U.S. patent application number 10/915239 was filed with the patent office on 2006-02-16 for elastomeric nonwoven laminates and process for producing same.
This patent application is currently assigned to The Procter & Gamble Company. Invention is credited to Donald Carroll Roe, Uwe Schneider.
Application Number | 20060035055 10/915239 |
Document ID | / |
Family ID | 35529658 |
Filed Date | 2006-02-16 |
United States Patent
Application |
20060035055 |
Kind Code |
A1 |
Schneider; Uwe ; et
al. |
February 16, 2006 |
Elastomeric nonwoven laminates and process for producing same
Abstract
An elastomeric laminate for use in an absorbent article can have
a first plurality of elastomeric strands and a second plurality of
elastomeric strands bonded to a first substrate. The first
plurality of elastomeric strands can be bonded to the first
substrate in a first orientation while the second plurality of
elastomeric strands is joined to the first substrate in a second
orientation. The first and second orientations can be different
such that the elastomeric laminate can accommodate tension forces
which act on the laminate from different axes. Optionally, a second
substrate or a third plurality of elastomeric strands may be added
to the elastomeric laminate.
Inventors: |
Schneider; Uwe; (Mason,
OH) ; Roe; Donald Carroll; (West Chester,
OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY;INTELLECTUAL PROPERTY DIVISION
WINTON HILL TECHNICAL CENTER - BOX 161
6110 CENTER HILL AVENUE
CINCINNATI
OH
45224
US
|
Assignee: |
The Procter & Gamble
Company
|
Family ID: |
35529658 |
Appl. No.: |
10/915239 |
Filed: |
August 10, 2004 |
Current U.S.
Class: |
428/105 ;
428/182 |
Current CPC
Class: |
B32B 5/12 20130101; Y10T
428/24083 20150115; Y10T 428/24744 20150115; Y10T 428/24 20150115;
Y10T 442/602 20150401; Y10T 156/10 20150115; A61F 13/4902 20130101;
Y10T 428/24694 20150115; Y10T 428/24074 20150115; Y10T 428/24132
20150115; Y10T 156/1051 20150115; Y10T 156/1082 20150115; Y10T
428/24058 20150115 |
Class at
Publication: |
428/105 ;
428/182 |
International
Class: |
B32B 5/12 20060101
B32B005/12 |
Claims
1. An elastomeric laminate comprising: an extensible intermediate
laminate comprising: a first substrate having a bonding surface and
a face opposite the bonding surface; and a first plurality of
elastomeric strands bonded to the bonding surface along a first
orientation; and a second plurality of elastomeric strands bonded
to the face or the bonding surface of the first substrate of the
extensible intermediate laminate along a second orientation,
wherein the first orientation differs from and is non-orthogonal to
the second orientation.
2. The elastomeric nonwoven laminate of claim 1, wherein the first
orientation is at least partially curvilinear.
3. The elastomeric laminate of claim 1, wherein the first
orientation or the second orientation is a pre-determined angle
from a longitudinal axis, the pre-determined angle ranging from
about 0 to about 360 degrees.
4. The elastomeric laminate of claim 1, further comprising a second
substrate having a second bonding surface, wherein the second
bonding surface of the second substrate is bonded to the first
plurality of elastomeric strands or the second plurality of
elastomeric strands such that the second substrate is joined to the
extensible intermediate laminate in a face to face arrangement.
5. The elastomeric laminate of claim 1, wherein the first
orientation is parallel to a longitudinal axis and the extensible
intermediate laminate is extensible in a direction parallel to the
longitudinal axis.
6. The elastomeric laminate of claim 5, wherein the first plurality
of elastomeric strands is pre-strained and bonded to the bonding
surface of the first substrate such that the extensible
intermediate laminate is extensible.
7. The elastomeric laminate of claim 5, wherein the extensible
intermediate laminate is mechanically activated such that the
extensible intermediate laminate is extensible.
8. The elastomeric laminate of claim 5, wherein the second
orientation of the second plurality of elastomeric strands is at
least partially curvilinear.
9. The elastomeric laminate of claim 5, wherein the second
orientation is a pre-determined angle from the machine direction,
the pre-determined angle ranging from about 0 to about 360
degrees.
10. An elastomeric laminate comprising: a first extensible
intermediate laminate comprising: a first substrate having a first
bonding surface and a first face opposite the bonding surface; and
a first plurality of elastomeric strands bonded to the first
bonding surface along a first orientation; a second extensible
intermediate laminate comprising: a second substrate having a
second bonding surface and a second face opposite the bonding
surface; and a second plurality of elastomeric strands bonded to
the second bonding surface along a second orientation, wherein the
first extensible intermediate laminate and the second extensible
intermediate laminate are joined in a face to face orientation; and
a third plurality of elastomeric strands bonded to at least one of
the first face of the first substrate, the first bonding surface of
the first substrate, the second face of the second substrate, and
the second bonding surface of the second substrate, along a third
orientation which is different from the first orientation and the
second orientation.
11. The elastomeric laminate of claim 10, wherein the first
orientation is parallel to a longitudinal axis and the first
plurality of elastomeric strands is pre-strained and bonded to the
first bonding surface such that the first extensible intermediate
laminate is extensible in a direction parallel to the longitudinal
axis, and wherein the second orientation is parallel to the
longitudinal axis and the second plurality of elastomeric strands
is pre-strained and bonded to the second bonding surface such that
the second extensible intermediate laminate is extensible in a
direction parallel to the longitudinal axis.
12. The elastomeric laminate of claim 11, wherein the third
orientation is at least partially curvilinear.
13. The elastomeric laminate of claim 11, wherein the third
orientation is a pre-determined angle from a longitudinal axis, the
pre-determined angle ranging from about 0 to about 360 degrees.
14. The elastomeric laminate of claim 11, wherein the first
substrate and the second substrate have a basis weight in the range
of about 10 gsm to about 40 gsm.
15. The elastomeric laminate of claim 10, wherein the first
substrate and second substrate are made up of a single substrate
comprising a first portion and a second portion, wherein the first
portion acts as the first substrate and the second portion acts as
the second substrate, wherein the first plurality of elastomeric
strands is bonded to the first portion and the second plurality of
elastomeric strands is bonded to the second portion, wherein the
second portion is disposed on top of the first portion such that
the first portion and the second portion are arranged in a face to
face orientation, and wherein the third plurality of elastomeric
strands is bonded to a face of the first portion or the second
portion.
16. The elastomeric laminate of claim 10, wherein the first
orientation is parallel to a longitudinal axis and the first
extensible intermediate laminate is activated such that the first
extensible intermediate laminate is extensible in a direction
parallel to the longitudinal axis, and wherein the second
orientation corresponds is parallel to the longitudinal axis and
the second extensible intermediate laminate is activated such that
the second extensible intermediate laminate is extensible in the
direction parallel to the longitudinal axis.
17. An absorbent article comprising: an extensible intermediate
laminate comprising: a first substrate having a bonding surface and
a face opposite the bonding surface; and a first plurality of
elastomeric strands bonded to the bonding surface along a first
orientation; and a second plurality of elastomeric strands bonded
to the face or the bonding surface of the first substrate of the
extensible intermediate laminate along a second orientation,
wherein the first orientation differs from and is non-orthogonal to
the second orientation.
18. The absorbent article of claim 17, wherein the first
orientation is parallel to a longitudinal axis and the extensible
intermediate laminate is extensible in a direction parallel to the
longitudinal axis.
19. The absorbent article of claim 18, wherein the second
orientation of the second plurality of elastomeric strands is at
least partially curvilinear.
20. The absorbent article of claim 18, wherein a strand of the
first plurality of elastomeric strands or the second plurality of
elastomeric strands comprise discrete portions of elastomeric
material.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an elastomeric laminate of
a strand elastic and a substrate. The elastomeric laminate may be
used in a variety of articles and is particularly useful in
disposable absorbent articles such as baby diapers, adult
incontinence articles, feminine hygiene articles, baby swim
diapers, bibs, wound dressings, and any other articles where a cost
effective stretchable material may be desirable. The present
invention also relates to a method and apparatus for manufacturing
the elastomeric laminate.
BACKGROUND
[0002] Elastomeric nonwoven laminates are used in a wide variety of
applications including extensive use in absorbent articles. For
example, such laminates have been used in the topsheet, backsheet,
waistband, and fastening elements of absorbent articles. Typical
elastomeric nonwoven laminates comprise a layer of nonwoven and a
layer of elastic. The layer of nonwoven can provide a feel of
softness to a wearer of the absorbent article and may protect a
wearer's skin from abrasion caused by the extension and contraction
of the elastic.
[0003] Elastomeric nonwoven laminates in an absorbent article are
subjected to many different forces. For example, in a waistband
application, a tension force can be applied to the elastomeric
nonwoven laminate such that the waistband is stretched from its
non-stretched state to a stretched state. In reaction to the
tension force, the waistband provides a contracting force in the
opposite direction of the tension force. Specifically, the elastic
layer wants to contract to a lower energy state, i.e. a
non-stretched state instead of being in a stretched state. The
contracting force in turn creates a normal force which acts against
a waist of a wearer. The normal force, which is proportional to the
contracting force, holds the absorbent article in place about the
waist of the wearer. Also, the weight of the absorbent article
provides a sagging tension force which tends to pull the absorbent
article downward. These sagging tension forces are increased with
the retention of body exudates by the absorbent article.
[0004] In general, the tension force provided acts in a primary
direction of extensibility of the elastomeric nonwoven laminate.
The primary direction of extensibility depends greatly on the
orientation of the elastic layer and the way in which the elastic
layer was bonded to the nonwoven. Typically, the primary direction
of extensibility is parallel to a longitudinal axis of the
elastomeric nonwoven laminate. In the primary direction of
extensibility, the elastomeric nonwoven laminate has the greatest
amount of elastic extensibility.
[0005] Contrarily, the sagging tension forces act in a direction
which is not parallel to the primary direction of extensibility.
Instead, the sagging tension forces tend to act more along a
secondary direction of extensibility. Because the nonwoven of the
elastomeric nonwoven laminate is elastically extensible to a small
degree, the elastomeric nonwoven laminate is also elastically
extensible in the secondary direction of extensibility. However,
because the elastomeric nonwoven is not necessarily intended to be
extensible in the secondary direction of extensibility, the
elastomeric nonwoven laminate generally has a higher modulus of
elasticity (resistance to stretching) in the secondary direction of
extensibility than the primary direction of extensibility.
[0006] Under initial loading conditions, i.e. fit when the
absorbent article is dry, the contracting force exerted by the
elastic layer of the waistband creates a sufficient normal force to
hold the absorbent article about the waist of the wearer and
thereby overcome the sagging tension forces exerted by the unloaded
absorbent article. In addition, the nonwoven of the elastomeric
nonwoven laminate generally has a modulus of elasticity in the
secondary direction of extensibility which is high enough to
overcome the sagging tension forces of an unloaded absorbent
article.
[0007] In contrast, once the absorbent article takes on body
exudates and becomes loaded, the sagging tension forces, which are
exerted on the waistband and are not in the primary direction of
extensibility, are increased. These sagging tension forces may
overcome the normal force exerted on the waist of the wearer. Thus,
the normal force may not be sufficient to prevent the absorbent
article from sagging/slumping on the waist of the wearer. Also,
these sagging tension forces, can also overcome the modulus of
elasticity of the nonwoven of the elastomeric nonwoven laminate
such that the nonwoven is extended in the secondary direction of
extensibility. This extension of the nonwoven in the secondary
direction of extensibility can exacerbate the sagging/slumping
effect of the absorbent article on the waist of the wearer.
[0008] Also exacerbating this problem is the fact that a wearer's
body is contoured. Because a wearer's body is contoured, the forces
that are exerted on a nonwoven laminate may not necessarily be
distributed evenly across the nonwoven laminate. Thus, the
elastomeric nonwoven laminate may experience higher forces on one
side of the elastomeric nonwoven laminate and lower forces on
another side.
[0009] Consequently, it would be beneficial to provide a cost
effective elastomeric laminate that can accommodate the tension
forces and the sagging tension forces of a loaded absorbent
article. Moreover, it would be beneficial to provide an elastomeric
laminate that can also better accommodate the contours of a
wearer's body. Also, it would be beneficial to provide a method and
apparatus for making such a material.
SUMMARY OF THE INVENTION
[0010] In order to solve one or more of the problems found in the
art, an elastomeric laminate and a method of producing the same is
provided. The elastomeric laminates discussed herein may be
incorporated into many different regions of absorbent articles. An
elastomeric laminate comprising an extensible intermediate laminate
and a second plurality of elastomeric strands is described herein.
The extensible intermediate laminate comprises a first substrate
having a bonding surface and a face opposite the bonding surface. A
first plurality of elastomeric strands is bonded to the bonding
surface of the first substrate along a first orientation. The
second plurality of elastomeric strands is bonded to the extensible
intermediate laminate along a second orientation wherein the first
orientation is different from and non-orthogonal to the second
orientation. The second plurality of elastomeric strands is joined
to the face or the bonding surface of the first substrate.
[0011] Another embodiment comprises a first extensible intermediate
laminate, a second extensible intermediate laminate, and a third
plurality of elastomeric strands. The first extensible intermediate
laminate comprises a first substrate having a first bonding surface
and a first face opposite the first bonding surface. A first
plurality of elastomeric strands extending along a first
orientation is bonded to the first bonding surface of the first
substrate.
[0012] The second extensible intermediate laminate comprises a
second substrate which has a second bonding surface and a second
face opposite the second bonding surface. A second plurality of
elastomeric strands extending along a second orientation is bonded
to the second bonding surface of the second substrate. In addition,
the first extensible intermediate laminate and the second
extensible intermediate laminate are joined in a face to face
orientation.
[0013] The third plurality of elastomeric strands extends along a
third orientation which is different from the first orientation and
the second orientation. The third plurality of elastomeric strands
is bonded to at least one of the first face, the first bonding
surface of the first extensible intermediate laminate, the second
face, and the second bonding surface of the second extensible
intermediate laminate.
BRIEF DESCRIPTION SHOWN IN THE DRAWINGS
[0014] While the specification concludes with claims particularly
pointing out and distinctly claiming the subject matter that is
regarded as the present invention, it is believed that the
invention will be more fully understood from the following
description taken in conjunction with the accompanying
drawings.
[0015] FIG. 1 is an exploded isometric view of an elastomeric
laminate.
[0016] FIG. 1A is a cross sectional view of the elastomeric
laminate of FIG. 1 through line 1A-1A.
[0017] FIG. 1B is an elevation view of an elastomeric laminate
which has continuous bonding between a substrate layer and a layer
of elastic.
[0018] FIG. 1C is an elevation view of an elastomeric laminate
which has point bonding between a substrate layer and a layer of
elastic.
[0019] FIGS. 1D-1F are plan views of a second plurality of
elastomeric strands when viewed from the z-direction, looking down
at the xy-plane.
[0020] FIG. 2 is an exploded isometric view of the elastomeric
laminate of FIG. 1 with the added benefit of a second substrate
added to the laminate structure.
[0021] FIG. 2A is a cross sectional view of the elastomeric
laminate of FIG. 2 through line 2A-2A.
[0022] FIG. 3 is an exploded isometric view of an elastomeric
laminate with the added benefit of a third plurality of elastomeric
strands comprising a third plurality of elastomeric strands.
[0023] FIG. 3A is a cross sectional view of the elastomeric
laminate of FIG. 3 through lines 3A-3A.
[0024] FIG. 3B is a cross sectional view of an alternate embodiment
of an elastomeric laminate.
[0025] FIG. 4 is a plan view of a diaper in accordance with the
invention.
[0026] FIG. 4A illustrates various regions of a diaper where
elastomeric laminates may be used.
[0027] FIG. 5 is a perspective view of a pull-on diaper in
accordance with the invention.
[0028] FIG. 6 is a plan view of the pull-on diaper of FIG. 5 shown
in a flattened state.
[0029] FIGS. 7A and 7B are cross-sectional views of the pull-on
diaper shown in FIG. 5-6.
[0030] FIG. 8 is a plan view of a diaper in accordance with the
invention in which elastomeric laminates are disposed in the diaper
ears and the front waist portion.
[0031] FIG. 9 is a plan view of a diaper in which elastomeric
laminates are disposed along the lateral portions of a diaper in
order to provide the desired elastic properties in the leg
openings.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The method, material, and the apparatus of the present
invention are designed to provide a more cost effective and/or
consumer desirable elastomeric laminate suitable for use in a
variety of articles including disposable absorbent articles.
Definitions
[0033] The following terminology is used herein consistent with the
plain meaning of the terms with further details provided in the
present specification.
[0034] The terms "activating", "activation" or "mechanical
activation" refer to the process of making a substrate, or an
elastomeric laminate more extensible than the it was prior to the
process.
[0035] "Basis weight" refers to the weight of a planar material for
a given surface area. Basis weight is typically measured in grams
per square meter (gsm). The basis weight of an elastomeric laminate
is typically measured in an unstrained configuration.
[0036] The terms "corrugations" or "ruggosities" are used to
describe hills and valleys that occur in a substrate or in a
laminate structure either via the activation or the live stretch
processes each described below. Note that neither term mandates
that either the hills or valleys created are uniform in nature.
[0037] A "disposable absorbent article" refers to an article device
that normally absorbs and/or retains fluids. In certain instances,
the phrase refers to articles that are placed against or in
proximity to the body of the wearer to absorb and contain the
excreta and/or exudates discharged from the body, and includes such
personal care articles as baby diapers, baby training pants, adult
incontinence articles, feminine hygiene articles, baby swim
diapers, wound dressing, and the like. A disposable absorbent
article may be worn by infants and other incontinent persons about
the lower torso.
[0038] The term "disposable" is used herein to describe products,
which generally are not intended to be laundered or otherwise
restored and reused for their original function. They are typically
intended to be discarded after about 1 or 2 uses. It is preferred
that such disposable articles be recycled, composted or otherwise
disposed of in an environmentally compatible manner.
[0039] An "elastic," "elastomer" or "elastomeric" refers to
polymers or laminates exhibiting elastic properties. They include
any material that upon application of a force to its relaxed,
initial length can stretch or elongate to an elongated length more
than 10% greater than its initial length and will substantially
recover back to about its initial length upon release of the
applied force.
[0040] An "extrusion apparatus" or "extruder" refers herein to any
machine capable of extruding a molten stream of material such as a
polymeric through one or more extrusion openings.
[0041] The term "extrude" or "extruding" refers herein to a process
by which a heated elastomer is forced through one or more extrusion
openings to form a molten stream of elastic that cools into a
solid.
[0042] The terms "face to face arrangement" or "face to face
orientation" as used herein refer to the joining of a first element
to a second element, wherein at least a portion of the first
element overlaps at least a portion of the second element or vice
versa. Note that the joining of the first element and the second
element does not necessarily mean that a face of the first element
and a face of the second element are directly bonded or in contact
with one another. There may be some intermediate element which
resides between the first element and the second element. The first
element and the second element in this context may comprise at
least one of a substrate, a nonwoven, a plurality of elastomeric
strands, or any combination thereof.
[0043] The term "force wall" refers herein to situation where a
force required for a 10% increase in strain for a given material
increases at least about 20%.
[0044] The term "joined" herein encompasses configurations whereby
a material or component is secured directly or indirectly (by one
or more intermediate members) to another material or component. An
example of indirect joining is an adhesive. Direct bonding includes
heat and or pressure bonding. Joining may include any means known
in the art including, for example, adhesives, heat bonds, pressure
bonds, ultrasonic bonds, and the like.
[0045] "Live stretch" includes stretching elastic and bonding the
stretched elastic to a substrate. After bonding, the stretched
elastic is released causing it to contract, resulting in a
"corrugated" substrate. The corrugated substrate can stretch as the
corrugated portion is pulled to about the point that the substrate
reaches at least one original flat dimension. However, if the
substrate is also elastic, then substrate can stretch beyond the
relaxed length of the substrate prior to bonding with the elastic.
The elastic is preferably stretched at least 25% and more
preferably at least 100% of its relaxed length when it is bonded to
the substrate.
[0046] The term "longitudinal axis" is used herein to refer to an
axis which extends parallel to the longest edge of a laminate or a
substrate. If the laminate or substrate has no edge which has a
longer length than other edges, then the longitudinal axis extends
parallel to an edge if more than one edge or tangent to the edge if
only one edge.
[0047] The term "transverse axis" is used herein to refer to an
axis which extends perpendicular to the longitudinal axis on a
laminate or a substrate.
[0048] The term "molten stream" refers herein to a linear deposit
of a heated liquid material such as a polymeric exiting an
extrusion apparatus. The stream may include continuous filaments,
discontinuous fibers, or continuous films of a polymeric material.
When cooled, the molten stream may form for example, a strand
elastic.
[0049] The term "machine direction" is used herein to refer to the
direction of material flow through a process.
[0050] The term "cross direction" is used herein to refer to a
direction that is perpendicular to the machine direction.
[0051] The term "nonwoven" refers herein to a material made from
continuous (long) filaments (fibers) and/or discontinuous (short)
filaments (fibers) by processes such as spunbonding, meltblowing,
and the like. Nonwovens do not have a woven or knitted filament
pattern. Nonwovens are typically described as having a machine
direction and a cross direction. The machine direction is the
direction in which the nonwoven is manufactured. Nonwovens are
typically formed with a machine direction that corresponds to the
long or rolled direction of fabrication.
[0052] The term "primary direction of extensibility" refers herein
to a direction in which an elastomeric laminate provides the lowest
resistance to elongation to an applied force.
[0053] The term "secondary direction of extensibility" refers
herein to a direction in which the elastomeric laminate provides
the highest resistance to elongation to an applied force.
[0054] The term "substrate(s)" refers herein to a material suitable
for use in an elastomeric laminate, particularly for use in a
disposable absorbent article. Examples of such materials are films,
nonwovens, wovens, fabrics, and other materials known in the art
for use in elastomeric laminates in absorbent articles.
Description
[0055] Elastomeric laminates are used extensively in absorbent
articles. Such laminates have been used in the topsheet, backsheet,
waistband, and fastening elements of absorbent articles. In a
waistband application, a tension force can be applied to the
waistband such that the elastomeric laminate therein is stretched
from its non-stretched state to a stretched state. Under initial
loading conditions, i.e. fit when the absorbent article is dry, the
tension force that can be applied is generally in a primary
direction of extensibility of the elastomeric laminate. However,
once the absorbent article takes on body exudates and becomes
loaded, sagging tension forces which are not predominantly in the
primary direction of extensibility are exerted on the elastomeric
laminate.
[0056] Examples of an elastomeric laminates that can accommodate
the sagging tension forces of a loaded absorbent article are
provided herein. Each elastomeric laminate discussed herein has a
longitudinal axis and a transverse axis. For ease of discussion,
coordinate systems have been provided with many of the figures. In
each instance, where a coordinate system is referenced, the
longitudinal axes are parallel to an x-axis and are parallel to
each other as well. Thus, the transverse axes for each coordinate
system referenced are also parallel to each other as well.
[0057] In one embodiment, as shown in FIGS. 1 and 1A, the
elastomeric laminate 100 comprises an extensible intermediate
laminate 102 and a second plurality of elastomeric strands 114. The
extensible intermediate laminate 102 includes a first substrate 122
which may comprise a first bonding surface 123, an adhesive 120,
and a first plurality of elastomeric strands 118. The first
plurality of elastomeric strands 118 can be bonded to the first
bonding surface 123 of the first substrate 122 via the adhesive 120
or by any means known in the art.
[0058] The first plurality of elastomeric strands 118 can be bonded
to the first bonding surface 123 of the first substrate 122 along a
first orientation (see discussion regarding FIGS. 1D-1F). The first
orientation may comprise many different arrangements. As an
example, the first plurality of elastomeric strands 118 may be
bonded to the first bonding surface 123 of the first substrate 122
where the first orientation 119 is parallel to a longitudinal axis
130 of the elastomeric laminate 100 as shown in FIG. 1 using the
coordinate system 199.
[0059] Similarly, the second plurality of elastomeric strands 114
may be bonded to the extensible intermediate laminate 102 in a
second orientation (see the discussion regarding FIGS. 1D-1F). As
shown in FIG. 1, the second plurality of elastomeric strands 114 is
joined to the first bonding surface 123 of the first substrate 122
via adhesive 120 or any means known in the art. Alternatively, the
second plurality of elastomeric strands may be joined to a face 101
(see FIG. 1A) of the first substrate 122 by any means known in the
art.
[0060] In order to accommodate the tension forces which act in the
primary direction of extensibility, the extensible intermediate
laminate 102 can be made extensible via live stretch or mechanical
activation. In one embodiment, the extensible intermediate laminate
102 is made extensible in the longitudinal direction 130 via live
stretch. The use of live stretch involves the joining of a
non-elastic substrate and an elastic while the elastic is in a
stretched condition. Once the elastic is bonded to the non-elastic,
at least a portion of the strain may be removed from a bonded
portion of elastic and non-elastic. Because the elastic is in a
stretched condition, when the elastic relaxes, the non-elastic
substrate gathers between the locations where it is bonded to the
elastic thereby forming corrugations.
[0061] Note that depending on the type of bonding, the plurality of
elastomeric strands could also corrugate along with the non-elastic
substrate. As shown in FIG. 1B, if a plurality of elastomeric
strands 14 (shown as a sheet in FIGS. 1B and 1C) is continuously
bonded to a substrate 10, i.e. bonded substantially throughout
their entire length 18, then the corrugations caused by the
relaxation of the plurality of elastomeric strands 14 may be
present in an entire elastomeric laminate 20. In contrast, as shown
in FIG. 1C, if the plurality of elastomeric strands 14 is only
bonded at certain points 16 to the substrate 10, then the substrate
10 will generally corrugate with the bonded points 16 corresponding
to corrugation valleys 24 and in between the bonded points the
corrugation hills 22.
[0062] The corrugation hills 22 and valleys 24 determine the
corrugation direction depending on which way they extend. If the
corrugation hills and corrugation valleys extend in a transverse
direction 140 (see coordinate system 198), the corrugation
direction is the transverse direction 140. The substrate 10 and/or
elastic laminate is generally extensible perpendicular to the
corrugation direction. For the elastic laminates 20 and 30, the
corrugation direction 75 may be in the transverse direction 140.
Therefore, the overall elastomeric laminate may be extensible in
the longitudinal direction 130.
[0063] In contrast to live stretch, mechanical activation
physically manipulates the elastic laminate such that it becomes
elastomeric. The mechanical activation process utilizes "zero
strain" stretch laminate webs which comprise at least two plies of
material secured to one another along at least a portion of their
coextensive surfaces while in a substantially untensioned ("zero
strain") condition. One of the plies employed in the "zero strain"
stretch laminate is comprised of a material, which is stretchable
and elastomeric, i.e., it will return substantially to its
untensioned dimensions after an applied tensile force has been
released. The second ply secured to the elastomeric ply is
elongatable but not necessarily elastomeric. Upon stretching, the
second ply will permanently elongate at least to a certain degree,
so that upon release of the applied tensile forces, it will not
fully return to its original undistorted configuration. The
stretching is induced by mechanical activation which may include,
for example meshing the laminate between corrugated mating
rolls.
[0064] Despite the fact that the second orientation is shown to
comprise a curvilinear component (see FIG. 1), the second
orientation can vary to the same degree as the first orientation;
however, for the sake of simplicity, reference shall only be made
to the second orientation when discussing FIGS. 1D-1F. In addition,
coordinate system 197 shall be referenced for FIGS. 1D-1F.
[0065] In order to accommodate tension forces which generally do
not act parallel to the primary direction of extensibility of the
elastomeric laminate, e.g. the sagging tension forces which are
exerted on an elastomeric laminate from an absorbent article, the
second orientation 115 preferably comprises a curvilinear component
177 as shown in FIG. 1D. The curvilinear component 177 may be
either concave or convex with respect to the longitudinal axis 130
or the transverse axis 140, or an elastomeric strand or the second
plurality of elastomeric strands may comprise a plurality of
curvilinear components thereby having both concave and convex
curvilinear components. The curvilinear component 177 may have
radii of curvature greater than about 1 mm, preferably greater than
about 10 mm, more preferably greater than about 50 mm. The radii
curvature may optionally be variable over the length or "path" of
the curvilinear component 177.
[0066] The addition of the curvilinear component 177 can increase
the contracting force exerted by the elastomeric laminate in the
primary direction of extensibility and also increase the modulus of
elasticity in the secondary direction of extensibility. For
example, the center portion 176 of laminate 103 comprises the
second plurality elastomeric strands 114 which include a
curvilinear component 177. Within the center portion 176, the
curvilinear component 177 provides physically more elastomeric
material in the center portion 176 than there would be if the
strands were merely straight lines extending through the center
portion 176. Because the curvilinear component 177 physically
provides more elastomeric material which increases the contracting
force in the primary direction of extensibility and also increases
the modulus of elasticity of the elastomeric laminate.
[0067] As another example, as shown in FIG. 1E, the second
plurality of elastomeric strands 114 can be bonded to the
extensible intermediate laminate where the second orientation 115
is at a predetermined angle 116 from the longitudinal axis 130 of
the elastomeric laminate 104. The pre-determined angle 116 can
range from zero to 360 degrees from the longitudinal axis 130.
Therefore, the second orientation 115 could in theory be parallel
to the first orientation 119; however, the second orientation 115
is preferably different from and therefore deviates from the first
orientation 119. In addition, in order to accommodate the curvature
of a wearer's body, the second orientation 115 is preferably
non-orthogonal to the first orientation 119. The second orientation
115 of the second plurality of elastomeric strands 114 may also
comprise combinations of the arrangements described above as shown
in FIG. 1F.
[0068] When an elastomeric laminate is utilized in an article,
exposure of a wearer's skin to a plurality of elastomeric strands,
as described above, could lead to skin irritation because of the
expansion and contraction of the elastomeric strands. A second
substrate is preferably included with the previously discussed
elastomeric laminate 100 of FIG. 1 as shown in FIGS. 2 and 2A in
order to reduce the likelihood of this irritation. With regard to
FIG. 2, coordinate system 299 shall be referenced.
[0069] A second substrate 210 having a second bonding surface 211
is included with an elastomeric laminate 200. The elastomeric
laminate 200 further comprises the extensible intermediate laminate
102 and the second plurality of elastomeric strands 114 as
described previously. The second plurality of elastomeric strands
114 can be bonded to the second bonding surface 211 of the second
substrate 210 via the adhesive 212 or by any means known in the
art. The second substrate 210 can be joined to the extensible
intermediate laminate 102 in a face to face arrangement.
[0070] Preferably, the elastomeric laminate 200 is extensible in a
direction parallel to the longitudinal axis 230 even with the
addition of the second substrate 210. The second substrate 210 may
be added to the extensible intermediate laminate 102 and the second
plurality of elastomeric strands 114 while the extensible
intermediate laminate 102 and the second plurality of elastomeric
strands 114 is at least partially extended such that the
elastomeric laminate 200 may be extensible in a direction that is
parallel to the longitudinal axis 230. Optionally, the second
substrate 210 may be added to the extensible intermediate laminate
102 while the extensible intermediate laminate 102 is in a relaxed
state. The resulting elastomeric laminate 200 may be mechanically
activated such that the elastomeric laminate 200 is extensible in a
direction parallel to the longitudinal axis 230. Optionally, after
the second substrate 210 is added to the extensible intermediate
laminate 102, the extensible intermediate laminate 102 may be
mechanically activated such that the elastomeric laminate 200 is
extensible in a direction that is not parallel to the longitudinal
axis 230, e.g. the elastomeric laminate 200 can be made extensible
in a direction parallel to the transverse axis 240.
[0071] In another embodiment, an elastomeric laminate 300 may
comprise a first extensible intermediate laminate 302, a second
extensible intermediate laminate 304, and a third plurality of
elastomeric strands 370 as shown in FIGS. 3 and 3A. With regard to
FIG. 3 coordinate system 399 shall be referenced.
[0072] The embodiment of FIGS. 3-3B have the added benefit of
providing more contracting force while accommodating the higher
sagging tension forces present in a loaded absorbent article. The
first extensible intermediate laminate 302 comprises a first
substrate 322 which has a first bonding surface 323. A first
plurality of elastomeric strands 318 extending along a first
orientation 319 can be bonded to the first bonding surface 323 of
the first substrate 322 via an adhesive 320 or by any means known
in the art.
[0073] The first orientation 319 can vary in accordance with the
discussion of the second orientation in FIGS. 1D-1F. As an example,
as shown in FIG. 3, the first orientation 319 can be parallel to a
longitudinal axis 330. The first extensible intermediate laminate
302 can be made extensible in a direction parallel to the
longitudinal axis 330 via the live stretch process or the
mechanical activation process as discussed previously.
[0074] The second extensible intermediate laminate 304 may comprise
a second substrate 310 having a second bonding surface 311. A
second plurality of elastomeric strands 314 extending along a
second orientation 315 may be bonded to the second bonding surface
311 of the second substrate 310 via an adhesive 312 or any means
known in the art. The second orientation 315 can vary in accordance
with the discussion of the second orientation in FIGS. 1D-1F except
that the first orientation 319 is not necessarily different from
the second orientation 315. In addition, the second extensible
intermediate laminate 304 can be made extensible via the live
stretch process or the mechanical activation process as discussed
previously.
[0075] Preferably, in order to provide more contracting force, the
first orientation 319 and the second orientation 315 are linear in
nature and are parallel to the longitudinal axis 330. In one
embodiment, the first extensible intermediate laminate 302 and the
second extensible intermediate laminate 304 are extensible in a
direction parallel to the longitudinal axis 330 and can be made
extensible via the live stretch process or the mechanical
activation process as discussed previously.
[0076] The third plurality of elastomeric strands 370 extend along
a third orientation 375 and may be bonded to the first extensible
intermediate laminate 302 and the second extensible intermediate
laminate 304 by any known means or method known in the art. The
third orientation 375 can vary in accordance with the discussion of
the second orientation in FIGS. 1D-1F. The third orientation 375
should be different from the first orientation 319 and the second
orientation 315 such that the third orientation can provide at
least some accommodation to the sagging tension forces which are
exerted on an elastomeric laminate from a loaded absorbent article.
The third orientation 375 may comprise a curvilinear component (see
177 in FIG. 1D). Additionally, the third orientation 375 may
correspond to an arrangement that is at an angle (see 116 in FIG.
1E) from the primary direction of extensibility, which is parallel
to the longitudinal axis 330. In order to accommodate the sagging
tension forces exerted by a loaded absorbent article, the angle is
preferably greater than about 20 degrees and less than about 160
degrees from the longitudinal axis 130.
[0077] The first extensible intermediate laminate 302 and the
second extensible intermediate laminate 304 may be joined in a face
to face orientation with the third plurality of elastomeric strands
370 disposed therebetween. However, the third plurality of
elastomeric strands 370 can be joined to a face 301 of the first
extensible intermediate laminate 302 or a face 303 of the second
extensible intermediate laminate 304 and is, not necessarily
limited to being joined between the first extensible intermediate
laminate 302 and the second extensible intermediate laminate
304.
[0078] In another embodiment, an elastomeric laminate 360, as shown
in FIG. 3B, can be created using a single substrate 350. The single
substrate 350 may comprise a first portion 342 and a second portion
344. The first portion 342 can act as the first substrate and the
second portion 344 can act as the second substrate. A first
plurality of elastomeric strands 318 may be bonded to the first
portion 342 via an adhesive 320 that is applied to the first
portion 342 thereby forming a first extensible intermediate
laminate 346. A second plurality of elastomeric strands 314 may be
bonded to the second portion 344 via an adhesive 312 that is
applied to the second portion 344 thereby forming a second
extensible intermediate laminate 348. A third plurality of
elastomeric strands 370 may be bonded to a face 353, 357 of the
first intermediate laminate 346 or a face 355, 359 of the second
intermediate laminate 348. The second portion 344 can be folded on
top of the first portion 342 such that the first portion 342 and
the second portion 344 are in a face-to-face orientation or vice
versa.
[0079] Instead of folding the second portion 344 on top of the
first portion 342 or vice versa, the single substrate 350 can be
slit such that the first intermediate laminate 346 and the second
intermediate laminate 348 form two distinct webs which are joined
in a face to face arrangement. Alternatively, the single substrate
350 can be slit such that the first portion 342 and the second
portion 344 form two distinct webs which are processed and
subsequently joined in a face to face arrangement.
[0080] The first plurality of elastomeric strands 318 and the
second plurality of elastomeric strands 314 can be pre-strained
prior to their bonding to the first portion 342 and second portion
344, respectively, such that the first and second portions 342, 344
are extensible. Alternatively, the first plurality of elastomeric
strands 318 and the second plurality of elastomeric strands 314 can
be bonded to the first portion 342 and second portion 344 in a
relaxed state, and subsequently, the elastomeric laminate 360 can
be mechanically activated such that it is extensible.
[0081] Suitable apparatuses for extruding the first plurality of
elastomeric strands, the second plurality of elastomeric strands,
and optionally the third plurality of elastomeric strands in the
first, second, and third orientations, respectively, are discussed
below. Apparatuses for applying elastomeric strands in a
longitudinal direction are described in U.S. application Ser. No.
10/452,438 entitled "Method and Apparatus for Producing Elastomeric
Nonwoven Laminates" filed on Jun. 2, 2003 and in U.S. application
Ser. No. 10/836,944 entitled "Apparatus for Producing Elastomeric
Nonwoven Laminates" filed on Apr. 30, 2004. Apparatuses for
applying elastomeric strands in a transverse direction, an angle
from the longitudinal direction, or in a curvilinear fashion are
described in U.S. application Ser. No. 10/779,338 entitled "Method
of Placing Material Transversely on a Moving Web" filed on Feb. 13,
2004. Apparatuses for applying elastomeric strands in the
longitudinal direction, an angle from the longitudinal direction,
or in a curvilinear fashion are described in U.S. application Ser.
No. 10/834,539 entitled "Extrusion Applicator Having Linear Motion
Operability" filed on Apr. 29, 2004, and in U.S. application Ser.
No. 10/834,503 entitled "Extrusion Applicator Having Rotational
Operability" filed on Apr. 29, 2004.
[0082] Suitable apparatuses and methods for printing elastomeric
strands in any of the above mentioned orientations and combinations
thereof are described in U.S. Application No. 60/557,272 entitled
"Letterpress Application of Elastomeric Compositions" filed on Mar.
29, 2004, in U.S. Application No. 60/557,245 entitled "Method of
Gravure Printing Elastomeric Compositions" filed on Mar. 29, 2004,
in U.S. application Ser. No. 10/811,671 entitled "Variable Stretch
Composites and Methods of Making the Composite" filed on Mar. 29,
2004, and in U.S. application Ser. No. 10/811,527 entitled
"Variable Stretch Composites and Methods of Making the Composite"
filed on Mar. 29, 2004.
[0083] As mentioned previously, an elastomeric laminate comprises a
substrate layer and a layer of elastic or a plurality of
elastomeric strands. The first substrate and second substrate for
any of the elastomeric laminates disclosed herein may comprise any
material known in the art for the construction of elastomeric
laminates. Preferably, both the first and second substrates
comprise nonwovens. If the first or second substrate comprise
nonwovens, then the nonwovens may comprise fibers made of
polypropylene, polyethylene, polyester, nylon, cellulose,
polyamide, or combinations of such materials. Fibers of one
material or fibers of different materials or material combinations
may be used in the first and/or second nonwoven. Exemplary nonwoven
materials include spunbond, spunbond meltblown spunbond (SMS),
spunbond meltblown meltblown spunbond (SMMS), carded and the like.
Particularly acceptable nonwovens include high elongation carded
(HEC) nonwovens and deep activation polypropylene (DAPP) nonwovens.
Any process known in the art may be used to make the nonwovens.
[0084] The nonwoven may comprise fibers that are bonded internally,
including fibers that are needle punched, hydro entangled, spun
bonded, thermally bonded, bonded by various types of chemical
bonding such as latex bonding, powder bonding, and the like.
Preferably, the basis weight of the first nonwoven and/or second
nonwoven is in the range of about 10 gsm to about 40 gsm. The basis
weight of the first nonwoven and the second nonwoven may range from
about 10 gsm to about 40 gsm.
[0085] The first substrate or second substrate may comprise more
than one layer of nonwoven material. For example the first
substrate may include a nonwoven adhesively bonded to another
nonwoven that is then bonded to the plurality of elastic strands.
Similarly, the second substrate may include a nonwoven bonded to
another nonwoven the combination of which is bonded to the
intermediate laminate and subsequently activated.
[0086] The first substrate, second substrate and a plurality of
elastomeric strands may be joined by any joining means known in the
art. Some examples of suitable joining means and/or methods for
joining include, but are not limited to, adhesives, cohesives,
thermal bonding, pressure bonding, mechanical bonds, ultrasonic
bonding, and/or any combination of any known methods of joining
such materials.
[0087] A plurality of elastomeric strands may extend in a generally
parallel spaced relationship between the first substrate and the
second substrate. However, the elastomeric strands may be arranged
in any configuration desired. For instance, the strands may be
arranged to provide a specific force profile in the elastomeric
laminate by varying the thickness of the individual strands or the
spacing between them. Moreover, the strands may be continuous
extending substantially across a face of a substrate or may
comprise discrete portions which extend substantially across the
face of the substrate.
[0088] The plurality of elastic strands is preferably made of a
resiliently elastic thermoplastic material. The elastic strands may
be made from liquid elastic that is extruded through a die to
achieve the desired strand elastic diameter and/or shape. The shape
of the extruded elastic strands is not limited. For example,
typical elastic strands have a circular cross sectional shape, but
sometimes the plurality of elastic strands may have different
shapes, such as a trilobal shape, or a flat (i.e., "ribbon" like)
shape. Suitable elastomeric strand shapes (not all shown) include
rectangles, circles, ellipses, diamonds, triangles, parallelograms,
trapezoids, wedges or other sections of circles or ellipses, other
polygons, or other irregular enclosed shapes. Furthermore, the
thickness or diameter of the elastic strands may vary in order to
accommodate a particular application. Typically, the thickness of
elastomeric strands may be in the range of about 0.02 mm to about 1
mm and the basis weight is in the range of about 20 g/m.sup.2 to
about 300 g/m.sup.2.
[0089] For the printing of elastomeric strands, the individual
elastomeric strands may be configured as lines or strands generally
having widths less than about 2 mm and typically less than about 1
mm. Linear elastomeric strands may be configured as bands generally
have widths between about 2 mm and about 20 mm and aspect ratios
ranging from about 2:1 to about 100:1. Typically, the thickness of
an elastomeric strand may be in the range of about 0.02 mm to about
5 mm and the basis weight is in the range of about 20 g/m.sup.2 to
about 300 g/m.sup.2.
[0090] Examples of the potential uses of the elastomeric laminates
described herein in an absorbent article are provided below.
Referring collectively to FIGS. 4-4A, an absorbent article in the
form of an open-style or taped diaper 400 is depicted. It should be
understood that while FIGS. 4-6 depict a diaper, the present
invention also contemplates other wearable absorbent articles that
encircle or enclose at least a portion of a wearer's anatomy or
which are otherwise secured to a wearer. The diaper 400 has a
longitudinal centerline 412 and a lateral centerline 414 as a frame
of reference for this discussion. The diaper 400 may have a pair of
opposed longitudinal edges 416 and 418, a pair of opposed lateral
edges 420 and 422, a rear waist region 424, a front waist region
426, a crotch region 428 disposed intermediate the front and rear
waist regions 426 and 424, respectively, and a pair of leg regions
430 and 432.
[0091] The diaper 400 also may comprise one or more ear or side
panels 434, 436, 438 and 440 disposed laterally outboard of the
front waist region 426 and/or rear waist region 424. In closable
diaper 400 embodiments, at least one fastener element 442 is
disposed on one or more of side panels 434 and 436 and is adapted
to be secured to at least a portion of the longitudinally opposing
front side panels 438 and 440, or a portion of the outer surface of
the front waist region 426 or a component thereof. An accompanying
fastener element 444 is shown in a folded back configuration to
expose the mechanical fasteners 446, which shown as hooks for a
hook-and-loop fastening system commercially available from 3M or
Velcro Industries. The fastener element 444 may be capable of
engaging loop material embodied in a landing zone 427 located on
the outer surface of the diaper 400.
[0092] Any one or more of regions 424, 426, 428, 430, 432, 434,
436, 438, 440, 442 or 444 may comprise an elastomeric laminate as
described herein. In this way, the diaper 400 may preferably be
configured to adapt to the specific wearer's anatomy upon
application and to maintain coordination with the wearer's anatomy
during wear (i.e., the fit should remain the same with minimal
sagging, achieving sustained fit).
[0093] An exemplary diaper chassis comprising arrays of elastomeric
laminates is diaper chassis 450 of the diaper 400 shown in FIG. 4A.
The diaper chassis 450 may include a liquid impermeable backsheet
and an outer cover made of a nonwoven material. Other chassis
components may be included but are not depicted for purposes of
clearly showing the multi-variant arrays of the present invention.
The backsheet may comprise the elastomeric laminates described
above such that the stretch properties of regions 452, 454, 456,
458, and 460 are different from one another. Specifically, the
elastomeric laminates may be oriented in different directions in
these regions in order to best accommodate the curvature of the
wearer's body as well as the sagging tension forces. By way of
example, region 452 may comprise an elastomeric laminate which
comprises a second plurality of strands which comprise a
curvilinear component while region 454 may comprise an elastomeric
laminate which comprises a second plurality of elastomeric strands
wherein the second orientation comprises a pre-determined angle
from a longitudinal axis of the elastomeric laminate. In certain
cases for purposes of enhancing fit on a wearer, the various
elastomeric laminate properties are symmetrical in that regions 452
and 460 have similar properties, regions 454 and 458 also have
similar properties while region 456 has a third type of property.
It should be understood, however, that this is not necessary and
that individual regions 452, 454, 456, 458 and 460 may vary
individually and widely in terms of properties, size, and shape,
without deviating from the scope of the invention.
[0094] Reference is now made to FIGS. 5, 6, and 7A-7B which show a
pant 670. The term "pant", as used herein, refers to disposable
garments having a waist opening and leg openings designed for
infant or adult wearers. A pant may be preformed by any suitable
technique including, but not limited to, joining together portions
of the article using refastenable and/or non-refastenable bonds
(e.g., seam, weld, adhesive, cohesive bond, fastener, etc.). A pant
may be preformed anywhere along the circumference of the article
(e.g., side fastened, front waist fastened). While the term "pant"
is used herein, pants are also commonly referred to as "closed
diapers", "prefastened diapers", "pull-on diapers", "training
pants" and "diaper-pants". Suitable pants are disclosed in U.S.
Pat. No. 5,246,433, U.S. Pat. No. 5,569,234, U.S. Pat. No.
6,120,487, U.S. Pat. No. 6,120,489, U.S. Pat. No. 4,940,464, U.S.
Pat. No. 5,092,861, U.S. patent application Ser. No. 10/171,249,
entitled "Highly Flexible And Low Deformation Fastening Device",
filed on Jun. 13, 2002; U.S. Pat. No. 5,897,545, U.S. Pat. No.
5,957,908.
[0095] For pant diaper 670, as shown in FIG. 5, the elastomeric
laminates of the present invention may be included anywhere on the
pant diaper 670. On the outer surface of the pant diaper 670, an
outer cover 678 typically comprising a nonwoven can be disposed.
The outer cover 678 can be joined to a backsheet (see 674 in FIGS.
7A-7B) so as to form a portion of a pair of leg openings and a
waist opening for the wearer. Also, two pair of side panels 680,
682, and 684, 686 are attached to the outer cover 678.
[0096] The two of the side panels 680 and 684 extend outward from a
longitudinal edge 704 as shown in FIG. 6. The other two side panels
686 and 682 extend outward from a longitudinal edge 702. The
elastomeric laminates disclosed herein may be incorporated into the
two pair of side panels 680, 682, and 684, 686 in order to
accommodate the tension forces, the sagging tension forces, and the
contours of a wearer's body. The elastomeric laminates of the
present invention may also be incorporated into pant 670 in a waist
feature (not shown) that is disposed adjacent end edges 665 and 669
or barrier leg cuffs 688 and 690. In addition, the pant diaper 670
may include an absorbent assembly including liquid permeable
topsheet 672, a liquid impermeable backsheet 674, and an absorbent
core 676 disposed between the topsheet 672 and the backsheet 674 as
shown in FIGS. 7A-7B.
[0097] Belt structures (not shown) may also comprise the
elastomeric laminates of the present invention. One such
alternative structure comprises the ear and/or side panel and at
least a portion of the waist functionality. In another alternative
belt structure, a belt completely encircling a wearer's waist (i.e.
a 360 degree belt) may be formed, referring to FIG. 6 for example,
by incorporating one or more elastomeric laminates of the present
invention adjacent the front and rear waist edges 665, 669 so as to
form a band of tension about the wearer's waist.
[0098] Referring to FIG. 8, another embodiment of diaper 800 is
depicted in which the front waist region 826 may comprise at least
one elastomeric laminate of the present invention. The function of
elastomeric laminate is to dynamically accommodate the contraction
and expansion cycles of the wearer's abdomen as the wearer moves
and/or changes position, preventing front waist sagging. The
elastomeric laminate is preferably substantially aligned with the
front waist end 818 of the diaper 800. In closable versions of
diaper 800 including a fastening landing zone 827 disposed in or
near the front waist end 818, the landing zone 827 may be shaped in
a configuration presenting a concavity to the front waist end 818
of the diaper 800. In these embodiments, elastomeric laminate may
at extend into the landing zone 827 concavity 872 as shown in FIG.
8.
[0099] Referring to FIG. 9, diaper 900 is shown in which leg
regions 930 and 932 may comprise elastomeric laminates 912 and 914.
Portions of the leg regions 930 and 932 may comprise one or more
additional elastomeric laminates 916 and 918 such that a plurality
of elastomeric strands are oriented at an angle to the longitudinal
centerline 912 of diaper 900. Typically, either the first or second
plurality of elastomeric strands may be at an angle of about 45
degrees to about 90 degrees from the longitudinal centerline
912.
[0100] All of the embodiments of the elastomeric laminates in FIGS.
1-3B may be incorporated into diaper components which may take any
one or more of the materials, designs, and methods of assembly
described hereinafter without departing from the scope of the
present invention. While any of the article components may be
assembled in a variety of well known configurations, exemplary
diaper configurations are described generally in U.S. Pat. No.
3,860,003; U.S. Pat. No. 5,151,092; and U.S. Pat. No. 5,221,274;
and U.S. Pat. No. 5,554,145; U.S. Pat. No. 5,569,234; U.S. Pat. No.
5,580,411; and U.S. Pat. No. 6,004,306.
[0101] The absorbent articles described herein can utilize a
variety of materials in their manufacture. Some examples of the
materials which can be used in the manufacture of absorbent
articles are provided below; however, the list of materials
provided is by no means exhaustive. For example, breathable
materials, which are used extensively in absorbent articles may
include materials such as woven webs, nonwoven webs, composite
materials such as film-coated nonwoven webs, microporous films such
as manufactured by Mitsui Toatsu Co., of Japan under the
designation ESPOIR NO and by Exxon Chemical Co., of Bay City, Tex.,
under the designation EXXAIRE, and monolithic films such as
manufactured by Clopay Corporation, Cincinnati, Ohio under the name
HYTREL blend P18-3097. Some breathable composite materials are
described in greater detail in U.S. Pat. No. 6,187,696; U.S. Pat.
No. 5,938,648; U.S. Pat. No. 5,865,823; and U.S. Pat. No.
5,571,096.
[0102] The article may also include a structural elastic-like film
web is an extensible material that exhibits an elastic-like
behavior in the direction of elongation without the use of added
elastic materials and is described in more detail in U.S. Pat. No.
5,518,801. In alternate embodiments, the backsheets may comprise
elastomeric films, foams, strands, or combinations of these or
other suitable materials with nonwovens or synthetic films.
[0103] Exemplary absorbent structures for use as the absorbent core
are described in U.S. Pat. No. 4,610,678; U.S. Pat. No. 4,673,402;
U.S. Pat. No. 4,834,735; U.S. Pat. No. 4,888,231; U.S. Pat. No.
5,137,537; U.S. Pat. No. 5,147,345; U.S. Pat. No. 5,342,338; U.S.
Pat. No. 5,260,345; U.S. Pat. No. 5,387,207; and U.S. Pat. No.
5,625,222.
[0104] Suitable absorbent and nonabsorbent sublayers are described
in European Patent Application No. EP 0 847 738 A1 and U.S. Pat.
No. 5,941,864. Further, the sublayer, or any portion thereof, may
include or be coated with a lotion or other known substances to
add, enhance or change the performance or other characteristics of
the element.
[0105] Some exemplary surface fastening systems are disclosed in
U.S. Pat. No. 3,848,594; U.S. Pat. No. B1 4,662,875; U.S. Pat. No.
4,846,815; U.S. Pat. No. 4,894,060; U.S. Pat. No. 4,946,527; the
herein before referenced U.S. Pat. No. 5,151,092; and U.S. Pat. No.
5,221,274. An exemplary interlocking fastening system is disclosed
in co-pending U.S. application Ser. No. 09/143,184 entitled
"Absorbent Article Fastening Device" in the names of Kline et al.
filed on Aug. 8, 1998. The fastening system may also: provide a
means for holding the article in a disposal configuration as
disclosed in U.S. Pat. No. 4,963,140; include primary and secondary
fastening systems, as disclosed in U.S. Pat. No. 4,699,622; means
to reduce shifting of overlapped portions or to improve fit as
disclosed in U.S. Pat. No. 5,242,436. means to resist gapping at a
wearer's belly as disclosed in U.S. Pat. No. 5,499,978 in U.S. Pat.
No. 5,507,736 and in U.S. Pat. No. 5,591,152.
[0106] Suitable training pants and pull-on diapers are disclosed in
U.S. Pat. No. 5,246,433; U.S. Pat. No. 5,569,234; U.S. Pat. No.
6,120,487; U.S. Pat. No. 6,120,489; U.S. Pat. No. 4,940,464; and
U.S. Pat. No. 5,092,861.
[0107] Examples of diapers with elasticized side panels are
disclosed in U.S. Pat. No. 4,857,067; U.S. Pat. No. 4,381,781; U.S.
Pat. No. 4,938,753; the herein before referenced U.S. Pat. No.
5,151,092; U.S. Pat. No. 5,221,274; U.S. Pat. No. 5,669,897; and
U.S. Pat. No. 6,004,306.
[0108] U.S. Pat. No. 3,860,003 describes a disposable diaper which
provides a contractible leg opening having a side flap and one or
more elastic members to provide an elasticized leg cuff (a
gasketting cuff). U.S. Pat. Nos. 4,808,178 and 4,909,803 describe
disposable diapers having "stand-up" elasticized flaps (barrier
cuffs) which improve the containment of the leg regions. U.S. Pat.
Nos. 4,695,278 and 4,795,454 describe disposable diapers having
dual cuffs, including gasketting cuffs and barrier cuffs.
[0109] Embodiments of the present invention may also include
pockets for receiving and containing waste, spacers which provide
voids for waste, barriers for limiting the movement of waste in the
article, compartments or voids which accept and contain waste
materials or any combinations thereof. Examples of pockets and
spacers for use in absorbent products are described in U.S. Pat.
No. 5,514,121; U.S. Pat. No. 5,171,236; U.S. Pat. No. 5,397,318;
U.S. Pat. No. 5,540,671; U.S. Pat. No. 6,168,584; U.S. Pat. No.
5,306,266; and U.S. Pat. No. 5,997,520. Examples of compartments or
voids are disclosed in U.S. Pat. No. 4,968,312; U.S. Pat. No.
4,990,147; U.S. Pat. No. 5,062,840; and U.S. Pat. No. 5,269,755.
Examples of suitable transverse barriers are described in U.S. Pat.
No. 5,554,142; U.S. Pat. No. 6,010,490; and U.S. Pat. No.
5,653,703. Examples of other structures especially suitable for
management of low viscosity feces are disclosed in U.S. Pat. Nos.
5,941,864; 5,977,430 and 6,013,063.
[0110] All documents cited in the Detailed Description of the
Invention are, in relevant part, incorporated herein by reference;
the citation of any document is not to be construed as an admission
that it is prior art with respect to the present invention.
[0111] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
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