cuffs formed along the opposite lateral sides of
the absorbent composite on the body side surface thereof.
[0107] The backsheet 68 is preferably liquid impermeable, but may
be liquid permeable, e.g., when an additional barrier layer is used
with the retention portion. For example, in one embodiment, the
backsheet can be made from a thin plastic film, or other flexible,
substantially liquid-impermeable material. As used herein, the term
"flexible" means a material that is compliant and which will
readily conform to the general shape and contour of the body of the
user. The backsheet prevents various bodily fluids and exudates
from wetting or otherwise contaminating various bedding or outer
garments worn by the user over the absorbent garment. In
particular, the backsheet can include a film, such as a
polyethylene film, having a thickness of from about 0.012 mm to
about 0.051 mm.
[0108] In various constructions, the topsheet can comprise various
woven or nonwoven materials. For example, the topsheet can be
composed of a meltblown or spunbonded web of desired fibers, and
may also be a bonded-carded web. For example, the topsheet can be
made of a substantially hydrophobic material, and the hydrophobic
material may optionally be treated with a surfactant or otherwise
processed to import a desired level of wettability and
hydrophilicity. In one particular embodiment of the invention, the
topsheet is a nonwoven, spunbond polypropylene fabric composed of
about 2.8-3.2 denier fibers formed into a web having a basis weight
of about 22 gsm and density of about 0.06 gm/cc. The fabric can be
surface treated with an operative amount of surfactant, such as
about 0.28% Triton X-102 surfactant. The surfactant can be applied
by any conventional means, such as spraying, printing, brush
coating or the like.
[0109] In various constructions, the backsheet can comprise a woven
or nonwoven fibrous web layer, which is treated or constructed,
partially or wholly, to impart the desired levels of liquid
impermeability to selected regions that are adjacent to or
proximate the absorbent retention portion. For example, the
backsheet may include a gas-permeable, nonwoven fabric layer
laminated to a polymer film layer which may or may not be
gas-permeable. Other examples of fibrous, cloth-like backsheet
materials can comprise a stretch thinned or stretch thermal
laminate material composed of a 0.6 mil (0.015 mm) thick
polypropylene cast film and a 0.7 ounce per square yard (23.8 gsm)
polypropylene spunbond material (2 denier fibers). A material of
this type has been employed to form the outercover of a
HUGGIES.RTM. Ultratrim Disposable Diaper, which has been
commercially available from Kimberly-Clark Corporation. The
backsheet can provide the outercover of the article, particularly
in the crotch region. Optionally, however, the article may include
a separate outercover component member, as disclosed herein, which
is additional to the backsheet. The outercover can be joined, for
example, to one or more of the absorbent composite and/or body
panels as explained above.
[0110] The backsheet may include a micro-porous, "breathable"
material which permits gases, such as water vapor, to escape from
the absorbent garment while substantially preventing liquid
exudates from passing through the backsheet. For example, the
breathable backsheet may be composed of a microporous polymer film
or a nonwoven fabric which has been coated or otherwise modified to
impart a desired level of liquid impermeability. For example, a
suitable microporous film can be a PMP-1 material, which is
available from Mitsui Toatsu Chemicals, Inc., a company having
offices in Tokyo, Japan; or an XKO-8044 polyolefin film available
from 3M Company of Minneapolis, Minn. The backsheet may also be
embossed or otherwise provided with a pattern or matte finish to
exhibit a more aesthetically pleasing appearance.
[0111] In various configurations of the invention, where a
component, such as the backsheet is configured to be permeable to
gas while having a resistance and limited permeability to aqueous
liquid, the liquid resistant component can have a construction
which is capable of supporting a selected hydrohead of water
substantially without leakage therethrough. A suitable technique
for determining the resistance of a material to liquid penetration
is Federal Test Method Standard FTMS 191 Method 5514, 1978, or an
equivalent thereof.
[0112] In one preferred embodiment, the backsheet is sufficiently
impermeable to liquid and semi-liquid materials to substantially
prevent the undesired leakage of waste materials, defined as
exudates, including for example urine and feces. For example, the
backsheet member can desirably support a hydrohead of at least
about 45 centimeters (cm) substantially without leakage. The
backsheet member can alternatively support a hydrohead of at least
about 55 cm, and optionally, can support a hydrohead of at least
about 60 cm, or more, to provide improved benefits.
[0113] The backsheet and/or outercover also can be extensible. In
one preferred embodiment, the backsheet and/or outercover is
capable of providing an elongation of at least about 1 cm when
subjected to a tensile force of 11.8 g/cm, and further provides a
substantially permanent deformation of at least about 20% when
subjected to a tensile force of 19.70 g/cm and is then allowed to
relax under a zero applied stress for a period of 1 minute.
[0114] For example, the extensible member can be composed of a
necked fiber, a creped fiber, a micro-pleated fiber, polymer films
or the like, as well as combinations thereof. The fabrics may be
woven or nonwoven materials, such as spunbond fabrics. One example
of a suitable extensible material is a 60% necked, polypropylene
spunbond having a basis weight of about 1.2 osy.
[0115] The backsheet and/or outercover also can be expandable, for
example when it has one or more folds, e.g., one or more z-folds
(not shown), or can be both extensible and expandable. The term
expandable as used herein means to enlarge or to increase the
extent or area, lateral and/or longitudinal, thereof, e.g., by
unfolding one or more folds.
[0116] The retention portion 70 is preferably made of an absorbent
material, which can be any material that tends to swell or expand
as it absorbs exudates, including various liquids and/or fluids
excreted or exuded by the user. For example, the absorbent material
can be made of airformed, airlaid and/or wetlaid composites of
fibers and high absorbency materials, referred to as
superabsorbents. Superabsorbents typically are made of polyacrylic
acids, such as FAVOR 880 available from Stockhausen, Inc. of
Greensboro, N.C. The fibers can be fluff pulp materials, such as
Alliance CR-1654, or any combination of crosslinked pulps,
hardwood, softwood, and synthetic fibers. Airlaid and wetlaid
structures typically include binding agents, which are used to
stabilize the structure. In addition, various foams, absorbent
films, and superabsorbent fabrics can be used as an absorbent
material. Various acceptable absorbent materials are disclosed in
U.S. Pat. No. 5,147,343 for Absorbent Products Containing Hydrogels
With Ability To Swell Against Pressure, U.S. Pat. No. 5,601,542 for
Absorbent Composite, and U.S. Pat. No. 5,651,862 for Wet Formed
Absorbent Composite, all of which are hereby incorporated herein by
reference. Furthermore, the proportion of high-absorbency particles
can range from about 0 to about 100%, and the proportion of fibrous
material from about 0 to about 100%. Additionally, high absorbency
fibers can be used such as Oasis type 121 and type 122
superabsorbent fibers available from Technical Absorbent Ltd.,
Grimsby, Lincolnshire, United Kingdom.
[0117] The retention portion 70 has laterally opposed side edges 74
and preferably can be made of a single or dual layer of absorbent
material. The retention portion preferably has an hour-glass shape
with enlarged end regions. Alternatively, the retention portion can
include a folded or multi-layered configuration. The retention
portion preferably has a length substantially equal to, or slightly
shorter than, the length of the absorbent composite. The retention
portion can include one or more barrier layers attached to the
absorbent material. In one embodiment, an upper tissue substrate is
disposed adjacent the retention portion. Alternatively, a lower
tissue substrate can be disposed adjacent an opposite side of the
retention portion, or the tissue can completely envelope the
retention position.
[0118] Referring to FIGS. 1-4, the opposite garment side of the end
regions of the absorbent composite, and in particular, the outer,
garment side surface of the backsheet 68, are secured to the
bodyside surface of the longitudinally opposed crotch ends of the
first and second body panels 4, 6, and in particular the liner
portion of those body panels. Likewise, and referring to FIG. 20,
the absorbent composite is secured to the bodyside surface of the
chassis 400. It should be understood that the absorbent composite
can be secured using any of the methods of attachment described
above, including for example various adhesives, stitching or other
bonding methods. The absorbent composite can be secured to the body
panels with any configuration of attachment lines, swirls,
patterns, spots, etc., or can be a full and continuous attachment
therebetween. In addition, it should be understood that the
absorbent composite can be attached to the garment side surface of
the body panels.
[0119] Referring to FIGS. 5-12, 13-15 and 19, various preferred
methods for fabricating one or more embodiments of the
aforedescribed refastenable absorbent garments are illustrated.
Although the processes are described in terms of various zones, it
should be understood that they are continuous processes.
[0120] Referring to FIGS. 5-12, a continuous first body panel web
120, which preferably forms the front body panel, and which is
preferably made of one or more of the materials described above, is
moved along in the process in a machine direction. The front body
panel web 120 is further secured to the absorbent composite 50,
which is also secured to a continuous rear body panel web 148 that
forms the rear body panel. In particular, the front body panel web
120 moves along a path parallel to the rear body panel web 148 in
the machine direction. The absorbent composite 50, extending in the
cross direction, is then applied to the bodyside of each of the
front and rear body panel base webs 120, 148 to form a ladder type
configuration, although it should be understood that the absorbent
composite could be attached to the garment side of each body panel.
The absorbent composite 50 can be assembled in a machine direction
and can thereafter be rotated and applied to the front and rear
body panel base webs. The absorbent composite can be incorporated
either before or after the assembly of the front and rear body
panel webs. In one preferred embodiment, where the outer cover is
secured to and forms part of the front and rear body panels and a
crotch portion 462 of the absorbent garment, the absorbent
composite 50 is applied to the body chassis after the outer cover
and body panel liners are joined with the elastic elements disposed
therebetween. The absorbent composite 50 is secured to the body
panel base webs 120, 148 by bonding and the like, or by other
devices known to those of skill in the art.
[0121] In one embodiment, where the front and rear body panel webs
are separate from one another and from the absorbent composite, leg
openings are formed between the successive cross direction
absorbent composites, which define the crotch portions and which
are spaced along the machine direction. In an alternative
embodiment, where the outer cover defines in part the front and
rear body panels, a die cutter successively cuts leg openings in
the outer cover between the absorbent composites to form the ladder
type configuration with a plurality of crotch portions. The cutter
can also shape one or both of the body panel webs.
[0122] A landing member, made of a landing material, can be applied
to the front body panel, preferably a garment side surface thereof,
as it moves therewith in a machine direction. The landing material
can be made of any of the above-described materials, including for
example a point unbonded, nonwoven material or a spunbond nonwoven
material. The landing material can also be made of various known
loop materials as described above. Alternatively, if the fastener
member is configured as a tape, the landing material preferably
made of various known materials that interface with such tape.
[0123] Referring to FIGS. 5, 6, 9-12 and 19 at zone A2, a plurality
of discrete fastener pieces 450 are successively applied to the
body side surface of the rear body panel web 148 along the machine
direction. Each fastener piece includes a first and second end 456,
454 spaced along the machine direction. In one preferred
embodiment, the fastener piece 450 includes a carrier material 452
and a refastenable portion 51 disposed thereon proximate each end
on a first side thereof. In one preferred embodiment, any elastic
elements in the body panels are deadened or deactivated beneath the
attachment of the fastener piece. In an alternative preferred
embodiment, the fastener piece 450 does not include a carrier
member, but rather is configured entirely of a refastenable
material, for example as a strip of refastenable material, having a
refastenable portion, for example an array of hooks, formed on a
first side thereof. Preferably, the refastenable portion(s) 51 of
each fastener piece are releasably engaged with the bodyside
surface of the rear body panel web.
[0124] Referring to zone A3, the first side of each fastener piece
450 is fixedly secured, preferably by bonding such as ultrasonic
bonding, to the body side surface of the body panel web 148 at an
attachment location 45 extending along a cross direction between
the refastenable portions 51, or approximately midway of the
fastener pieces 450.
[0125] Referring to zone A4 of FIGS. 5-6 and 9-12, the crotch
portion 462 is folded such that the rear body panel base web 148
overlies and faces the front body panel base web 120. Likewise at
zone A4 of FIG. 20, the crotch portion of the chassis is folded
such that the end portion overlies or faces the rear body panel.
The front and/or rear body panel webs 120, 148 and fastener pieces
450 are then successively cut with a cutter along the cross
direction at the attachment locations 45 so as to form a plurality
of discrete body panels 4, 6 and refastenable absorbent garments,
with each of the rear body panels 6 having a fastener member 42
secured to the opposite sides 28, 410 thereof. In an alternative
embodiment, the front and rear body panels also can be cut before
the crotch portion if folded. The cutter can be a knife and anvil
cutter, a laser, or water jet cutter, or any other cutter known to
those of skill in the art. Each of the pair of fastener members 42
formed from a single fastener piece 450 are attached proximate to
adjacent side edges 28 of successive body panels 6 and absorbent
garments in the stream of such body panels and garments. In this
embodiment, the absorbent product is formed as an "open" product,
with the fastener members 42 folded over and releasably secured to
the body side surface 10 of the rear body panel 6. When used, the
fastener members 42 are disengaged from the rear body panel,
rotated about the attachment location 45 and releasably engaged
with the garment side surface 12 of the front body panel 4 to
secure the garment on the user.
[0126] The lateral width of the fastener pieces can be shortened or
lengthened to provide a smaller or larger absorbent garment
respectively without altering the distance or machine pitch between
the cross direction cuts. As such, the process can be easily
changed to manufacture various size garments without having to
reconfigure the various cutters and other apparatus. For example, a
first group of fastener pieces, and in particular a first group of
carrier members has a greater width than a second group of fastener
pieces, and in particular a second group of carrier members.
Accordingly, absorbent garments made with the first group of
fastener pieces, although having the same body panels as absorbent
garments made with the second group of fastener pieces, can
accommodate user's having a larger waist.
[0127] Referring to FIG. 6, a plurality of extension pieces 500 are
successively applied to the front body panel web in a similar
fashion as the fastener pieces. In particular, each extension piece
500 is successively fixedly secured to the body side surface 10 of
the front body panel web 120 at an attachment location 484, which
locations are preferably aligned with the attachment locations 45.
Alternatively, the extension piece can be secured to the garment
side surface of the front body panel. After the crotch portion is
folded, as explained above, the extension piece 500 is successively
cut with the front body panel web 120 along the cross direction at
the attachment location 484 to form a pair of extension members 414
attached respectively to successive front body panels 4 and
absorbent garments in the stream of plurality of such body panels
and garments. The extension pieces can be folded over the front
body panel, along either of the body side or garment side surface
thereof, prior to use by the user.
[0128] Referring to zone A2 of FIGS. 7 and 8, the plurality of
discrete fastener pieces 450 are successively applied to the
garment side surface of the front body panel web 120 along the
machine direction. Each fastener piece includes a first and second
end 456, 454 spaced along the machine direction. Fastener piece 450
includes a carrier material 452 and a refastenable portion 51
disposed thereon proximate each end on a first side thereof. In one
preferred embodiment, the entire fastener piece 450 is configured
with a refastenable portion formed on a first side thereof.
Preferably, the refastenable portion(s) 51 of each fastener piece
are releasably engaged with the garment side surface of the front
body panel web. In one embodiment, the first side of each fastener
piece is then fixedly secured, preferably by bonding such as
ultrasonic bonding, to the garment side surface of the body panel
web at an attachment location extending along a cross direction
between the refastenable portions, or approximately midway of the
fastener pieces. An exemplary ultrasonic bonder is the rotating
horn and anvil type ultrasonic bonder disclosed in U.S. Pat. No.
5,660,679, the entirety of which is hereby incorporated herein by
reference. Another type of ultrasonic bonder is disclosed in U.S.
Pat. No. 6,123,792, the entire disclosure of which is hereby
incorporated herein by reference. It should be understood that the
fastener pieces can be fixedly secured to the body panel web using
adhesive bonds, thermal bonds, stitching and other attachment
devices known to those of skill in the art.
[0129] Referring to zone A4 of FIGS. 7 and 8, the crotch portion is
folded such that the rear body panel base web 148 overlies and
faces the front body panel base web 120. Side seams 39 are formed
by attaching the side edges 24 and 28 of the front and rear body
panels, preferably by ultrasonic bonding, or with adhesive bonds,
stitching or other suitable means known to those skilled in the
art. In one preferred embodiment, shown in FIGS. 7 and 8, the
crotch portion 462 is folded prior to fixedly securing the fastener
piece 450 to the front body panel web 120, with the fastener piece
450 releasably connected to the garment side surface 12 of the
front body panel web 12 by way of the releasable connection between
the refastenable portion and the front body panel, or landing
member disposed thereon. The fastener piece 450 is simultaneously
bonded to the front body panel web 120 at location 45 as the front
body panel web 120 is bonded or connected to the rear body panel
web 148, preferably by ultrasonic bonding. Of course, it should be
understood that the fastener piece can be first bonded or connected
to one or the other of the front and rear body panels prior to
folding, and that the front body panel can be connected to the rear
body panel along the same location after the crotch portion is
folded. The connection between the front and rear body panels can
also serve to create an additional bond between the fastener piece
and either the front or rear body panel.
[0130] At zone A5, a cross direction cut 150 is made through the
side seam 39 and attachment location 45 to separate the
refastenable absorbent garments. As explained above, the side seam
can also be omitted. The cut can be made with a knife and anvil
cutter, or other suitable cutter as explained above. The
refastenable absorbent garments can thereafter be folded and
packaged for sale to the end user. The plurality of discrete body
panels and refastenable absorbent garments each have a front body
panel with a fastener member 42 secured to the opposite sides
thereof. Each of the pair of fastener members 42 formed from a
single fastener piece are attached to adjacent side edges of
successive body panels and absorbent garments in the stream of such
body panels and garments. In this embodiment, the absorbent product
is formed as pant type product.
[0131] As shown in FIG. 8, a pair of cross direction cuts 140
spaced along the machine direction are successively made in the
front body panel web with a cutter to form the lines of weakness
37, preferably spaced on each side of the attachment location 45
and side seam 39, but between the attachment location 45 and the
area where the refastenable portion 51 is engaged with the front
body panel, or landing member secured thereto. Preferably, the cuts
are formed as perforations or like penetrations that do not
completely separate the web. Referring to zone A1, preferably the
cross direction cuts 140 are made prior to the application of the
fastener piece 450 to the front body panel web 120. In the
embodiment wherein the entirety of the fastener piece includes a
refastenable portion, the line of weakness is positioned between
the ends of the fastener member, and more preferably between the
ends of the fastener piece and a midpoint of the fastener piece.
Preferably, engagement between the refastenable portion 51 of the
fastener material and the middle portion 33 of the front body
panel, whether it be of a hook and loop engagement or an adhesive
engagement, is the only type of engagement between those two
members. Alternatively, one or more secondary, breakable bonds can
be formed between the fastener member and the landing member or
front body panel on the inboard side of the line of weakness. The
breakable bond can be broken when the garment is put into use, for
example, when it is desired to use the refastenable feature of the
garment.
[0132] Referring to FIGS. 13-15, the rear body panel web 148 and
fastener pieces 450 are successively cut along the cross direction
so as to form a plurality of discrete body panels 6 and
refastenable absorbent garments, with each of the rear body panels
having one or more fastener members 42 formed along the opposite
sides thereof. The body panel web and fastener pieces can be cut
with a rotary die cutter, a knife and anvil cutter, or any other
cutter suitable for such a cut as known by those of skill in the
art. Preferably, where a plurality of tab members 47 are spaced
longitudinally along the base web, as shown for example in FIGS. 13
and 14, a serpentine cross direction cut 624 is made through the
body panel web 148 and fastener pieces 450 to form a plurality of
fastener tabs 47. Preferably, the cut 624 forms mirror image tabs
47 in the successive absorbent garments, with waste material 620
between each set of tab members being collected and recycled. Each
of the pair of fastener members 42 formed from the fastener pieces
450 are formed along adjacent side edges 28 of successive body
panels and absorbent garments in the stream of such body panels and
garments. In this embodiment, the absorbent product is formed as an
"open" product. When used, the fastener members are releasably
engaged with the garment side surface 12 of the front body panel 4
to secure the garment on the user.
[0133] Various aspects of the process for making the absorbent
garment are further disclosed in U.S. application Ser. No.
09/834,870, filed Apr. 13, 2001, and entitled "Multiple Component
Web," U.S. application Ser. No. 09/834,875, filed Apr. 13, 2001 and
entitled "Method of Assembling Personal Care Absorbent Article,"
U.S. application Ser. No. 09/834,869, filed Apr. 13, 2001, and
entitled "Pant-Type Personal Care Articles, and Methods of Making
and Using Such Personal Care Articles," U.S. application Ser. No.
09/834,787, filed Apr. 13, 2001 and entitled "Methods of Changing
Size of Pant-Type Personal Care Articles Outputted from a
Manufacturing Process," and U.S. application Ser. No. 09/834,682,
filed Apr. 13, 2001 and entitled "Passive Bonds For Personal Care
Article," the entire disclosures of which are hereby incorporated
by reference.
[0134] In other aspects, the absorbent garment and the process for
making the absorbent garment are further disclosed in U.S.
Application Serial No. 60/303,307, filed Jul. 5, 2001, and entitled
"Refastenable Absorbent Garment," the entire disclosure of which is
hereby incorporated by reference.
[0135] Although the present invention has been described with
reference to preferred embodiments, those skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention. As such, it
is intended that the foregoing detailed description be regarded as
illustrative rather than limiting and that it is the appended
claims, including all equivalents thereof, which are intended to
define the scope of the invention.
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