U.S. patent application number 11/430388 was filed with the patent office on 2006-09-14 for disposable absorbent articles having multiple absorbent core components including replaceable components.
Invention is credited to Theodora Beck, Gary Dean LaVon, Gerald Alfred Young.
Application Number | 20060206087 11/430388 |
Document ID | / |
Family ID | 32467805 |
Filed Date | 2006-09-14 |
United States Patent
Application |
20060206087 |
Kind Code |
A1 |
LaVon; Gary Dean ; et
al. |
September 14, 2006 |
Disposable absorbent articles having multiple absorbent core
components including replaceable components
Abstract
A disposable absorbent article adapted to be worn about a lower
torso of a human body and having a chassis, a non-removable
absorbent core component disposed in a crotch region of the
chassis, and a replaceable absorbent core component disposed in
capillary liquid communication with the non-removable absorbent
core component. The replaceable absorbent core component may be
removed and a like component may be substituted in place of the
removed component without the removal of the absorbent article from
the wearer. The replaceable absorbent core component may be
disposed inside an openable chassis pocket, with access for its
removal and replacement provided by an aperture in a backsheet, an
openable end of an external pocket, or an openable end of an
internal pocket formed at an area of a waist end edge where the
backsheet and a topsheet may be separated. Additional replaceable
absorbent core components may also be incorporated.
Inventors: |
LaVon; Gary Dean; (Liberty
Township, OH) ; Beck; Theodora; (Colerain Township,
OH) ; Young; Gerald Alfred; (Miller Township,
IN) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY;INTELLECTUAL PROPERTY DIVISION
WINTON HILL BUSINESS CENTER - BOX 161
6110 CENTER HILL AVENUE
CINCINNATI
OH
45224
US
|
Family ID: |
32467805 |
Appl. No.: |
11/430388 |
Filed: |
May 9, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10308430 |
Dec 3, 2002 |
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11430388 |
May 9, 2006 |
|
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|
09911108 |
Jul 23, 2001 |
6932800 |
|
|
10308430 |
Dec 3, 2002 |
|
|
|
09431322 |
Nov 2, 1999 |
|
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|
09911108 |
Jul 23, 2001 |
|
|
|
08825071 |
Mar 27, 1997 |
6015935 |
|
|
09431322 |
Nov 2, 1999 |
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|
08828005 |
Mar 27, 1997 |
6989005 |
|
|
10308430 |
|
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Current U.S.
Class: |
604/385.14 ;
604/385.19 |
Current CPC
Class: |
A61F 13/42 20130101;
A61F 13/49011 20130101; A61F 13/84 20130101; A61F 13/532 20130101;
A61F 13/15203 20130101; Y10T 442/693 20150401; A61F 13/535
20130101; A61F 13/8405 20130101; A61F 13/539 20130101; A61F 13/505
20130101 |
Class at
Publication: |
604/385.14 ;
604/385.19 |
International
Class: |
A61F 13/15 20060101
A61F013/15 |
Claims
1. A disposable absorbent article adapted to be worn about a lower
torso of a human body, comprising: a chassis forming a waist
opening and a pair of leg openings and having longitudinally
opposing first and second waist end edges, longitudinally opposing
first and second waist regions adjacent to the respective waist end
edges, and a crotch region longitudinally intermediate of the waist
regions, the chassis comprising a topsheet having a wearer-facing
surface disposed such that at least a portion of the wearer-facing
surface contacts the body when the article is worn, a backsheet
defining a garment-facing surface of the article, and a first
topsheet pocket sheet affixed onto the wearer-facing surface of the
topsheet and forming a first openable chassis pocket between the
first topsheet pocket sheet and the topsheet in at least the first
waist region; and a non-removable absorbent core component disposed
in the crotch region between the topsheet and the backsheet,
wherein the chassis forms a second openable chassis pocket in at
least the second waist region.
2. The disposable absorbent article of claim 1 wherein the first
openable chassis pocket extends from the first waist region into
and ends in the crotch region.
3. The disposable absorbent article of claim 1 wherein the second
openable chassis pocket extends from the second waist region into
and ends in the crotch region.
4. The disposable absorbent article of claim 1 wherein the topsheet
has a topsheet aperture between the first openable chassis pocket
and the non-removable absorbent core component.
5. The disposable absorbent article of claim 1 wherein the first
openable chassis pocket has an openable end in the first waist
region.
6. The disposable absorbent article of claim 1 wherein the second
openable chassis pocket has an openable end in the second waist
region.
7. The disposable absorbent article of claim 1 wherein the chassis
further comprises a second topsheet pocket sheet affixed onto the
wearer-facing surface of the topsheet, the second openable chassis
pocket being formed between the second topsheet pocket sheet and
the topsheet.
8. The disposable absorbent article of claim 7 wherein the topsheet
has a topsheet aperture between the second openable chassis pocket
and the non-removable absorbent core component.
9. The disposable absorbent article of claim 1 wherein the second
openable chassis pocket is disposed between the topsheet and the
backsheet.
10. The disposable absorbent article of claim 9 wherein the second
openable chassis pocket is disposed between the non-removable
absorbent core component and the topsheet.
11. The disposable absorbent article of claim 9 wherein the
non-removable absorbent core component comprises absorbent layers
and the second openable chassis pocket is disposed between the
absorbent layers.
12. The disposable absorbent article of claim 9 wherein the second
openable chassis pocket is disposed between the non-removable
absorbent core component and the backsheet.
13. The disposable absorbent article of claim 9 wherein the second
openable chassis pocket is disposed in two portions sandwiching at
least a portion of the non-removable absorbent core component.
14. The disposable absorbent article of claim 9 wherein the second
openable chassis pocket is accessible at the second waist end edge
where the topsheet and the backsheet are separable.
15. The disposable absorbent article of claim 9 wherein the second
openable chassis pocket is accessible through an aperture in the
topsheet.
16. The disposable absorbent article of claim 9 wherein the second
openable chassis pocket is accessible through an aperture in the
backsheet.
17. The disposable absorbent article of claim 1 wherein the chassis
further comprises a backsheet pocket sheet affixed onto the
garment-facing surface of the backsheet, the second openable
chassis pocket being formed between the backsheet pocket sheet and
the backsheet.
18. A disposable absorbent article adapted to be worn about a lower
torso of a human body, comprising: a chassis forming a waist
opening and a pair of leg openings and having longitudinally
opposing first and second waist end edges, longitudinally opposing
first and second waist regions adjacent to the respective waist end
edges, and a crotch region longitudinally intermediate of the waist
regions, the chassis comprising a topsheet having a wearer-facing
surface disposed such that at least a portion of the wearer-facing
surface contacts the body when the article is worn and a backsheet
defining a garment-facing surface of the article, the topsheet and
the backsheet forming a first openable chassis pocket between the
topsheet and the backsheet in at least the first waist region; and
a non-removable absorbent core component disposed in the crotch
region between the topsheet and the backsheet, wherein the chassis
forms a second openable chassis pocket in at least the second waist
region.
19. The disposable absorbent article of claim 18 wherein the first
openable chassis pocket extends from the first waist region into
and ends in the crotch region.
20. The disposable absorbent article of claim 18 wherein the second
openable chassis pocket extends from the second waist region into
and ends in the crotch region.
21. The disposable absorbent article of claim 18 wherein the first
openable chassis pocket has an openable end in the first waist
region.
22. The disposable absorbent article of claim 18 wherein the second
openable chassis pocket has an openable end in the second waist
region.
23. The disposable absorbent article of claim 18 wherein the second
openable chassis pocket is disposed between the topsheet and the
backsheet.
24. The disposable absorbent article of claim 23 wherein the second
openable chassis pocket is disposed between the non-removable
absorbent core component and the topsheet.
25. The disposable absorbent article of claim 23 wherein the
non-removable absorbent core component comprises absorbent layers
and the second openable chassis pocket is disposed between the
absorbent layers.
26. The disposable absorbent article of claim 23 wherein the second
openable chassis pocket is disposed between the non-removable
absorbent core component and the backsheet.
27. The disposable absorbent article of claim 23 wherein the second
openable chassis pocket is disposed in two portions sandwiching at
least a portion of the non-removable absorbent core component.
28. The disposable absorbent article of claim 23 wherein the second
openable chassis pocket is accessible at the second waist end edge
where the topsheet and the backsheet are separable.
29. The disposable absorbent article of claim 23 wherein the second
openable chassis pocket is accessible through an aperture in the
topsheet.
30. The disposable absorbent article of claim 23 wherein the second
openable chassis pocket is accessible through an aperture in the
backsheet.
31. The disposable absorbent article of claim 18 wherein the
chassis further comprises a backsheet pocket sheet affixed onto the
garment-facing surface of the backsheet, the second openable
chassis pocket being formed between the backsheet pocket sheet and
the backsheet.
32. The disposable absorbent article of claim 18 wherein the first
openable chassis pocket is accessible at the first waist end edge
where the topsheet and the backsheet are separable.
33. The disposable absorbent article of claim 18 wherein the first
openable chassis pocket is accessible through an aperture in the
topsheet.
34. The disposable absorbent article of claim 18 wherein the first
openable chassis pocket is accessible through an aperture in the
backsheet.
35. A disposable absorbent article adapted to be worn about a lower
torso of a human body, comprising: a chassis forming a waist
opening and a pair of leg openings and having longitudinally
opposing first and second waist end edges, longitudinally opposing
first and second waist regions adjacent to the respective waist end
edges, and a crotch region longitudinally intermediate of the waist
regions, the chassis comprising a topsheet having a wearer-facing
surface disposed such that at least a portion of the wearer-facing
surface contacts the body when the article is worn and a backsheet
defining a garment-facing surface of the article, and a first
backsheet pocket sheet affixed onto the garment-facing surface of
the backsheet and forming a first openable chassis pocket between
the first backsheet pocket sheet and the backsheet in at least the
first waist region; and a non-removable absorbent core component
disposed in the crotch region between the topsheet and the
backsheet, wherein the chassis forms a second openable chassis
pocket in at least the second waist region.
36. The disposable absorbent article of claim 35 wherein the first
openable chassis pocket extends from the first waist region into
and ends in the crotch region.
37. The disposable absorbent article of claim 35 wherein the second
openable chassis pocket extends from the second waist region into
and ends in the crotch region.
38. The disposable absorbent article of claim 35 wherein the first
openable chassis pocket has an openable end in the first waist
region.
39. The disposable absorbent article of claim 35 wherein the second
openable chassis pocket has an openable end in the second waist
region.
40. The disposable absorbent article of claim 35 wherein the second
openable chassis pocket is disposed between the non-removable
absorbent core component and the topsheet.
41. The disposable absorbent article of claim 35 wherein the
non-removable absorbent core component comprises absorbent layers
and the second openable chassis pocket is disposed between the
absorbent layers.
42. The disposable absorbent article of claim 35 wherein the second
openable chassis pocket is disposed between the non-removable
absorbent core component and the backsheet.
43. The disposable absorbent article of claim 35 wherein the second
openable chassis pocket is disposed in two portions sandwiching at
least a portion of the non-removable absorbent core component.
44. The disposable absorbent article of claim 35 wherein the second
openable chassis pocket is accessible at the second waist end edge
where the topsheet and the backsheet are separable.
45. The disposable absorbent article of claim 35 wherein the second
openable chassis pocket is accessible through an aperture in the
topsheet.
46. The disposable absorbent article of claim 35 wherein the second
openable chassis pocket is accessible through an aperture in the
backsheet.
47. The disposable absorbent article of claim 35 wherein the
chassis further comprises a second backsheet pocket sheet affixed
onto the garment-facing surface of the backsheet, the second
openable chassis pocket being formed between the second backsheet
pocket sheet and the backsheet.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending application
Ser. No. 10/308,430 filed on 3 Dec. 2002, which was a
continuation-in-part of application Ser. No. 09/911,108 filed on 23
Jul. 2001, now U.S. Pat. No. 6,932,800, which in turn was a
continuation-in-part of application Ser. No. 09/431,322 filed on 2
Nov. 1999, now abandoned, which in turn was a continuation of
application Ser. No. 08/825,071 filed on 27 Mar. 1997, now U.S.
Pat. No. 6,015,935. application Ser. No. 10/308,430 was also a
continuation-in-part of application Ser. No. 08/828,005 filed on 27
Mar. 1997, now U.S. Pat. No. 6,989,005. All of the above-identified
priority documents are hereby incorporated in their entirety herein
by reference.
FIELD OF THE INVENTION
[0002] This invention relates to disposable absorbent articles,
such as disposable diapers and particularly to disposable absorbent
articles having multi-piece absorbent cores in which some absorbent
core components are non-removable and other absorbent core
components are removable and replaceable.
BACKGROUND OF THE INVENTION
[0003] Disposable absorbent articles such as disposable diapers,
incontinence pads, training pants, and catamenial napkins generally
include an absorbent core for receiving and holding bodily
exudates. The absorbent core typically includes a fibrous web,
which can be a nonwoven, airlaid web of natural or synthetic
fibers, or combinations thereof. Fibrous webs used in such
absorbent articles also often include certain absorbent gelling
materials usually referred to as "hydrogels", "superabsorbents", or
"hydrocolloid" materials to store large quantities of the
discharged bodily liquids. These materials absorb through capillary
or osmotic forces, or a combination of both.
[0004] Many absorbent articles such as catamenial pads, adult
incontinent products, and diapers are subject to leakage due to an
inability to absorb second and subsequent discharges of liquid even
if the first liquid discharge has been effectively absorbed.
Leakage due to second and subsequent discharges is especially
prevalent during the night, when users commonly experience multiple
discharges before the absorbent article is changed. One reason for
the inability of many absorbent articles to adequately handle
multiple discharges of liquid is the inability of the absorbent
core to transport discharged liquid away from the region of
discharge once the absorbent capacity of that region has been
reached. Thus, the overall performance of the absorbent article is
limited by the inability to transport the liquid to the farthest
reaches of the absorbent core.
[0005] An alternative absorbent material capable of providing
capillary liquid transport is open-celled polymeric foam.
Appropriately made open-celled polymeric foams provide features of
capillary liquid acquisition, transport, and storage required for
use in high performance absorbent cores for absorbent articles such
as diapers. Shaped or contoured absorbent cores made from such
open-celled foam materials having particularly desirable liquid
transport characteristics are disclosed in U.S. Pat. No. 5,147,345
issued to Young et al. on Sep. 15, 1992. The Young et al. '345
absorbent core includes both a liquid acquisition/distribution
member and a liquid storage/redistribution member. The liquid
acquisition/distribution member is positioned within the absorbent
article in such a way as to receive or contact aqueous bodily
liquid which has been discharged into the absorbent article by the
wearer of the article. The liquid storage/redistribution member, in
turn, is positioned within the article to be in capillary liquid
communication with the liquid acquisition/distribution member.
[0006] Absorbent cores providing the desirable absorbent
characteristics of the Young et al. '345 patent in an exemplary
multi-piece configuration are disclosed in U.S. Pat. No. 5,906,602
issued to Weber et al. on 25 May 1999, which describes shaped
absorbent cores having a front panel and a back panel in capillary
liquid communication with a center section. The center section
includes material generally suitable for liquid
acquisition/distribution, while the front and back panels include
material generally suitable for liquid storage/redistribution.
[0007] Despite the advances in absorbent articles and in liquid
handling absorbent core materials, absorbent articles having
multiple absorbent core components as well as those having unitary
absorbent cores are generally designed for single use wear. Once
the storage/redistribution member is saturated with bodily
discharges, such as urine, the entire absorbent article is
generally discarded and replaced. Often parts of the absorbent
article are still usable, and except for being unitary with the
absorbent core, these parts could be used further. In addition to
the added cost and waste associated with discarding reusable
materials, it is often inconvenient to remove and replace the
entire absorbent article when absorbent core components are
saturated.
[0008] Absorbent articles having removable absorbent inserts and
thereby being potentially usable for more than a single use are
known in the art. For example, U.S. Pat. No. 4,597,761 to Buell,
issued Jul. 1, 1986, discloses a disposable absorbent insert for
use inside an over-garment such as a conventional reusable diaper,
or a disposable diaper. Once the absorbent insert becomes saturated
it may be removed and discarded. The absorbent article may then be
reused with a fresh absorbent insert. However, because the
absorbent insert is removable only from the body side of the
article, the absorbent article must be removed from the wearer in
order to remove the insert. Therefore, the removal of the absorbent
insert is often inconvenient and time consuming.
[0009] Accordingly, it would be desirable to provide an absorbent
article having a replaceable absorbent core component wherein the
absorbent core component can be replaced without having to remove
the absorbent article from the wearer.
[0010] Additionally, it would be desirable to provide an absorbent
article having a replaceable absorbent core component and an
apertured backsheet, allowing a saturated component of the
absorbent core to be removed through the backsheet aperture,
thereby exposing an unsaturated component and allowing for
prolonged use of the reusable portions of the absorbent
article.
[0011] Furthermore, it would be desirable to provide an absorbent
article having a replaceable absorbent core component disposed
between a topsheet and a backsheet, configured such that access to
the replaceable absorbent core component is gained by separating
the topsheet and the backsheet in a predetermined area to form an
opening.
SUMMARY OF THE INVENTION
[0012] The present invention provides a disposable absorbent
article adapted to be worn about a lower torso of a human body,
including a chassis forming a waist opening and a pair of leg
openings and having longitudinally opposed waist end edges,
longitudinally opposed waist regions, and a crotch region
longitudinally intermediate of the waist regions, a non-removable
absorbent core component disposed in the crotch region, and a
replaceable absorbent core component disposed in capillary liquid
communication with the non-removable absorbent core component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] While the specification concludes with claims particularly
pointing out and distinctly claiming the present invention, it is
believed that the present invention will be better understood from
the following description in conjunction with the accompanying
Drawing Figures, in which like reference numerals identify like
elements, and wherein:
[0014] FIG. 1 is a plan view of an exemplary diaper of the present
invention in its flat-out, uncontracted state, i.e., with all
elastic induced contraction pulled out, with portions of the
structure being cut away to more clearly show the construction of
the diaper, and with the portion of the diaper that contacts the
wearer facing the viewer;
[0015] FIG. 2 is an exploded perspective view depicting an
exemplary absorbent article, with the portion of the article that
contacts the wearer facing upward;
[0016] FIG. 3 is a perspective, partially segmented illustration of
an exemplary diaper embodiment of an absorbent article according to
the present invention;
[0017] FIG. 4 is a side view, showing in partial cross-section, the
exemplary absorbent article of FIG. 3;
[0018] FIG. 5 is an exploded perspective view depicting the
relationship between the elements of an exemplary absorbent core of
the present invention, with the portion of the core that faces the
wearer facing upward;
[0019] FIG. 6 shows a top plan view of an exemplary absorbent core
useful in an absorbent article according to the present
invention;
[0020] FIG. 7 is a sectional view of an exemplary absorbent core
similar to that shown in FIG. 6, taken along line 7-7, with the
portion of the core that faces the wearer oriented upward;
[0021] FIG. 8 shows a sectional view of another alternative
exemplary absorbent core, with the portion of the core that faces
the wearer oriented upward;
[0022] FIG. 9 shows a section view of another alternative exemplary
absorbent core, with the portion of the core that faces the wearer
oriented upward;
[0023] FIG. 10 shows a section view of another alternative
exemplary absorbent core, with the portion of the core that faces
the wearer oriented upward;
[0024] FIG. 11 is an exploded, perspective, partially segmented
illustration of an alternative exemplary absorbent article
according to the present invention;
[0025] FIG. 12 is a side view, showing in partial cross-section,
another alternative exemplary absorbent article;
[0026] FIG. 13 is a cross-section illustration of a portion of an
exemplary absorbent article having an opening through the
backsheet;
[0027] FIG. 14 is a cross-section detail of an exemplary
configuration of removable and replaceable absorbent core
layers;
[0028] FIG. 15 is a cross-section detail of an alternative
exemplary configuration of a removable and replaceable absorbent
core component;
[0029] FIG. 16 is a cross-section depiction of an additional
alternative exemplary configuration of removable and replaceable
absorbent core layers.
[0030] FIG. 17 is a plan view of another exemplary diaper of the
present invention in its flat-out, uncontracted state, i.e., with
all elastic induced contraction pulled out, with portions of the
structure being cut away to more clearly show the construction of
the diaper, and with the portion of the diaper that contacts the
wearer facing the viewer, showing an apertured topsheet;
[0031] FIG. 18 is a cross-section view of an exemplary pants-type
diaper having an apertured topsheet.
[0032] FIG. 19 is a back view of a diaper embodiment having two
layered waistbands.
[0033] FIG. 20 is a section view of the embodiment of FIG. 19.
[0034] FIG. 21 is a back view of a diaper embodiment having two
side-by-side waistbands.
[0035] FIG. 22 is a section view of the embodiment of FIG. 21.
[0036] FIG. 23 is a back view of a diaper embodiment having an
apertured waistband.
[0037] FIG. 24 is a section view of the embodiment of FIG. 23.
[0038] FIG. 25 is a back view of a diaper embodiment having two
side-by-side waistbands in different layers.
[0039] FIG. 26 is a section view of the embodiment of FIG. 25.
[0040] FIG. 27 is a partial section view showing chassis layers and
non-removable absorbent core layers in relation to a replaceable
absorbent core component.
[0041] FIG. 28 is a plan view of another exemplary diaper of the
present invention in its flat-out, uncontracted state, i.e., with
all elastic induced contraction pulled out, with portions of the
structure being cut away to more clearly show the construction of
the diaper, and with the portion of the diaper that contacts the
wearer facing the viewer, showing a chassis pocket having a
separator;
[0042] FIG. 29 is a simplified plan view illustrating the method of
determining the crotch point of an absorbent article;
[0043] FIG. 30 is an exploded view of the layers of a replaceable
absorbent core component;
[0044] FIG. 31 is a view of the layers of FIG. 30 in a stacked
arrangement;
[0045] FIG. 32 is a plan view showing a replaceable absorbent core
component illustratively divided into four longitudinal
segments;
[0046] FIG. 33 is a plan view showing an absorbent layer of a
replaceable absorbent core component illustratively divided into
four longitudinal segments;
[0047] FIG. 34 is a plan view showing another absorbent layer of a
replaceable absorbent core component illustratively divided into
four longitudinal segments;
[0048] FIG. 35 is a partial section view showing an extensible
covering layer in an unextended state;
[0049] FIG. 36 is a partial section view showing the extensible
covering layer of FIG. 35 in an extended state;
[0050] FIG. 37 is a partial section view showing a folded
extensible covering layer in an unextended state;
[0051] FIG. 38 is a partial section view showing the folded
extensible covering layer of FIG. 37 in an extended state;
[0052] FIG. 39 is a plan view showing a replaceable absorbent core
component having a pull tab at its outer end;
[0053] FIG. 40 is a plan view showing another replaceable absorbent
core component having a pull ring at its outer end;
[0054] FIG. 41 is a plan view showing a replaceable absorbent core
component having an insertion depth indicator;
[0055] FIG. 42 is a plan view showing a replaceable absorbent core
component having a graphical object insertion depth indicator in a
partially inserted state;
[0056] FIG. 43 is a plan view showing the replaceable absorbent
core component of FIG. 42 in a fully inserted state;
[0057] FIG. 44 is a plan view showing a replaceable absorbent core
component having another graphical object insertion depth indicator
in a partially inserted state;
[0058] FIG. 45 is a plan view showing the replaceable absorbent
core component of FIG. 44 in a fully inserted state;
[0059] FIG. 46 is a partial section view showing a replaceable
absorbent core component having a mechanical insertion depth
indicator;
[0060] FIG. 47 is a partial section view showing a replaceable
absorbent core component having another mechanical insertion depth
indicator;
[0061] FIG. 48 is a partial section view showing a replaceable
absorbent core component having directional coefficient of friction
elements in a proper end-to-end orientation;
[0062] FIG. 49 is a partial section view showing the replaceable
absorbent core component of FIG. 48 in an improper end-to-end
orientation;
[0063] FIG. 50 is a partial section view showing a replaceable
absorbent core component having directional coefficient of friction
elements in a proper orientation of its wearer-facing and
garment-facing surfaces;
[0064] FIG. 51 is a partial section view showing the replaceable
absorbent core component of FIG. 50 in an improper orientation of
its wearer-facing and garment-facing surfaces;
[0065] FIG. 52 is a partial section view showing a replaceable
absorbent core component having directional coefficient of friction
elements in a proper orientation of both its wearer-facing and
garment-facing surfaces and its inner and outer ends;
[0066] FIG. 53 is a partial section view showing a replaceable
absorbent core component of FIG. 52 in an improper orientation of
its wearer-facing and garment-facing surfaces and a proper
orientation of its inner and outer ends;
[0067] FIG. 54 is a partial section view showing the replaceable
absorbent core component of FIG. 52 in an improper orientation of
both its inner and outer ends and its wearer-facing and
garment-facing surfaces;
[0068] FIG. 55 is a partial section view showing the replaceable
absorbent core component of FIG. 52 in an improper orientation of
its inner and outer ends and a proper orientation of its
wearer-facing and garment-facing surfaces;
[0069] FIG. 56 is a plan view showing a replaceable absorbent core
component having a relatively shallow insertion pocket on its outer
surface;
[0070] IS FIG. 57 is a partial section view showing the replaceable
absorbent core component of FIG. 56;
[0071] FIG. 58 is a plan view showing a replaceable absorbent core
component having a relatively deep insertion pocket on its outer
surface;
[0072] FIG. 59 is a partial section view showing the replaceable
absorbent core component of FIG. 58;
[0073] FIG. 60 is a plan view showing a replaceable absorbent core
component having intermittent linear bonds attaching an insertion
pocket to its outer surface;
[0074] FIG. 61 is a plan view showing a replaceable absorbent core
component having spot bonds attaching an insertion pocket to its
outer surface;
[0075] FIG. 62 is a plan view showing a replaceable absorbent core
component having continuous linear bonds attaching an insertion
pocket to its outer surface;
[0076] FIG. 63 is a plan view showing a replaceable absorbent core
component having a rectangular inner end and an insertion pocket on
its outer surface;
[0077] FIG. 64 is a partial section view showing a replaceable
absorbent core component having two relatively shallow insertion
pockets on its two major surfaces;
[0078] FIG. 65 is a partial section view showing a replaceable
absorbent core component having two relatively deep insertion
pockets on its two major surfaces;
[0079] FIG. 66 is a partial section view showing a replaceable
absorbent core component folded inside an extensible insertion
pocket layer for disposal;
[0080] FIG. 67 is a partial section view showing a replaceable
absorbent core component having an insertion pocket sheet in its
initial pocket-forming configuration;
[0081] FIG. 68 is a partial section view showing the insertion
pocket sheet of FIG. 67 folded over the inner end of the
replaceable absorbent component to cover a permeable region for
disposal;
[0082] FIG. 69 is a partial section view showing a replaceable
absorbent core component having a covering sheet wrapping over its
inner end;
[0083] FIG. 70 is a partial section view showing a replaceable
absorbent core component having a covering sheet wrapping over its
inner end and forming an insertion pocket;
[0084] FIG. 71 is a partial section view showing a replaceable
absorbent core component having an internal insertion pocket formed
between absorbent layers;
[0085] FIG. 72 is a partial section view showing a replaceable
absorbent core component having an internal insertion pocket formed
between an absorbent layer and an inner layer;
[0086] FIG. 73 is a partial section view showing a replaceable
absorbent core component having an internal insertion pocket formed
between two inner layers;
[0087] FIG. 74 is a partial section view showing a replaceable
absorbent core component having an internal insertion pocket and an
inverting pull tab in its initial state;
[0088] FIG. 75 is a partial section view showing the replaceable
absorbent core component of FIG. 74 in its inverted state;
[0089] FIG. 76 is a plan view showing a replaceable absorbent core
component having a liquid presence indicator including wicking
strips;
[0090] FIG. 77 is a plan view showing a replaceable absorbent core
component having a liquid presence indicator including an
indicating composition disposed on an absorbent layer;
[0091] FIG. 78 is a plan view showing a replaceable absorbent core
component having a liquid presence indicator in the form of a
stationary absorbent strip indicating a wetted area;
[0092] FIG. 79 is a plan view showing a replaceable absorbent core
component having a liquid presence indicator in the form of a
stationary absorbent strip including a series of visible liquid
presence indication means;
[0093] FIG. 80 is a plan view showing a replaceable absorbent core
component having a "dipstick" type liquid presence indicator in its
fully inserted position;
[0094] FIG. 81 is a plan view showing the "dipstick" type liquid
presence indicator of FIG. 80 in its partially withdrawn
position;
[0095] FIG. 82 is a plan view showing a replaceable absorbent core
component having a series of visible liquid presence indication
means on a "dipstick" type liquid presence indicator;
[0096] FIG. 83 is a plan view showing a replaceable absorbent core
component having a liquid presence indicator covered by a movable
indicator strip;
[0097] FIG. 84 is a plan view showing the liquid presence indicator
of FIG. 83 after the movable indicator strip has moved to uncover
it;
[0098] FIG. 85 is a plan view showing a replaceable absorbent core
component having a liquid presence indicator disposed on a movable
indicator strip and in its initial hidden state;
[0099] FIG. 86 is a plan view showing the liquid presence indicator
of FIG. 85 after the movable indicator strip has moved to reveal
it;
[0100] FIG. 87 is a plan view showing a replaceable absorbent core
component having an insertion tool disposed in an insertion
pocket;
[0101] FIG. 88 is a plan view showing a replaceable absorbent core
component having another insertion tool disposed in an insertion
pocket;
[0102] FIG. 89 is a plan view showing a replaceable absorbent core
component having another insertion tool disposed in an insertion
pocket;
[0103] FIG. 90 is a partial section view showing the replaceable
absorbent core component of FIG. 89;
[0104] FIG. 91 is a plan view showing a replaceable absorbent core
component having a rectangular inner end and having another
insertion tool disposed in an insertion pocket;
[0105] FIG. 92 is a plan view showing a replaceable absorbent core
component having a rectangular inner end and having another
insertion tool disposed in an insertion pocket;
[0106] FIG. 93 is a partial section view showing a replaceable
absorbent core component having two insertion tools disposed in two
insertion pockets on its two major surfaces;
[0107] FIG. 94 is a partial section view showing a replaceable
absorbent core component having an insertion tool joined to it
through an intermediate member in its configuration for
insertion;
[0108] FIG. 95 is a partial section view showing the replaceable
absorbent core component of FIG. 94 having the insertion tool
joined to it through the intermediate member in its partially
detached configuration during withdrawal of the insertion tool;
[0109] FIG. 96 is a side elevation view showing an insertion tool
formed by a card-like element attached to a bag-like element;
[0110] FIG. 97 is a side elevation view showing an insertion tool
formed by two card-like elements attached to a bag-like
element;
[0111] FIG. 98 is an elevation view showing one major surface of
the insertion tool of FIG. 97;
[0112] FIG. 99 is a partial section view showing a replaceable
absorbent core component disposed inside an insertion tool pocket
in an insertion tool configured for insertion;
[0113] FIG. 100 is a plan view showing one major surface of the
insertion tool of FIG. 99 containing the replaceable absorbent core
component;
[0114] FIG. 101 is a plan view showing an insertion tool having a
relatively thicker inner end portion;
[0115] FIG. 102 is an edge view showing the insertion tool of FIG.
101;
[0116] FIG. 103 is a plan view showing another insertion tool
having a relatively thicker inner end portion;
[0117] FIG. 104 is an edge view showing the insertion tool of FIG.
103;
[0118] FIG. 105 is a plan view showing another insertion tool
having a relatively thicker inner end portion;
[0119] FIG. 106 is an edge view showing the insertion tool of FIG.
105;
[0120] FIG. 107 is a plan view showing a replaceable absorbent core
component and an insertion tool having a longitudinal slot; and
[0121] FIG. 108 is a plan view showing a replaceable absorbent core
component having a longitudinal slot and an insertion tool having
two finger-like sections.
DETAILED DESCRIPTION OF THE INVENTION
[0122] The disclosures of all patents, patent applications and any
patents which issue thereon, as well as any corresponding published
foreign patent applications, and all publications listed and/or
referenced hereafter in this description, are hereby incorporated
herein by reference. It is expressly not admitted, however, that
any of the documents or any combination of the documents
incorporated herein by reference teaches or discloses the present
invention. To the extent that any meaning or definition of a term
assigned herein conflicts with any meaning or definition of the
same term in a document incorporated by reference, the meaning or
definition assigned herein governs.
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DEFINITIONS
[0197] The following definitions of terms may be useful for
understanding the disclosure of the present invention.
[0198] Absorbent article: A device that absorbs and contains bodily
exudates by means of an absorbent core, and, more specifically, a
device which is placed against or in proximity to the body of a
wearer to absorb and contain the various exudates discharged from
the body. An exemplary embodiment of an absorbent article of the
present invention is the disposable absorbent article, diaper 60,
as shown in the drawing figures. It should be understood, however,
that the present invention is also applicable to other absorbent
articles such as incontinence briefs, incontinence undergarments,
diaper holders and liners, training pants, pull-on diapers, and the
like.
[0199] Absorbent core: An element of an absorbent article
containing a material or a combination of materials suitable for
absorbing, distributing, and storing aqueous liquids such as bodily
exudates.
[0200] Absorbent core component: A structural constituent of an
absorbent core, e.g., a piece of an absorbent core, such as one of
multiple pieces in a multi-piece absorbent core.
[0201] Absorbent layer: A term referring to a discrete,
identifiable sheet-like or web-like element of an absorbent core
structure which may remain detached and relatively movable with
respect to another such element or may be bonded or joined so as to
remain permanently associated with another such element. Each
absorbent layer may itself include a laminate or combination of
several sheets or webs of similar or diverse compositions.
[0202] Absorbent member: A functional constituent of an absorbent
core, e.g., a liquid acquisition member, a liquid
acquisition/distribution member, or a liquid storage/redistribution
member formed of a material or materials having particular liquid
handling characteristics suitable for the specific function.
[0203] Absorbent insert: A device adapted for insertion into an
absorbent article and to serve as an absorbent core component when
so inserted. A replaceable absorbent core component is an absorbent
insert, the latter term being especially descriptive when referring
to the device alone.
[0204] Chassis: A foundational constituent of an absorbent article
upon which the remainder of the structure of the article is built
up or overlaid, e.g., in a diaper, the structural elements that
give the diaper the form of briefs or short pants when configured
for wearing, such as a backsheet, a topsheet, or a combination of a
topsheet and a backsheet.
[0205] Diaper: An absorbent article generally worn by infants and
incontinent persons about the lower torso of the wearer.
[0206] Disposable: A term used to describe absorbent articles that
are not intended to be laundered or otherwise restored or reused as
an absorbent article after use, i.e., that are intended to be
discarded after a single use and, preferably, to be recycled,
composted or otherwise disposed of in an environmentally compatible
manner. Note that, as described in this disclosure, a single use of
a chassis and a non-removable core component may correspond to
several uses and replacements of replaceable core components.
[0207] Capillary liquid communication: The flow of a liquid from
one absorbent element to another absorbent element by capillary
transport. Also, a term used to describe a structural disposition
of absorbent elements in which the flow of a liquid from one of the
absorbent elements to the other occurs through capillary transport
of the liquid, generally requiring either the direct face-to-face
contact of the absorbent elements with each other, the direct
face-to-face contact of each of the absorbent elements with a
hydrophilic intermediate layer providing capillary conduction of
the liquid from one absorbent element to the other, or the
protrusion of the fibers of a fibrous absorbent element through a
porous and/or permeable intermediate layer into contact with the
other absorbent element.
[0208] Join, joined, joining: Terms encompassing configurations
wherein an element is directly secured to another element by
affixing the element directly to the other element, as well as
configurations wherein the element is indirectly secured to the
other element by affixing the element to an intermediate member or
members which in turn is or are affixed to the other element.
[0209] Major surface: A term used to describe the surfaces of
greatest extent of a generally planar or sheet-like structural
element and to distinguish these surfaces from the minor surfaces
of the end edges and the side edges, i.e., in an element having a
length, a width, and a thickness, the thickness being the smallest
of the three dimensions, the major surfaces are those defined by
the length and the width and thus having the greatest extent.
[0210] Replaceable: A term used to describe a component of an
absorbent article that can be replaced, that is, a component that
can be removed and for which a like component can be substituted in
place of the removed component, e.g., a replaceable absorbent core
component or absorbent insert.
[0211] Stratum, stratified: Terms referring herein to overlying or
superimposed regions within a given layer or structure which have
identifiably diverse compositions, densities, or other material
properties such that the layer or structure is non-homogeneous
through a cross section from one surface to an opposing
surface.
[0212] Wearer-facing layer: The elements of the chassis that form
the inner surface of the absorbent article, such as the topsheet,
the leg cuffs, and the side panels, etc., when such elements are
present.
[0213] Garment-facing layer: The elements of the chassis that form
the outer surface of the absorbent article, such as the backsheet,
the side panels, the waist fasteners, and the like, when such
elements are present.
Overall Description
[0214] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm".
[0215] As described below in detail, the present invention relates
to absorbent articles suitable for absorbing and retaining aqueous
bodily liquids. These absorbent articles of the present invention
generally include a backsheet formed of a substantially liquid
impervious material and an absorbent core disposed adjacent to the
backsheet. The absorbent core includes at least one removable core
component disposed in capillary liquid communication with at least
one non-removable core component. The removable core component may
be inserted into the absorbent article prior to the application of
the absorbent article to the wearer or while the absorbent article
is being worn. When the removable core component or a member of it
is removed, a replacement absorbent core component or member may be
inserted in place of the removed component or member.
[0216] In some exemplary embodiments, the absorbent article may
include a plurality of absorbent core components, including a front
panel and a rear panel in capillary liquid communication with a
center section. Each of the absorbent core components may include
multiple absorbent layers. Upon saturation with bodily discharges,
removable components or absorbent layers of the absorbent core may
be removed from the absorbent article. New, unsaturated absorbent
core components or absorbent layers may then be positioned in place
of the removed saturated core components or absorbent layers.
[0217] In some exemplary embodiments, the removable core component
is disposed adjacent to the body-facing surface of the backsheet
and is accessible through an aperture in the backsheet. In other
exemplary embodiments, the removable core component is disposed
adjacent to the garment-facing surface of the backsheet and is
contained in a pocket formed by a piece of sheet material affixed
to the outer surface of the backsheet.
[0218] In some exemplary embodiments, the absorbent article
includes a liquid pervious topsheet and a substantially liquid
impervious backsheet joined to the topsheet about the periphery of
the absorbent article. In a predetermined area of the periphery,
the topsheet and the backsheet may be separated to form an opening
providing access to a removable core component disposed between the
topsheet and the backsheet and for the insertion of a replacement
core component.
[0219] In these exemplary embodiments, the center absorbent core
component preferably has suitable liquid acquisition and/or
acquisition/distribution characteristics, while the front and rear
absorbent core panels or components preferably have suitable
storage/redistribution characteristics.
Exemplary Diaper Embodiment
[0220] FIG. 1 is a plan view of an exemplary embodiment of an
absorbent article of the present invention and shows exemplary
diaper 60 in its flat-out, uncontracted state, i.e., with all
elastic induced contraction pulled out, with portions of the
structure being cut away to more clearly show the construction of
the diaper, and with the portion of the diaper which contacts the
wearer facing the viewer. FIG. 2 also shows an exemplary diaper 60
in an exploded perspective view, with the portion that contacts the
wearer on top. In these exemplary embodiments, the diaper is shown
to have a periphery 57 defined by the outer edges of the diaper,
with the longitudinal edges being designated 64 and the waist end
edges being designated 16. The diaper additionally has a lateral
centerline which is designated 18 and a longitudinal centerline
which is designated 17. The front waist region 12 and the back
waist region 14 extend, respectively, from the waist end edges 16
toward the lateral centerline 18 a distance from about 1/4 to about
1/3 the length of the diaper. The waist regions form those portions
of the diaper which, when worn, encircle the waist of the wearer.
The crotch region 66 is that portion of the diaper between the
waist regions, and forms that portion of the diaper which, when
worn, is positioned between the legs of the wearer and covers the
lower torso of the wearer.
[0221] Another exemplary disposable diaper 60 embodiment of an
absorbent article of the present invention is shown in partially
segmented perspective view in FIG. 3 and in a side view, partial
cross-section in FIG. 4. The multi-piece absorbent core 10
including multiple absorbent core components, such as the center
section 50, the front panel 20, and the back panel 30, is more
fully illustrated and described below. The multi-piece absorbent
core is also described in the Weber et al. '602 patent.
[0222] A multi-piece absorbent core having discrete components
provides several benefits. First, the core exhibits desirable
aesthetics and fit when used in an absorbent article of the present
invention due to the use of discontinuous absorbent layers or
panels of absorbent material. For example, the center section may
include separate absorbent layers, allowing the center section to
bend and buckle somewhat independently from adjacent absorbent
layers and the front and rear panels and thereby provide better fit
and comfort in the crotch area than is typically achieved with
one-piece absorbent cores.
[0223] A second advantage provided by a multi-piece absorbent core
is the ability to independently vary selected characteristics of
the absorbent core components and members. The characteristics that
may be varied include the acquisition rates, distribution rates,
storage capacities and rates, interfacial liquid transfer rates and
efficiencies, thickness, functionality, and the shape or
configuration of the absorbent layers or panels. For example, in an
exemplary embodiment of an absorbent article of the present
invention, three absorbent layers may form the center section, with
the absorbent layer closest to the body of the wearer having
relatively greater acquisition characteristics than the remaining
two outer absorbent layers having relatively greater
acquisition/distribution characteristics. In this configuration,
bodily discharges such as urine are quickly acquired by the
body-side absorbent layer serving as an acquisition member and then
desorbed into the adjacent absorbent layers serving as
acquisition/distribution members for distribution to the front and
back panels, which preferably have greater storage/redistribution
characteristics.
[0224] A third benefit resulting from the use of a multi-piece
absorbent core in an absorbent article of the present invention is
the capability of removing and/or replacing components of the
absorbent core to regenerate the storage/redistribution capacity of
the absorbent core. The provision of access to the removable
absorbent core components, for example, to the back panel, allows
the removal and/or replacement of those absorbent core components.
In this disclosure, all description of the back panels, their
removal and replacement, and access to them for their removal and
replacement, is generally applicable to the front panels and vice
versa, in various exemplary embodiments.
[0225] By replacing absorbent core components, particularly
absorbent core components that are primarily suited for
storage/redistribution, the use of the absorbent article, such as
the disposable diaper, may be prolonged while continuing to draw
moisture away from the wearer's skin. As storage/redistribution
absorbent core members in, e.g., the front panel and the back
panel, become saturated, they may become substantially less
effective at absorbing moisture from acquisition/distribution
members in the center section. Consequently, the center section
becomes more saturated, thereby hindering its ability to absorb as
much moisture away from the wearer's skin. However, once an
absorbent core component such as the back panel is replaced, the
absorbent suction of that absorbent core component is regenerated,
and it once again becomes capable of absorbing moisture from the
acquisition/distribution member of the center section. Therefore,
the disposable diaper may be worn longer, and regeneration of the
absorbent core may be made without removal of the diaper from the
wearer.
[0226] It should be understood that the absorbent core described
herein may also be useful for other absorbent articles such as
incontinent briefs, incontinent pads, training pants, and the like,
and that the present invention is not limited to the particular
type or configuration of diaper shown in the drawing figures.
[0227] In the incorporated references, the entire absorbent core is
typically non-removably disposed in the absorbent article. However,
as described throughout this disclosure, specific components of the
multi-piece absorbent core are removable and replaceable in
absorbent articles of the present invention. For instance, the
front panel 20 and/or the back panel 30 may be removable and
replaceable, while another component, such as the center section
50, may be non-removably disposed in any of the previously known
configurations and thereby be made non-removable from the absorbent
article. Thus, absorbent articles of the present invention have
both non-removable absorbent core components and absorbent core
components that are removable and replaceable.
[0228] As described in the incorporated references, components of
the absorbent core may be made non-removable from the chassis by
being secured, attached, affixed, and/or sandwiched to or in the
chassis. For example, as described in the Buell '003 patent, an
absorbent core component can be rendered immobile by, for example,
bonding the backsheet and the absorbent core component together,
bonding the absorbent core component to a topsheet and the topsheet
to the backsheet, or tightly sandwiching the absorbent core
component between a topsheet and the backsheet. Also, as described
in the Lawson '278 patent, an absorbent core component may be
superimposed on the backsheet and attached thereto by attachment
means such as those well known in the art. For example, the
absorbent core component may be secured to the backsheet by a
uniform continuous layer of adhesive, a patterned layer of
adhesive, or an array of separate lines or spots of adhesive. In
some exemplary embodiments, an absorbent core component may be
affixed in the crotch area of the chassis, as described in the
DesMarais et al. '345 patent. Similarly, as described in the Osborn
'264 patent, an absorbent core component may be attached over the
core's upper or lower major surfaces, respectively, to adjacent
members such as the topsheet and the backsheet by any of the means
well known in the art, such as by spray-gluing or lines or spots of
adhesive. In fact, such attachment may facilitate the integrity and
recoverability of the absorbent materials while in use so as to
maintain an optimum degree of absorbency.
[0229] In some exemplary embodiments of the present invention, a
non-removable absorbent core component, such as the center section,
may be joined to the chassis in a portion of the crotch region by
affixing the non-removable core component to the topsheet or the
backsheet or to both the topsheet and the backsheet. For example,
the non-removable core component may be joined at the crotch point
to the chassis. The end portions of the non-removable core
component, i.e., the portions extending from the crotch region
toward the front and back waist regions, may remain unattached to
the chassis and thereby be free to "float" within the absorbent
article. Alternatively, the front portion of the non-removable core
component may be affixed to the chassis and only the rear portion
may be allowed to float. This floating core configuration allows
the unattached portion of the non-removable core component to slide
relative to the backsheet and or the topsheet when the absorbent
article is applied to the wearer. The floating core configuration
also allows the unattached portion of the non-removable core
component to slide in response to the contraction of the chassis
caused by the elastics in the leg cuff regions of the absorbent
article. Allowing a portion of the non-removable core component to
slide relative to the chassis may avoid the folding and wrinkling
of the non-removable core component that typically occurs in
absorbent articles having the entire non-removable core component
affixed to the distorted and/or contracted chassis.
The Absorbent Article Chassis
[0230] As described throughout this disclosure, the liquid
absorbent core can be utilized in disposable absorbent products
which are capable of absorbing significant quantities of bodily
liquids, such as urine, perspiration, menses, and water in bodily
wastes. These disposable absorbent articles may be prepared in the
form of disposable diapers, adult incontinence briefs, training
pants, and the like. Such form-fitting articles will generally
include a flexible substrate fashioned into a chassis in the form
of briefs or shorts when configured for wearing. A flexible
substrate which forms the chassis of such a form-fitting article
may include cloth or paper or other kinds of nonwoven substrate or
formed films and may be elasticized or otherwise extensible. The
chassis is the foundational element upon which the remainder of the
structure of the article is built up or overlaid. Because the
designs of the chassis and the absorbent core are interrelated, the
absorbent core is included in the following description in order to
make the structural relationship between the two clear. A more
detailed description of the absorbent core, itself, may be found in
the next section of this disclosure.
[0231] In the exemplary embodiments shown in FIG. 1 and FIG. 2, the
diaper has a substantially liquid impervious backsheet 62. On top
of this backsheet is disposed an absorbent core 10 which may
include one or more discrete absorbent layers and may include a
superabsorbent material in one or more of the absorbent layers. On
top of this absorbent core and joined to the backsheet is a fluid
pervious topsheet 61. The topsheet is the element of the article
that is placed next to the skin of the wearer. Additional
structural features such as elastic members and fastening means for
securing the diaper in place upon a wearer, such as tape tab
fasteners, may also be included, as will be described below.
[0232] In these exemplary embodiments, the topsheet and the
backsheet are coextensive and have length and width dimensions
generally larger than those of the absorbent core. The topsheet is
joined with and superimposed on the backsheet, thereby forming the
chassis. While the topsheet, the backsheet, and the absorbent core
can be assembled in a variety of well known configurations, an
exemplary diaper configuration is described generally in the Buell
'003 patent. Alternative exemplary configurations for disposable
diapers herein are also disclosed in the Aziz et al. '178 patent;
the Lawson '278 patent; and the Foreman '025 patent.
[0233] The backsheet is typically made of a material substantially
impervious to liquids and is preferably manufactured from a thin
plastic film, although other flexible liquid impervious materials
may also be used. The backsheet prevents the exudates absorbed and
contained in the absorbent core from wetting articles, such as bed
sheets and undergarments, which contact the diaper. An exemplary
backsheet may be made of polyethylene film having a thickness from
about 0.013 mm (0.5 mil) to about 0.051 mm (2.0 mils), although
other flexible liquid impervious materials can be used. As used
herein, the term "flexible" refers to materials which are compliant
and which will readily conform to the general shape and contour of
the wearer's body. A suitable polyethylene film is manufactured by
Monsanto Chemical Corporation and marketed in the trade as Film No.
8020. The backsheet may be embossed and/or matte finished to
provide a more clothlike appearance.
[0234] At least a portion of the backsheet may be subjected to
mechanical stretching to make it elongatable or drawable in order
to provide a "zero strain" stretch laminate for, for example,
forming elastic side panels. Suitable equipment and processes for
such mechanical stretching and for the formation of such a zero
strain stretch laminate are described in the Weber et al. '679
patent, the Buell et al. '793 patent, and the Weber et al. '897
patent.
[0235] Further, the backsheet may be "breathable", permitting
vapors to escape from the absorbent core while still preventing
exudates from passing through the backsheet. It is contemplated
that a backsheet that is highly breathable but substantially
impervious to liquid may be desirable for certain absorbent
articles. Such breathable composite materials are described in
greater detail in the Lim et al. '696 patent, in PCT Application
No. WO 95/16746 in the name of Cardinal et al., published on Jun.
22, 1995, and in the Curro '823 patent. Other breathable backsheets
including nonwoven webs and apertured formed films are described in
the Dobrin et al. '096 patent.
[0236] The size of the backsheet is dictated by the size of the
absorbent core and the exact diaper design selected. In an
exemplary embodiment, the backsheet has a modified hourglass-shape
extending beyond the absorbent core a minimum distance of at least
about 1.3 centimeters to at least about 2.5 centimeters (about 0.5
to about 1.0 inch) around the entire diaper periphery.
[0237] The topsheet is compliant, soft feeling, and non-irritating
to the wearer's skin. Further, at least a portion of the topsheet
is liquid pervious permitting bodily liquids to readily penetrate
through its thickness. A suitable topsheet can be manufactured from
a wide range of materials such as woven and nonwoven materials;
polymeric materials such as apertured formed thermoplastic films,
apertured plastic films, and hydroformed thermoplastic films;
porous foams; reticulated foams; reticulated thermoplastic films;
and thermoplastic scrims. Suitable woven and nonwoven materials can
include natural fibers, e.g., wood or cotton fibers, synthetic
fibers, e.g., polymeric fibers such as polyester, polypropylene, or
polyethylene fibers, or a combination of natural and synthetic
fibers. Preferably, the topsheet is made of a hydrophobic material
to isolate the wearer's skin from liquids in the absorbent core.
Like the backsheet, at least a portion of the topsheet may be
subjected to mechanical stretching to make it elongatable or
drawable, in order to provide a "zero strain" stretch laminate for,
for example, forming elastic side panels.
[0238] A number of manufacturing techniques may be used to
manufacture the topsheet. For example, the topsheet can be formed
of woven, nonwoven, spunbonded, carded, or like materials. In
nonwoven topsheets, the fibers are typically bound together by a
thermal binding procedure or by a polymeric binder such as
polyacrylate. This sheet is substantially porous and permits a
liquid to readily pass through it into the underlying absorbent
core. The topsheet material will preferably have no affinity for
holding aqueous bodily liquids in the area of contact between the
topsheet and the wearer's skin.
[0239] High loft nonwoven topsheets and apertured formed film
topsheets may be used in absorbent articles of the present
invention. In some exemplary embodiments, apertured formed films
may be preferred for the topsheet because they are pervious to
bodily liquids and yet non-absorbent, and they have a reduced
tendency to allow liquids to pass through in a direction away from
the absorbent core and thereby rewet the wearer's skin. Thus, the
surface of the formed film that is in contact with the body remains
dry, thereby reducing bodily soiling and creating a more
comfortable feel for the wearer. The body-facing surface of the
formed film topsheet can be hydrophilic, thereby helping bodily
liquids transfer through the topsheet faster and diminishing the
likelihood that liquid will flow off the topsheet rather than
flowing into and being absorbed by the absorbent core.
[0240] The topsheet may have an elasticated aperture adapted to
permit feces to pass through in a direction away from the wearer
and be unattached in a portion of the crotch region and a portion
of the rear of the chassis. The topsheet may be fully or partially
elasticized or may be foreshortened to provide a void space between
the topsheet and the non-removable core component. Exemplary
structures including elasticized or foreshortened topsheets are
described in more detail in the DesMarais et al. '536 patent, in
the Freeland '147 patent, in the Allen et al. '416 patent, and in
the Freeland et al. '775 patent.
[0241] The topsheet and the backsheet are joined together in any
suitable manner. As used herein, the term "joined" encompasses
configurations wherein the topsheet is directly joined to the
backsheet by affixing the topsheet directly to the backsheet, and
configurations wherein the topsheet is indirectly joined to the
backsheet by affixing the topsheet to intermediate members which in
turn are affixed to the backsheet. In an exemplary embodiment, the
topsheet and the backsheet are affixed directly to each other in
the absorbent article's periphery by attachment means (not shown)
such as an adhesive or any other attachment means known in the art.
For example, a uniform continuous layer of adhesive, a patterned
layer of adhesive, or an array of separate lines or spots of
adhesive can be used to affix the topsheet to the backsheet. The
topsheet may also be adhered to the absorbent core.
[0242] Furthermore, it is contemplated that a suitable absorbent
core structure without a topsheet could be used to provide
desirable results, such as comfort and absorbency, as well as
simplicity in manufacturing and material cost savings. For example,
the body-side surface of the absorbent core could be made of liquid
pervious, soft, compliant, non-irritating materials, thereby making
a separate topsheet unnecessary. Such an absorbent core could be
used in combination with a backsheet to provide the desired comfort
and absorbency in an absorbent article.
[0243] Fastening means, such as tape tab fasteners 65, are
typically disposed in the waistband region 63 of the diaper for
holding the diaper on the wearer. The waistband region is generally
considered to be that portion of the diaper extending from the
waist end edge of the diaper to about the laterally extending
margin of the absorbent core. The tape tab fasteners depicted are
representative, only, and the fastening means can be any of those
well known in the art, such as the fastening tape disclosed in the
Buell '594 patent, mechanical fasteners, hook and loop fasteners,
zippers, buttons, and the like. These tape tab fasteners or other
diaper fastening means are typically applied near the corners of
the diaper.
[0244] The absorbent article may have an "open" chassis
configuration, as shown in FIG. 1, in which the chassis is adapted
to be fastened together about the lower torso of a wearer by the
fastening means. Suitable non-limiting examples of an open chassis
include the disposable diaper embodiments described in the Buell
'092 patent and in the LaVon et al. '500 patent.
[0245] An open chassis may be at least partially pre-fastened prior
to its application onto the wearer. For example, articles capable
of being pre-fastened and then applied in a pull-on fashion include
those described in the Kline et al. '097 patent and in the Kline et
al. '098 patent. In certain embodiments, the article may require a
subsequent fastening step to adjust the size of, or the tension in,
the waist circumference of the article once the article has been
applied over the wearer's lower torso. For example, articles having
such two-step fastening/tensioning systems include those described
in the Magee et al. '866 patent.
[0246] Alternatively, the absorbent article may have a "closed"
chassis configuration, such as that of a pull-on pant-type diaper
or training pant, in which the chassis is adapted to be pulled on
over the legs and lower torso of the wearer without any additional
fastening steps. Suitable non-limiting examples of a closed system
include the disposable diapers and training pants described in the
Buell '234 patent and in the Ashton '487 patent.
[0247] In both open and closed chassis configurations, it is
desirable for the absorbent article to have extensible side panels
210 and preferably elastically extensible side panels to maximize
the ease of insertion and removal of the replaceable core
component.
[0248] Suitable non-limiting examples of disposable absorbent
articles having extensible side panels are described in the Buell
et al. '092 patent, in the Buell et al. '274 patent, in the Roe et
al. '145 patent, in the LaVon et al. '500 patent, in the Kline et
al. '545 patent, and in the Robles et al. '306 patent.
[0249] Leg elastic members 69 may be disposed adjacent to the
periphery of the diaper, preferably along each longitudinal edge 64
to form an elastically contractible leg cuff or side flap, so that
the elastic members tend to draw and hold the diaper against the
legs of the wearer. The leg elastic members may extend along a
portion of the length of the diaper. Alternatively, the leg elastic
members can extend the entire length of the diaper, or any other
length suitable to provide an elastically contractible line. The
length of the leg elastic members is dictated by the diaper
design.
[0250] A barrier leg cuff 240 including a barrier leg cuff elastic
member 241 may be disposed adjacent to each longitudinal edge 64 or
between the longitudinal edge and the longitudinal centerline 17 of
the diaper. Suitable barrier leg cuff materials and structures are
described in the Lawson '278 patent, in the Young et al. '345
patent, in the DesMarais et al. '345 patent, in the Dyer et al.,
'207 patent, in the Foreman '025 patent, and in the Aziz et al.
'178 patent.
[0251] Additionally, waist elastic members 67 can be disposed
adjacent to either the front, the back, or both of the waistband
regions of the diaper to provide a waistband as well as or rather
than leg cuffs. While the waistband can comprise a separate element
affixed to the body of the disposable diaper, it more often is an
extension of other elements of the disposable diaper, such as the
backsheet or the topsheet or both the backsheet and the topsheet.
Disposable diapers are normally constructed so as to have two
waistbands: a front and a rear.
[0252] A suitable waistband is disclosed in the Kievit et al. '595
patent. In one exemplary embodiment illustrated in the Kievit et
al. '595 patent, elastic waist elements extend across essentially
the entire lateral width of the disposable diaper. While this
construction may be preferred in some exemplary embodiments,
similar waistbands may be useful in designs wherein the elastic
waist elements extend across only a portion of the lateral width of
the diaper. Preferably, the elastic waist elements extend across a
major portion of the lateral width of the disposable diaper.
[0253] The elastic members are secured to the diaper in an
elastically contractible condition so that in a normally
unrestrained configuration, the elastic members effectively
contract or gather portions of the diaper. The elastic members can
be secured in an elastically contractible condition in at least two
ways. For example, the elastic members can be stretched and secured
while the diaper is in an uncontracted condition. Alternatively,
the diaper can be contracted, for example, by pleating, and the
elastic members can be secured and connected to the diaper while
the elastic members are in their unrelaxed or unstretched
condition. A method and apparatus suitable for manufacturing a
disposable diaper having elastically contractible elastic members
is described in the Buell '301 patent.
[0254] In use, an open chassis version of the diaper is applied to
a wearer by positioning one waistband region under the wearer's
back, and drawing the remainder of the diaper between the wearer's
legs so that the other waistband region is positioned across the
front of the wearer. The tape-tab or other fasteners are then
secured, preferably to outwardly facing areas of the diaper, as
shown in FIG. 4, for example. As can be seen in FIG. 4, the chassis
forms a waist opening 13 and leg openings 15 when configured for
wearing.
The Absorbent Core
[0255] In use, the disposable diapers or other absorbent articles
of the present invention tend to more quickly and efficiently
distribute and store liquids and to remain dry due to the high
absorbent capacity of the absorbent core components. Disposable
diapers incorporating the absorbent core components of the present
invention can also be thinner and more flexible.
[0256] FIG. 5 shows an exploded perspective view depicting the
elements of an exemplary embodiment of a shaped absorbent core 10
such as may be used in an absorbent article according to the
present invention, for example, in a disposable diaper. FIG. 6
shows a top plan view of such a shaped absorbent core 10.
[0257] As depicted in FIG. 5 and FIG. 6, the absorbent core 10
includes a front panel 20 and a back panel 30, both made of
absorbent material, preferably material suitable for liquid
storage/redistribution. The front panel has an outer front end 21,
an inner front end 22, and a pair of sides 23. Similarly, the back
panel has an outer back end 31, an inner back end 32, and a pair of
sides 33. In this exemplary embodiment, the front and back panels,
together with the center section 50, generally form an elongated
hourglass shape suitable for use in a disposable diaper or similar
absorbent article.
[0258] Since the center section 50 and the front panel 20 and the
back panel 30 are discrete absorbent core components, the center
section 50 may be non-removable, while the front panel 20 or the
back panel 30, or both, may be removable from the diaper 60. Thus,
when the front panel 20 or the back panel 30 becomes saturated with
bodily discharges, such as urine, it can be removed and replaced
with a fresh panel for continued use of the absorbent article.
[0259] The center section may be generally rectilinear. The term
"generally rectilinear" refers to the center section having a
generally constant width along its length. In general, however, the
center section may have a varying width along its length. The
center section may extend from about the outer front end 21 of the
front panel, to about the outer back end 31 of the back panel, as
shown in FIG. 6. In use, however, the center section need only be
in capillary liquid communication with the front and back panels,
such as by overlapping in a layered relationship, and may not
extend to the outer front end or the outer back end.
[0260] In an exemplary embodiment, the width 53 of the center
section is suitable for comfortably fitting within the crotch area
of the wearer when the absorbent core is incorporated into an
absorbent article, such as a disposable diaper. The length of the
generally rectilinear center section may be varied to provide a
suitable fit for various wearer sizes.
[0261] In a generally flat, unfolded state, the front panel and the
back panel are disposed such that the inner front end 22 of the
front panel is opposed to and spaced from the inner back end 32 of
the back panel as shown in FIG. 5 and FIG. 6. The distance between
the front and back panels may be varied as necessary. In general,
the distance will increase as the crotch length increases with the
size of the absorbent article. The front panel generally lies in
the front waist region, with the outer front end 21 being generally
near the front waist end edge and the inner front end 22 lying in
the crotch region. Similarly, the back panel lies in the back waist
region, with the outer back end 31 being generally near the back
waist end edge and the inner back end 32 lying in the crotch
region. In some exemplary embodiments, the back panel 30 is longer
than the front panel 20. Such a configuration lends itself to a
better fit when the absorbent core is used in a disposable
diaper.
[0262] As shown in FIG. 2, FIG. 3, FIG. 5, and FIG. 6, the front
panel 20 may have cut-out areas 40 at the intersection of the sides
23 and the inner front end 22 and the back panel 30 may have
cut-out areas 40 at the intersection of the sides 33 and the inner
back end 32. The cut-out areas, or notched portions, join the sides
and the inner ends such that the resulting widths of the inner ends
22 and 32 are narrower than those of the outer ends 21 and 31,
respectively and, as shown in the figures, approach the width 53 of
the center section, which is suitable for comfortably fitting
within the crotch area of the wearer when the absorbent core is
incorporated into an absorbent article, as stated above. The term
"notched" refers to a shape in which, instead of a side and an end
meeting generally at a right angle, some amount of material is
removed from the corner to produce an additional edge portion
joining the side and the end. The additional edge portion of the
cut-out areas may be generally straight, but in an exemplary
embodiment it is generally arcuate, as depicted in FIG. 6. It is
also contemplated that the cut-out areas may have generally
straight sides, with the limiting example resulting in a back panel
or a front panel being substantially trapezoidal in shape.
[0263] It is important for understanding the present invention to
note that, unlike the front panel and the back panel of the
absorbent core of the present invention, an absorbent core
component that extends from one waist region through the crotch
region to the opposing waist region of an absorbent article
typically presents several disadvantages relative to its potential
use as a replaceable core component. Fundamentally, any such core
component must both fit comfortably in the relatively narrow crotch
of the wearer and provide a useful amount of absorbent capacity,
both in the crotch region and in the waist regions. The hourglass
shape of many absorbent cores in absorbent articles known in the
art represents a compromise between the requirements of making the
crotch portion of the core narrow enough to fit comfortably, yet
wide enough to provide sufficient absorbent capacity in the crotch
region to accept gushes of urine, and making the waist region
portions of the core large enough to provide sufficient overall
absorbent capacity. The removal or the insertion of such an
absorbent core component extending through the crotch region while
the absorbent article is being worn would be relatively difficult
and/or impractical, because either the removal or the insertion
would necessitate passing an entire relatively wide waist region
portion of the absorbent core component directly through the
relatively narrow crotch of the wearer. Specifically, the removal
would require either pulling one relatively wide waist region
portion of the core component through the wearer's relatively
narrow crotch toward the opposing waist region without tearing or
otherwise disassembling the core component, or reaching into both
the front and the back of the waist opening to both push and pull
the core component through the wearer's crotch. The insertion would
require both forcing a relatively wide waist region portion of the
core component through the wearer's relatively narrow crotch,
either by pushing it through the crotch or by both pulling and
pushing it through the crotch, and then spreading that waist region
portion of the core component in order to dispose it properly in
the waist region of the absorbent article. It is clear that the
performance of such a removal or, especially, of such an insertion,
would be highly uncomfortable for the wearer and that the
likelihood of its successful completion, i.e., the likelihood of
its completion without tearing or otherwise damaging the absorbent
core component or the chassis of the absorbent article, would be
low.
[0264] It is also important to note that if, in an attempt to
facilitate the removal and/or the insertion of such an absorbent
core component extending through the crotch region, an oversized
absorbent article is applied to a wearer or an absorbent article is
applied relatively loosely onto the torso of a wearer, the likely
results are the undesirable leakage of bodily liquids from the
poorly fitted leg openings and the sagging or sliding of the
absorbent article toward the knees of the wearer. The occurrence of
either of these problems would clearly negate the very benefits of
containment of bodily liquids that the absorbent article is
intended to provide. Similarly, if an absorbent article is applied
properly but then must be loosened in order to facilitate the
removal and/or the insertion of such an absorbent core component,
not only is the same unacceptable leakage likely to occur, but the
proper fit of the absorbent article on the torso of the wearer is
likely to be difficult to restore. In addition, such loosening,
manipulation of the absorbent core component through the wearer's
crotch, and restoration of the fit by tightening the absorbent
article, is very likely to be annoying to the wearer and,
therefore, difficult for the caregiver to accomplish. Hence, the
removable absorbent core components and absorbent inserts known in
the art that extend from one waist region through the crotch region
to the opposing waist region are typically intended to be removed
only when the absorbent article has been opened and/or removed from
the body of the wearer, rather than while the absorbent article is
being worn. In the few instances where such a removable absorbent
core component is asserted to be removable while the article is
being worn, no assertion is made of the impractical contention that
a like replacement core component can be inserted.
[0265] In particular, it is preferred that the front panel or the
back panel of the absorbent core of the present invention extend
from the respective waist region into the crotch region no farther
than the crotch point of the absorbent article. Thus, the front
panel and the back panel are particularly well suited for use as
replaceable core components. Because each of these panels extends
only from a waist region into the crotch region, but not through
the crotch region to the opposing waist region, it can be removed
and replaced without the necessity of passing any portion of the
panel, the fingers or hand of the caregiver, or an insertion tool
through the wearer's crotch. Nevertheless, because the inner end of
each of these panels can be shaped to fit comfortably into the
crotch area of the wearer's body, as described above, the inner end
can be optimally positioned for the absorption of liquid from the
center section, i.e., from the non-removable core component that
extends through the wearer's crotch and thus can serve to transport
liquid from the front waist region to the back panel or from the
back waist region to the front panel.
[0266] The center section may include multiple layers of absorbent
material, each having individual liquid acquisition,
acquisition/distribution or storage/redistribution characteristics,
as well as individual shape, width, length and thickness
characteristics. The number and placement of absorbent layers of
the center section may be varied to achieve desired characteristics
such as thinness, softness, flexibility, or beneficial liquid
acquisition, distribution, and storage rates. For example, the
layers of the center section need not extend from one waist region
through the crotch to the opposing waist region. In particular, the
center section may include an absorbent layer extending from one
waist region into the crotch region, where it ends, and another
absorbent layer extending from the opposing waist region into and
ending in the crotch region. The number of absorbent layers of the
front and back panels may also be varied to achieve desired
characteristics such as beneficial liquid acquisition and
distribution rates, as well as capacity and storage rates, and
wearer comfort. For example, in FIG. 3, the absorbent core is shown
with the center section 50 and the front and back panels 20 and 30
each having a single absorbent layer. However, the center section
has three absorbent layers in the exemplary embodiments shown in
FIG. 2 and FIG. 5, with two absorbent layers designated 51 and one
absorbent layer designated 52. Also, the back panel is shown in
FIG. 12 as a core component made up of back panel absorbent layers
34, 35, and 36.
[0267] In the exemplary embodiment shown in cross section in FIG. 7
and corresponding to the general top view of FIG. 6, one upper
absorbent layer 52 and one lower absorbent layer 51 are both placed
over front and back panels 20 and 30, resulting in a thin, flexible
absorbent core. The term "over" refers to the surface of the
absorbent core of the invention corresponding to the wearer's body
when used in an absorbent article such as a disposable diaper,
i.e., the body-facing surface. It is noted, however, that FIG. 7 is
representative of only one exemplary embodiment and it may be
beneficial to place the absorbent layers 51 or 52 under the front
and back panels 20 and 30. The term "under"refers to the surface of
the absorbent core of the invention corresponding to the garment
side when used in an absorbent article such as a catamenial pad or
disposable diaper, i.e., the garment-facing surface. It should also
be understood that the term "upper" refers to the absorbent layer
of the absorbent core which is nearest to and faces the article
topsheet; conversely, the term "lower" refers to the absorbent
layer of the absorbent core which is nearest to and faces the
article backsheet.
[0268] Other arrangements of the absorbent layers of the center
section and the front and back panels are also possible. For
example, FIG. 8 shows in cross-section an additional exemplary
embodiment corresponding to the general top view of FIG. 6, in
which two absorbent layers of front and back panels 20 and 30 are
placed under the center section 50. As shown in the Weber et al.
'602 patent and in FIG. 9, an alternative embodiment may have a
center section 50 having two absorbent layers 51, one placed over
front and back panels 20 and 30, and one placed under the front and
back panels, thereby sandwiching the front and back panels between
absorbent layers of the center section. As another example, as
shown in the Weber et al. '602 patent and in FIG. 10, the front and
back panels 20 and 30 may have two absorbent layers, with one
absorbent layer placed over the center section 50 and one absorbent
layer placed under the center section 50, thereby sandwiching the
ends of the center section between absorbent layers of the front
and back panels.
[0269] As shown in FIG. 7, the uppermost absorbent layer 52 is
generally on the side corresponding to the body side of an
absorbent article, such as a disposable diaper. Therefore, the
uppermost absorbent layer 52 is generally in capillary liquid
communication with the topsheet 61 of the disposable diaper,
thereby acting to quickly acquire and partition bodily exudates
away from the wearer's body to the generally more absorptive lower
absorbent layers 51 and to the front and back panels 20 and 30.
Adhesive bonding of the uppermost absorbent layer 52 to the
topsheet 61 may enhance the capillary liquid communication by
providing interfacial bonding and preventing topsheet separation
from impeding liquid flow.
The Absorbent Core Materials
[0270] The components or members of the absorbent core may include
laminates or combinations of several sheets or webs of the
requisite types of materials. In general, each absorbent core
component or member may be made of any absorbent material or
combination of materials having enough structural integrity to be
handled as a discrete unit.
[0271] For example, in order for a non-removable core component,
such as the center section, to function properly in use, it is
preferable to maintain the structural integrity of the component in
order to maintain its ability to transport liquid from the front of
the absorbent article to the rear of the absorbent article and/or
from the crotch region of the absorbent article to the waist
regions. If an absorbent layer of the non-removable core component
is torn or fractured, the liquid transport and capillary liquid
communication with the replaceable core component can be
interrupted. Therefore, it is preferred that, when dry, the
absorbent layer or layers of the non-removable core component have
a tensile strength to break of greater than about 200 grams force
and, more preferably, greater than about 400 grams force and, most
preferably, greater than about 1000 grams force. It is also
preferred that, when completely wetted, the absorbent layer or
layers of the non-removable core component have a tensile strength
to break of greater than about 100 grams force and, more
preferably, greater than about 200 grams force and, most
preferably, greater than about 400 grams force. The structural
integrity can also be achieved by affixing a carrier layer having
the required tensile to break characteristics to the non-removable
core component or to the absorbent layer along its major surfaces
or, alternatively, by wrapping the non-removable core component or
the absorbent layer in the carrier layer.
[0272] Typical materials known in the art may be used for the
absorbent core components and/or members, such as fibrous nonwoven
materials, fibrous air-laid materials, fibrous wet-laid web
materials, and combinations of fibrous materials having absorbent
gelling materials dispersed upon or within the fibrous structure.
If necessary, such absorbent core components or members may be
formed into a packet having the fibrous materials substantially
enveloped by a liquid pervious web that provides the structural
integrity for the removal and replacement into the absorbent
article. An exemplary form of a non-woven fibrous absorbent
structure that may be utilized in the present invention is
constructed from hydrophilic chemically stiffened cellulosic
fibers, as taught in the Lash '728 patent and the Young et al. '345
patent, as well as in the Seger et al. '416 patent.
[0273] Absorbent materials for use as absorbent core components or
members may also be foam-based. For example, a component of the
absorbent core may include a foam material in the form of a sheet
or a plurality of foam pieces or particles, which may be adhesively
bonded together or which may simply be constrained into an unbonded
aggregate held together by an overwrapping of envelope tissue or by
means of the topsheet and backsheet of the absorbent article.
Particularly suitable absorbent foams for absorbent articles such
as diapers have been made from High Internal Phase Emulsions,
hereafter referred to as "HIPE". See, for example, the DesMarais et
al. '345 patent, the DesMarais et al. '224 patent, and the Stone et
al. '179 patent.
[0274] The absorbent core of the absorbent articles described
herein can also include a combination of conventional elements or
materials and one or more foam absorbent structures. For example,
the absorbent articles may utilize an absorbent core which includes
a combination, e.g., an airlaid mixture, of particles or pieces of
the foam absorbent structures and conventional absorbent materials
such as wood pulp or other cellulosic fibers and/or particles or
fibers of polymeric gelling agents.
[0275] Besides acquiring bodily liquids rapidly, the absorbent
acquisition member of the present invention should give up this
liquid efficiently to the liquid acquisition/distribution or
storage/redistribution members. This liquid transfer function of
the acquisition member is of particular importance because the
acquisition member must have sufficient capillary suction to
substantially drain the liquid from the topsheet and yet not
exhibit excessive liquid retention, which would make it difficult
for the underlying absorbent layer to desorb the acquisition
member.
[0276] In particular, the liquid acquisition member should have a
suitable capillary desorption pressure relative to the absorption
pressure of other absorbent core members, especially those intended
for liquid storage. If the liquid acquisition member of the
absorbent article holds the acquired liquid too tenaciously, this
will inhibit the ability of these other members to partition liquid
away and can cause the acquisition member to remain so heavily
loaded with liquid that the absorbent article is more susceptible
to leaking.
[0277] This principle, according to which the relationship of the
capillary absorption pressure of one absorbent element and the
capillary desorption pressure of another absorbent element defines
the liquid flow, liquid transfer, and capillary liquid
communication characteristics of the absorbent article, is that of
a capillary cascade. For example, the wearer-facing layer of the
absorbent article, e.g., a topsheet, is liquid pervious and has
particular capillary absorption and desorption pressures. The
capillary desorption pressure of this topsheet is preferably less
than the capillary absorption pressure of the non-removable core
component and, specifically, less than the capillary absorption
pressure of the uppermost absorbent layer of the non-removable core
component, with which the topsheet will be in contact. It is also
preferred that the capillary absorption pressure of an intermediate
or lowermost absorbent layer of the non-removable core component is
greater than the capillary desorption pressure of the topsheet. In
addition, it is preferred that the absorption pressure of a lower
absorbent layer of the non-removable component be greater than the
capillary desorption pressure of the uppermost absorbent layer of
the non-removable core component. Furthermore, it is preferable
that the capillary absorption pressure of the
storage/redistribution member of the replaceable core component be
greater than the capillary desorption pressure of the absorbent
layer of the non-removable core component in contact with the
replaceable core component.
[0278] In addition to having to overcome the capillary desorption
pressure of an adjacent absorbent structure, an absorbent layer
must overcome the difference in vertical height between a source of
liquid and the portion of the absorbent layer to which it is
desired to move the liquid by capillary transport. The magnitude of
this vertical head may be on the order of 15 cm to 20 cm in some
embodiments of the present invention, in which liquid is moved from
the lower portion of the crotch region to the upper waist region of
an absorbent article worn by a standing wearer, is moved from the
front portion to the back panel of an absorbent article worn by a
wearer lying in a face-down posture, or is moved from the back
portion to the front panel of an absorbent article worn by a wearer
lying in a face-up posture.
[0279] As an example of a suitable capillary cascade relationship,
in some exemplary embodiments, it is preferred that the uppermost
absorbent layer of the non-removable core component have a
capillary absorption pressure of between 2 cm and 10 cm and a
capillary desorption pressure of between 5 cm and 25 cm. A lower
absorbent layer of this non-removable core component preferably has
a capillary absorption pressure of between 10 cm and 40 cm and a
capillary desorption pressure of between 20 cm and 60 cm and is
thereby capable of desorbing liquid from the uppermost absorbent
layer. For embodiments in which the non-removable core component
includes only a single absorbent layer of material or a stratified
structure, the capillary absorption pressure of the non-removable
core component is preferably between 2 cm and 40 cm and the
capillary desorption pressure is between 5 cm and 60 cm.
[0280] The liquid acquisition/distribution member may include
materials similar to those used in the acquisition member, but
preferably having more distributive characteristics. Since
discharged aqueous bodily liquid, e.g., urine, is frequently
discharged in gushes, the acquisition/distribution member must be
able to quickly acquire this liquid and must also transport the
liquid by wicking or another mechanism from the point of initial
liquid loading to other parts of the acquisition/distribution
member for eventual desorption to the adjacent liquid
storage/redistribution member. Thus, such materials preferably have
a greater degree of distributive capacity than the acquisition
member materials, such that bodily exudates may be efficiently
transported from the acquisition zone to the storage members of the
absorbent core.
[0281] In some embodiments, it may be desirable to have a "biased"
absorbent core structure, wherein a portion adjacent to one surface
is capable of rapidly acquiring a liquid with minimal dispersion,
while a portion adjacent to an opposing surface is capable of
rapidly dispersing a liquid with lesser acquisition capability.
When oriented in an absorbent article such that the "acquisition
side" is oriented toward the wearer and the "distribution side" is
oriented away from the wearer, a "down and out" functionality is
provided, whereby liquid is rapidly acquired into the absorbent
core structure with minimal dispersion on its wearer-facing side
and is rapidly distributed throughout the portion of the absorbent
core structure on its garment-facing side. This functionality
allows the maintenance of a clean and dry visible and tactile
impression of the absorbent core structure, and hence the absorbent
article, while effectively utilizing the absorptive capacity of the
regions of the absorbent article oriented away from the wearer.
[0282] In order to provide the above-described functionality in
some exemplary embodiments, compositions for the absorbent core may
be selected such that the acquisition side of the absorbent layer
is comparatively free of small, high surface area fibers which
provide good distributive and storage characteristics but less than
optimal acquisition characteristics and such that the distributive
side of the absorbent layer has a comparatively higher proportion
of such small, high surface area fibers so as to provide greater
distribution characteristics. In some embodiments, the acquisition
area may have both a relatively lower average density and lower
average basis weight per unit area than the distribution area to
establish the preferred capillarity force gradient between them.
Also, in foam absorbent core structures, cell sizes and hole sizes
are parameters that can impact a number of important mechanical and
performance features of the foams, including their fluid wicking
properties and the capillary pressure that is developed within the
foam structure, as described in the Stone '179 patent.
[0283] Optionally, a liquid pervious sheet, e.g., a tissue sheet,
or a scrim layer is positioned between the acquisition/distribution
member and the storage/redistribution member to maintain the
physical integrity of the acquisition/distribution member during
processing and/or use. This liquid pervious sheet can envelop all
or part of the acquisition/distribution member, or simply be
positioned as described above, without necessarily enveloping the
acquisition/distribution member. In embodiments in which the center
section of the absorbent core includes the acquisition and
acquisition/distribution members and is placed over or under a
replaceable absorbent core component or absorbent insert including
the storage/redistribution member, such as a back panel, a single
such liquid pervious sheet may suffice. Alternatively, in
embodiments in which absorbent layers of the center section
sandwich the replaceable absorbent core component or absorbent
insert, two or more such liquid pervious sheets may be positioned
to separate the absorbent layers of the center section and the
replaceable core component. These multiple liquid pervious sheets
may be described as forming a surface of or lining the openable
chassis pocket formed by and between the sandwiching absorbent
layers of the center section. Similarly, in embodiments in which
absorbent layers of a replaceable absorbent core component or
absorbent insert sandwich an end of the center section, two or more
such liquid pervious sheets may be positioned to separate the
absorbent layers of the center section and the replaceable core
component. In the latter embodiment, the multiple liquid pervious
sheets may be described as forming a surface of or lining the
two-part openable chassis pocket into which the replaceable
absorbent core component or absorbent insert is inserted and which
is formed by and between the topsheet and the center section and by
and between the center section and the backsheet,
respectively,.
[0284] An absorbent core suitable for use with the present
invention includes at least one absorbent core component including
a liquid storage/redistribution member and may include two such
components, e.g., in the form of front and back panels. Each
absorbent core component having a liquid storage/redistribution
member acts to store bodily exudates away from the wearer's body,
so as to leave the wearer with a feeling of dryness and to prevent
leakage. The absorbent core component having the liquid
storage/redistribution member is maintained in capillary liquid
communication with the acquisition and/or acquisition/distribution
member(s), such that urine or other aqueous bodily liquid can be
desorbed from the acquisition and/or acquisition/distribution
member(s) and be absorbed by the liquid storage/redistribution
member.
[0285] The storage/redistribution member may include a member or
members having primarily liquid storage characteristics. Such a
storage member may have limited transport and wicking capabilities
but high storage or retention capacity, and rely upon a liquid
distribution member to distribute incoming liquid over a larger
area of the storage/redistribution member.
[0286] In order for a replaceable core component such as the back
panel to function well within the context of the present invention,
an absorbent layer of the replaceable core component preferably has
an absorption pressure that is sufficient to desorb liquid from an
acquisition/distribution member of a non-removable absorbent core
component such as the center section, i.e., the absorption pressure
of the absorbent layer of the replaceable core component is
preferably greater than the desorption pressure of the
acquisition/distribution member. Therefore, the absorbent layer of
the replaceable core component preferably has an absorption
pressure of between 25 cm and 80 cm. An exemplary material capable
of providing absorption pressures within the specified range is a
collapsed polymeric foam material comprising a hydrophilic,
flexible, nonionic polymeric foam structure of interconnected open
cells, which foam material, upon contact with body temperature
liquid, expands and absorbs the liquid. An important parameter of
these foams is their glass transition temperature. The glass
transition temperature represents the midpoint of the transition
between the glassy and rubbery states of the polymer. Foams that
have a higher glass transition temperature than the temperature of
use can be very strong but will also be very rigid and potentially
prone to fracture. When such foams are collapsible, but have been
stored in the collapsed state for prolonged periods, they also
typically take a long time to recover to the expanded state when
wetted with aqueous fluids colder than the glass transition
temperature of the polymer. Such a foam may have a capillary
suction specific surface area per gram in the range from about 0.7
to about 8 m.sup.2/g or, preferably, from about 1 to about 7
m.sup.2/g, and most preferably from about 1.5 to about 6 m.sup.2/g.
Such a foam will preferably have a number average cell size of
about 50 microns or less and typically in the range of from about 5
to about 50 microns. More preferably, the number average cell size
will be in the range from about 5 to about 40 microns and, most
preferably, from about 5 to about 35 microns.
[0287] The absorbent articles of the present invention are
preferably constructed such that when liquid is deposited in the
article, the liquid is quickly absorbed and transported from the
non-removable core component to the replaceable core component. In
order to minimize the bulk of the absorbent article and to maximize
the benefits of skin health and dryness, it is preferable that the
non-removable core component have a liquid storage capacity that is
low relative to the total capacity of the absorbent core, i.e.,
relative to the total of the summed capacities of the non-removable
and replaceable core components. Furthermore, it is desirable to
remove the majority of the liquid deposited in the article by
removing the replaceable core component and replacing it with a
fresh dry component.
[0288] Therefore, it is preferred that the liquid absorptive
capacity of the replaceable core component be significantly greater
than the liquid absorptive capacity of the non-removable core
component. The liquid absorptive capacity of the replaceable core
component is preferably at least about 1.5 times as great as the
liquid absorptive capacity of the non-removable core component,
more preferably at least about 2 times as great, and most
preferably at least about 4 times as great as the liquid absorptive
capacity of the non-removable core component.
[0289] The replaceable core component may include an absorbent
layer including an acquisition material, which may be the same
material as the uppermost absorbent layer of the non-removable core
component. This acquisition material may form a portion of the
outer surface of the replaceable core component or, alternatively,
the acquisition material may be disposed under another layer of
liquid pervious material. The absorbent layer of the replaceable
core component including the acquisition material may be disposed
in capillary liquid communication with the topsheet or in capillary
liquid communication with a portion of the non-removable core
component.
[0290] In some embodiments, the replaceable core component may
include an absorbent layer including a distribution material, which
may be the same material as that in an intermediate or a lower
absorbent layer of the non-removable core component. This
distribution material may form a portion of the outer surface of
the replaceable core component or, alternatively, the distribution
material may be disposed under another layer of liquid pervious
material. The distribution material may be disposed adjacent to
either the wearer-facing surface of the replaceable core component
or the garment-facing surface of the replaceable core component, or
both. Furthermore, the distribution material may be in capillary
liquid communication with the topsheet or in capillary liquid
communication with a portion of the non-removable core
component.
[0291] The replaceable core component may include multiple
absorbent layers or pieces, including at least a liquid storage
member and/or a liquid storage/redistribution member. The
replaceable core component may also have one or more layers forming
a packet to partially or completely contain the absorbent layer or
layers. The packet layers may include liquid pervious materials,
liquid impervious materials, or combinations thereof, and at least
a portion of one of the packet layers forming the outer surface of
the replaceable core component must have a liquid pervious region.
In some embodiments, an outer surface of the replaceable core
component may be formed by an acquisition member, a distribution
member, or an acquisition/distribution member disposed in such a
way as to contain the absorbent layer or layers in which the liquid
storage member and/or the liquid storage/redistribution member is
included. Also, in some embodiments, these additional absorbent
members may be disposed between the packet layers forming the outer
surface of the replaceable core component and the storage or
storage/redistribution member.
[0292] In summary, the absorbent core 10 includes a plurality of
discrete components, each component having distinct liquid
acquisition, acquisition/distribution, or storage/redistribution
characteristics. So long as each of the acquisition,
acquisition/distribution, and storage/redistribution members is in
capillary liquid communication with an adjacent member or members,
the absorbent core components may be positioned relative to one
another in a wide variety of configurations. There is no particular
criticality with respect to the positional relationship of the
acquisition/distribution member and the liquid
storage/redistribution member within the absorbent core so long as
these members are in effective capillary liquid communication with
each other and so long as each member is capable of effectively
holding and/or transporting the amount of aqueous bodily liquid
that is expected to be discharged into the absorbent article. It
should be noted that the various structures of absorbent articles
according to the present invention may or may not be generally
planar in nature, and may be shaped or profiled in any desired
configuration.
The Structure Allowing Removal and Replacement of Core
Components
[0293] As shown in FIG. 2, FIG. 3, and FIG. 4, the backsheet 62 of
some exemplary embodiments of an absorbent article of the present
invention may have an aperture 44 in the general proximity of the
front panel 20 or rear panel 30, or both.
[0294] As shown in FIG. 4, the aperture 44 provides access into
what may be described as an openable chassis pocket 5, with a
removable absorbent core component, for example, the back panel 30,
being disposed inside the openable chassis pocket when the diaper
is being worn, and being removable from and replaceable into the
openable chassis pocket through the aperture. For example, after
the removal of a saturated back panel, a fresh, unused absorbent
core component may be reinserted through the aperture. A flap 42
may be provided to cover the aperture. The material used for the
backsheet may be used for the flap as well. When the disposable
diaper is being worn, the flap may be secured over the aperture by
suitable fasteners 43, such as VELCRO strips or adhesive strips
(not shown). For example, FIG. 4 shows the flap in the closed
position over the aperture adjacent to the front panel 20 (shown in
FIG. 3). More preferably, the flap is sealed with releasable
adhesive, thereby providing for liquid impermeability when closed,
but allowing for multiple openings and closings.
[0295] In the exemplary embodiment shown in FIG. 3 and FIG. 4, the
back panel 30 is disposed under the center section, as in the
description of FIG. 7, above, and the openable chassis pocket 5 is
formed by and between the center section 50 and the backsheet 62.
In other exemplary embodiments, in which the center section and the
removable core component or components are arranged differently,
the openable chassis pocket may be formed by and between different
components and layers. For example, in an embodiment in which the
back panel is disposed above the center section, the openable
chassis pocket may be formed by and between a topsheet and the
center section. Similarly, when the back panel is sandwiched
between absorbent layers of the center section, as in FIG. 9, the
openable chassis pocket may be formed by and between the
sandwiching absorbent layers of the center section. Also, when the
center section is sandwiched between absorbent layers of the back
panel, as in FIG. 10, the openable chassis pocket may be formed in
two parts, by and between the topsheet and the center section and
by and between the center section and the backsheet,
respectively.
[0296] In general, the front panel, the back panel, and the
corresponding apertures and flaps are substantially similar, but
need not be. In an alternative exemplary embodiment, it may be
desired to include only one aperture and flap, for example, for
access to the back panel, without providing a similar aperture for
access to the front panel.
[0297] Alternatively, as shown in FIG. 11 and FIG. 12, a backsheet
pocket sheet 45 may be affixed on the garment-facing surface of the
backsheet adjacent to the aperture 44 to form an openable chassis
pocket 5 between the backsheet pocket sheet and the backsheet. In
these embodiments, a removable and replaceable core component, such
as back panel 30, may be disposed outside, relative to the
aperture, and a core component that remains in the absorbent
article, i.e., a non-removable core component, such as center
section 50, may be disposed inside, relative to the aperture, such
that the aperture allows capillary liquid communication between the
replaceable core component and the non-removable core
component.
[0298] The openable chassis pocket 5 formed by the backsheet pocket
sheet 45 may have its openable end 41 longitudinally nearest the
adjacent waist end edge. The openable chassis pocket may be
reclosable and may be resealable, and is preferably positioned so
that the back panel is urged into capillary liquid communication
with the center section. The backsheet pocket sheet is preferably
resilient and pliable, and forms a substantially liquid impervious
barrier over the aperture, functionally becoming an extension of
the backsheet when the openable chassis pocket is closed.
[0299] The back panel is shown in FIG. 12 as a core component made
up of individual back panel absorbent layers 34, 35, and 36. In
such an embodiment, as one back panel absorbent layer, e.g., the
uppermost back panel absorbent layer 34, becomes saturated with
bodily discharge it may be removed, thereby exposing an adjacent
prepositioned back panel absorbent layer, e.g., the adjacent back
panel absorbent layer 35.
[0300] FIG. 13 shows an exemplary embodiment of the arrangement of
the back panel 30, again showing representative back panel
absorbent layers 34, 35, and 36 in a layered relationship adjacent
to the aperture 44 and in capillary liquid communication with the
center section 50. Removal of the back panel absorbent layers
through the openable end 41 of the openable chassis pocket 5 may be
facilitated by the use of pull tabs 46, which may be of any type
known in the art, such as a strip of plastic film adhered to each
back panel absorbent layer.
[0301] Additionally, the back panel absorbent layers may be
separated from one another by a liquid impervious blocking layer 47
so that adjacent back panel absorbent layers are not in capillary
liquid communication with each other. The blocking layer 47 may be
any liquid impervious polymer film, such as film suitable for use
as a liquid impervious backsheet. As one back panel absorbent layer
becomes saturated by absorption of liquid from the center section
50, it may be removed, thereby exposing a substantially dry, fresh
adjacent back panel absorbent layer for additional absorption from
the center section 50. In this manner, the absorbent article may be
refreshed or regenerated for a prolonged period of time without the
necessity of its removal from the wearer.
[0302] FIG. 14 shows an exemplary arrangement of the back panel
absorbent layers 35 and 36 in a layered relationship with the
liquid impervious blocking layer 47 disposed to form a liquid
impervious layer between them. A portion of the blocking layer is
preferably affixed, for example at an attachment point 48, to the
back panel absorbent layer being removed. As this back panel
absorbent layer 35 is removed, the blocking layer 47 is removed as
well, thereby leaving the adjacent back panel absorbent layer 36 in
position to be urged into capillary liquid communication with the
center section 50.
[0303] An alternative exemplary embodiment of the back panel 30 of
an absorbent article of the present invention is shown in
cross-section in FIG. 15, in which a back panel envelope 49 is
shown in position to be attached to the backsheet 62. The back
panel envelope is shown as containing a single back panel absorbent
layer 34 enveloped between a substantially liquid impervious layer
54 and a substantially liquid pervious layer 55, and may be
releasably affixed, for example, by a suitable releasable adhesive
39 known in the art, adjacent to the perimeter 38 of the aperture
44. When such a releasably affixed back panel envelope becomes
saturated due to the absorption of liquid from the center section
50, it may be removed and replaced with a fresh, dry back panel
envelope 49.
[0304] In another alternative exemplary embodiment of an absorbent
article of the present invention shown in cross-section in FIG. 16,
the openable end 41 of the openable chassis pocket 5 may be formed
along a predetermined area of the periphery 57, such as along the
waist end edge 16, either in the front, in the back, or both, where
the topsheet 61 and the backsheet 62 are separable to provide
access to the removable absorbent core component, e.g., the back
panel absorbent layers 34 and 35. The openable end formed by the
separation of the topsheet and the backsheet allows the removal and
replacement of the removable absorbent core components and may be
resealable to provide a substantial degree of liquid impermeability
when closed. The openable end may be made resealable, for example,
with a suitable releasable and resealable adhesive 56 known in the
art.
[0305] As can be seen in FIG. 13 and in FIG. 16, the openable
chassis pocket 5 generally has an outer end 27 and an inner end 28
corresponding to the outer end 31 and the inner end 32,
respectively, of the back panel 30. In the exemplary embodiments
shown in FIG. 13 and FIG. 16, the outer end 27 of the openable
chassis pocket coincides with its openable end 41. The inner end of
the openable chassis pocket may be formed in several ways. For
example, as shown in FIG. 13, the inner end may be formed at the
area of attachment of the backsheet pocket sheet 45 to the
backsheet. As described above, the backsheet, the topsheet, and the
non-removable absorbent core component may be secured, attached, or
affixed to each other in a variety of configurations. Thus, as
another example of the formation of the inner end of the openable
chassis pocket, an area of attachment of the non-removable
absorbent core component to the chassis, e.g., to the backsheet,
the topsheet, or both, in the crotch region may form the inner end
of the openable chassis pocket.
[0306] In alternative embodiments, as shown in FIG. 17 and FIG. 18,
a topsheet pocket sheet 202 may be affixed on the wearer-facing
surface of the topsheet 61 to form an openable chassis pocket 5
between the topsheet pocket sheet and the topsheet. The openable
chassis pocket 5 formed by the topsheet pocket sheet 202 may have
its openable end 41 adjacent to the nearest waist end edge 16. The
openable chassis pocket may be reclosable and may be resealable,
and is preferably positioned so that an inserted back panel is
urged into capillary liquid communication with the center section.
The topsheet pocket sheet is preferably resilient, pliable, and
liquid pervious and may be formed of the same material as the
topsheet.
[0307] As is also shown in FIG. 17 and in FIG. 18, in some
exemplary embodiments having such an openable chassis pocket 5
formed by a topsheet pocket sheet 202, the topsheet 61 may have a
topsheet aperture 200 allowing face-to-face contact and capillary
liquid communication between a replaceable absorbent core component
disposed in the openable chassis pocket, such as the back panel 30,
and a non-removable absorbent core component, such as the center
section 50, disposed adjacent to an opposing surface of the
topsheet. Such a topsheet aperture may have an area of
approximately 1 cm.sup.2 or greater, and a smaller of its length
and width dimensions may be approximately 5 mm or greater. Such a
topsheet aperture may have a generally rectangular shape, a
generally circular shape, or any other geometric shape having a
ratio of smallest dimension to greatest dimension of from 1:1 to
approximately 1:100, including all intermediate ratios. In some
exemplary embodiments, such a topsheet aperture may be covered with
a layer of a permanently hydrophilic fibrous material. This
topsheet aperture covering layer 201 may be formed of fibers that
are naturally hydrophilic or of fibers that have been treated to
make them permanently hydrophilic in the sheet structure.
Alternatively, the topsheet aperture may be covered with a mesh
having openings sufficiently large to allow the direct face-to-face
contact of the absorbent layers disposed on either side of the
topsheet. Suitable non-limiting examples of materials that can be
used to cover the topsheet aperture include a permanently
hydrophilic non-woven available from SciMAT Limited of Swindon,
U.K. under product code 900/20, a mesh material such as a 100%
nylon netting available from WYLA, Inc. of New York, N.Y., U.S.A.
under product designation RT80, and a tissue such as a cellulose
tissue available from Georgia-Pacific Corporation of Atlanta, Ga.,
U.S.A. under the designation of 65588. Another suitable material
for use as the topsheet aperture covering layer comprises a bonded
structure of curly cellulosic fibers, which may also include high
surface area fibers as described herein.
[0308] As described in the chassis description, an elastic
waistband 67 may be disposed in the waistband region 63 between the
waist end edge 16 and the adjacent end of the absorbent core, as
shown in FIG. 1 and in FIG. 2. When such an elastic waistband is
disposed adjacent to an opening formed by the separation of the
topsheet and the backsheet along a waist end edge, the waistband
may serve to make the opening elastically openable and
self-closing. For example, such an elastic waistband, formed as
either a separate element affixed to the backsheet or as an
extension of the backsheet in the waistband region, may exert a
contractive force tending to draw the waist end edge of the
backsheet at the periphery toward the topsheet, thus tending to
close the openable end of the openable chassis pocket when it is
released.
[0309] As another example, an elastic waistband, formed as either a
separate element affixed to the topsheet or as an extension of the
topsheet in the waistband region, may exert a contractive force
tending to hold the waist end edge of the topsheet against the body
of the wearer at all times, including when the waist end edge of
the backsheet is pulled away from the topsheet to form the opening
and thereby gain access into the openable chassis pocket. In
addition, as described above in the chassis description, a flexible
substrate forming the chassis, such as the backsheet and the
topsheet, may be elasticized or otherwise extensible. Thus, the
superposed or layered portions of both the topsheet and the
backsheet in the openable area along the waist end edge may be
elastically contractible, either by means of a waistband or
otherwise. In such an embodiment, when the backsheet is pulled away
for access into the openable chassis pocket, the waist end edge of
the topsheet may be held elastically against the body of the
wearer, thereby facilitating the access, and the opening may also
be self-closing by means of the elastic contraction of the waist
end edge of the backsheet when it is released.
[0310] In some exemplary embodiments, two elastically extensible
waistbands may be disposed in a layered configuration in a waist
region of the chassis and may be separable for access into the
openable chassis pocket formed between the topsheet and the
backsheet, as shown in FIG. 19 and in FIG. 20. In such an
embodiment, a first extensible waistband 216 may be disposed on the
wearer-facing surface of, and attached to, the wearer-facing layer
of the chassis formed by, for example, the topsheet 61, the side
panels 210, and/or the barrier leg cuffs 240, when these elements
are present. A second extensible waistband 217 may be attached to
the garment-facing layer of the chassis formed by, for example, the
backsheet 62. The first extensible waistband may have an extensible
portion 218 and a non-extensible portion 219 and may also have a
free portion 220 that is not attached to the wearer-facing layer of
the chassis, i.e., that is free to move independently of the
wearer-facing layer of the chassis. The extensible portion 218 may
be attached to the wearer-facing layer of the chassis by
intermittent bonds 222, such as those described in the Kievit et
al. '595 patent. The first extensible waistband may have two
laterally opposing ends 221 joined to the chassis. For a closed
configuration, such as the pull-on style pant shown in FIG. 18, the
opposing ends 221 are preferably joined to the chassis at or near
the laterally opposed side seams 8. For an open configuration, such
as the taped diaper shown in FIG. 17 or another chassis having
laterally opposed side fasteners, the opposing ends 221 may be
attached to the wearer-facing layer at or near the laterally
opposed side fasteners, such as tape tab fasteners 65.
[0311] In such an embodiment, as can be seen in FIG. 20, this
layered dual extensible waistband structure forms three openings
when the second extensible waistband and the garment-facing layer
of the chassis are separated from the first extensible waistband
and the wearer-facing layer of the chassis for access into the
openable chassis pocket. Each of two laterally opposed
substantially triangular openings 223 is formed by the
non-extensible portion 219 of the first extensible waistband 216,
the adjacent side panel 210, and the adjacent connecting leg of the
triangle formed by the topsheet 61 and/or the barrier leg cuff 240.
Between these triangular openings 223, a quadrangular opening 224
is formed by the topsheet 61, the second extensible waistband 217
and the adjacent portion of the backsheet 62 on which it is
disposed, and the laterally opposed connecting legs of the
trapezoid formed by the topsheet 61 and/or the laterally opposed
barrier leg cuffs 240. The centrally located quadrangular opening
224 forms the openable end 41 of the openable chassis pocket 5,
which is formed and bounded by the same four elements as the
quadrangular opening. In particular embodiments, such as that shown
in FIG. 20, the quadrangular opening may have a trapezoidal shape,
while in other embodiments, it may have a substantially rectangular
shape.
[0312] By forming these three openings when separated, this layered
dual extensible waistband structure provides several advantages.
For example, this waistband structure allows the first extensible
waistband and the wearer-facing layer of the chassis to remain in
contact with the body of the wearer at all times, including when
the second extensible waistband and the garment-facing layer of the
chassis are separated from the first extensible waistband and the
wearer-facing layer of the chassis for access into the openable
chassis pocket. By remaining in contact with the body of the
wearer, the first extensible waistband and the wearer-facing layer
of the chassis can continue to perform their intended function of
helping to support the absorbent article and prevent its slippage
downward on the torso of a standing wearer, even during the removal
and replacement of the replaceable core component. Also, the
centrally located quadrangular opening provides a readily visible
"target" for the insertion of a replacement core component, as well
as a structurally bounded channel allowing the insertion of the
replacement core component only when it is substantially properly
laterally aligned with respect to the chassis.
[0313] In an alternative embodiment, as shown in FIG. 21 and FIG.
22, a first extensible waistband 216 may be sandwiched between and
attached to the wearer-facing layer and the garment-facing layer
and a second extensible waistband 217 attached to or forming an
extension of only the garment-facing layer may be disposed adjacent
to the first extensible waistband in a position farther from the
adjacent waist end edge 16, i.e., toward the crotch region 66,
relative to the first extensible waistband. The garment-facing
layer, e.g., the backsheet 62, in such an embodiment may include an
aperture 44 between the two extensible waistbands providing access
into the openable chassis pocket 5 formed between the wearer-facing
layer and the garment-facing layer when the second extensible
waistband 217 is separated from the first extensible waistband 216
as shown in FIG. 22. Preferably, at least the second extensible
waistband is elastically extensible. In some embodiments, the
portion of the garment-facing layer surrounding the second
extensible waistband may also be extensible.
[0314] In an alternative embodiment shown in FIG. 23 and FIG. 24,
an extensible waistband 215 may include a first portion 215a
sandwiched between and attached to the wearer-facing layer and the
garment-facing layer in a portion of the waistband region adjacent
to the waist end edge 16 and a second portion 215b attached to only
the garment-facing layer and disposed farther from the adjacent
waist end edge, i.e., toward the crotch region 66, relative to the
first portion of the extensible waistband. The extensible waistband
and the garment-facing layer, e.g., the backsheet 62, in such an
embodiment may each include an aperture 44 between the two portions
of the extensible waistband providing access into the openable
chassis pocket 5 formed between the wearer-facing layer and the
garment-facing layer when the second portion 215b is separated from
the first portion 215a as shown in FIG. 24. Preferably, the
extensible waistband is elastically extensible. In some
embodiments, the portion of the garment-facing layer surrounding
the extensible waistband may also be extensible.
[0315] In another alternative embodiment shown in FIG. 25 and FIG.
26, a first extensible waistband 216 may be attached to the
wearer-facing layer and a second extensible waistband 217 attached
to or forming an extension of the garment-facing layer may be
disposed adjacent to the first extensible waistband in a position
closer to the adjacent waist end edge 16, i.e., farther from the
crotch region 66, relative to the first extensible waistband. The
wearer-facing layer and the garment-facing layer may be separable
in the waistband region 63, providing access into the openable
chassis pocket 5 formed between the wearer-facing layer and the
garment-facing layer when the second extensible waistband and the
garment-facing layer of the chassis are separated from the first
extensible waistband and the wearer-facing layer of the chassis.
Preferably, at least the second extensible waistband is elastically
extensible. In some embodiments, the portion of the garment-facing
layer surrounding the second extensible waistband may also be
extensible.
[0316] As shown in FIG. 27, a portion of the non-removable core
component, such as the uppermost absorbent layer 52 of the center
section, may be disposed between a liquid pervious wearer-facing
layer of the chassis, such as the topsheet 61, and another liquid
pervious layer 205 of the chassis. One or both of the liquid
pervious layers may form a portion of the openable chassis pocket 5
adapted to receive the replaceable absorbent core component, e.g.,
back panel 30. Preferably, an acquisition member, a distribution
member, or an acquisition/distribution member of the non-removable
core component is disposed between the liquid pervious layers. In
some embodiments, at least one of the liquid pervious layers may be
disposed between two members of the non-removable core
component.
[0317] Alternatively, a portion of the non-removable core
component, such as the lowermost absorbent layer 51 of the center
section shown in FIG. 27, may be disposed between a liquid pervious
layer 205 of the chassis and a liquid impervious layer of the
chassis, such as the backsheet 62. One or both of the liquid
pervious layer and the liquid impervious layer may form a portion
of the openable chassis pocket 5 adapted to receive the replaceable
absorbent core component, e.g., back panel 30. Preferably, a
distribution or acquisition/distribution member of the
non-removable core component is disposed between the liquid
pervious and the liquid impervious layers. In some embodiments, the
liquid pervious layer may be disposed between two members of the
non-removable core component.
[0318] In order to provide additional space within the openable
chassis pocket, the surfaces forming the openable chassis pocket,
e.g., the topsheet, the backsheet, the barrier leg cuffs, etc., may
be formed from extensible materials, preferably elastically
extensible materials, to permit the expansion of the pocket. These
materials are preferably extensible in at least in the lateral
direction and preferably in both the lateral and longitudinal
directions. This expansibility of the openable chassis pocket may
facilitate the removal and/or the insertion of a replaceable core
component and may also be useful in embodiments in which the
replaceable core component includes an absorbent layer that expands
as it absorbs liquid.
[0319] In some exemplary embodiments, the openable chassis pocket
and the replaceable core component may be "keyed" to each other, so
as to prevent the insertion of the replaceable core component in
any orientation other than a predetermined orientation contemplated
in the design of the replaceable core component. Thus, the openable
chassis pocket may be shaped and the replaceable core component may
be correspondingly shaped to fit within the shaped openable chassis
pocket.
[0320] For example, in some embodiments as shown in FIG. 28, the
openable chassis pocket 5 may include a separator 225 that
bifurcates or partitions the pocket into at least two connected
branches forming the shaped openable chassis pocket. The separator
may be formed by an area of joining of the topsheet and the
backsheet or by an area of joining of the topsheet or the
backsheet, or both, to the non-removable core component, thereby
bifurcating or partitioning the openable chassis pocket. In
embodiments having such a bifurcated openable chassis pocket, the
replaceable core component, e.g., back panel 30, may include a
cooperative structure 226 that permits the insertion of its inner
end 32 beyond the outer end 228 of the separator, i.e., to a point
farther from the waist end edge than the outer end of the
separator. Such a cooperative structure may include a slit, a slot,
or a groove formed in the replaceable core component for receiving
and/or bypassing the separator. The separator in the openable
chassis pocket may be formed along the longitudinal centerline 17
of the chassis and the cooperative structure in the replaceable
core component may be formed along the longitudinal centerline 25
of the replaceable core component or, alternatively, either the
separator or the cooperative structure, or both, may be offset from
the respective longitudinal centerline. Either the symmetric or the
offset configuration may serve to ensure that the replaceable core
component is inserted in the intended end-to-end orientation, i.e.,
with its inner end in the crotch region and its outer end in the
waist region. Either configuration may also serve to ensure that
the replaceable core component is inserted in a predetermined
lateral position, is inserted with its liquid pervious surface
region in a predetermined longitudinal and/or lateral position, and
so on. In addition, an offset configuration may be especially
useful because, in order to fit into the asymmetrically bifurcated
openable chassis pocket, the replaceable core component must be
inserted in both the intended end-to-end orientation and the
intended orientation of its predetermined wearer-facing and
garment-facing surfaces.
[0321] It is noted that more than one shaping element, such as more
than one separator, as well as shaping elements other than a
separator, are envisioned. Exemplary shaping elements may include a
slot into which a corresponding "key" fits in only a predetermined
orientation, one or more holes or depressions into which one or
more corresponding pins, bosses, or protuberances fits in only a
predetermined orientation, a partition within the openable chassis
pocket that requires the replaceable core component to be partially
inserted and then rotated and/or translated in order for the
insertion to be completed, and similar configurations.
[0322] In embodiments in which the openable chassis pocket is
divided into several separate connected branches or into
non-interconnected sections, i.e., divided effectively into
separate openable chassis pockets, a corresponding number of
replaceable core components may be placed into the sections of the
openable chassis pocket in a side-by-side lateral relationship. For
example, in some embodiments as shown in FIG. 28, a pair of front
panels 20 may be inserted into a bifurcated openable chassis
pocket.
[0323] In some embodiments, the openable chassis pocket may extend
from a waist region into the crotch region as far as the crotch
point. In particular, it is preferred that the openable chassis
pocket extend from the respective waist region into the crotch
region no farther than the crotch point of the absorbent article,
so as to thereby limit the depth of insertion of a replaceable core
component to no farther than the crotch point. The "crotch point"
of an absorbent article and of the absorbent article's absorbent
core is determined by placing the article on a wearer of the
physical size for which the absorbent article is designed and who
is in a fully upright standing position with his or her feet a
shoulder width apart and then placing an extensible filament 256
around the legs 255 in a FIG. eight configuration as shown in FIG.
29. The point in the absorbent article and the absorbent core
corresponding to the point of intersection 257 of the filament is
considered to be the crotch point of the absorbent article and of
the absorbent core. It is understood that the crotch point is
determined by placing an absorbent article in the intended manner
on a standing wearer of the correct size for the article and
determining where the crossed filament would contact the absorbent
article and/or the absorbent core.
The Replaceable Absorbent Core Component
[0324] In order for the absorbent layer of the replaceable core
component to be in capillary liquid communication with the
non-removable core component, at least a portion of one major
surface of the replaceable core component must be pervious to
liquid. This pervious portion of the major surface may be described
as forming a permeable liquid transfer region 246. In exemplary
embodiments, at least about 20% of the area of this major surface
is liquid pervious. Preferably, at least about 50%, and more
preferably, at least about 80%, of this major surface may be liquid
pervious. The permeable liquid transfer region may be covered by a
liquid pervious sheet 247. Also, the replaceable core component may
have permeable liquid transfer regions in both of its major
surfaces. For example, in the exemplary embodiment shown in FIG. 30
and FIG. 31, the back panel 30 has the permeable liquid transfer
region 246a in its upper major surface formed by the upper packet
layer 250a and the permeable liquid transfer region 246b in its
lower major surface formed by the lower packet layer 250b.
[0325] Except for the permeable liquid transfer region or regions,
the major surfaces of the replaceable core component may be liquid
impervious. In particular, it may be desirable for the outer end
segment or at least the area of the pull tab at the outer end to be
liquid impervious in order to prevent the escape or the leakage of
liquid from this portion of the replaceable core component. The
prevention of leakage from this area may enable a caregiver to
avoid contact during the removal of a used replaceable core
component with the liquid contained in it. A liquid impervious
region may be formed by a liquid impervious layer disposed between
the absorbent layer of the replaceable core component and the layer
forming the surface, such as by the liquid impervious layer 253
disposed between the absorbent layer 34 of the back panel 30 and
the packet layer 250 shown in FIG. 27. Alternatively, the liquid
impervious region may be formed by a liquid impervious layer
forming the major surface or by the treatment of an otherwise
liquid pervious layer to render it liquid impervious in the desired
region. For example, in the embodiment shown in FIG. 31, the
portions of the packet layers 250 between the permeable liquid
transfer regions 246 and the outer end 31 of the back panel 30 may
either include a liquid impervious sheet material or be treated to
become liquid impervious.
[0326] The replaceable core component, e.g., the back panel 30
shown in FIG. 32, has an inner end 32 and an outer end 31 and may
be divided longitudinally for descriptive purposes into successive
first, second, third, and fourth segments defined by respective
quarters of its length. The replaceable core component may have two
major surfaces having substantially equal areas and, for
descriptive purposes, the area of each of the four longitudinal
segments may be expressed as the area of the portion of one of the
major surfaces falling within the segment. When so divided, the
first segment 111, which is also referred to herein as the inner
end segment, includes the inner end and may have an area less than
an area of any one of the second, third, and fourth segments. For
example, the inner end of the replaceable core component may have a
smaller width 115 than the width 116 of the second segment 112 and
may have converging sides 117, i.e., the inner end segment may
convergingly taper toward the inner end. The fourth segment 114,
which is also referred to herein as the outer end segment, includes
the outer end and may have an area less than the area of at least
one of the second segment or the third segment 113. The areas of
the second and third segments may be substantially equal or the
second segment may have an area less than that of the third
segment. In some embodiments, the four segments may have the
following areas. The first segment may have an area of between 10
cm.sup.2 and 110 cm.sup.2 or, preferably, between 30 cm.sup.2 and
70 cm.sup.2. The second segment may have an area of between 10
cm.sup.2 and 110 cm.sup.2 or, preferably, between 30 cm.sup.2 and
100 cm.sup.2. The fourth segment may have an area of between 10
cm.sup.2 and 110 cm.sup.2 or, preferably, between 30 cm.sup.2 and
100 cm.sup.2. The third segment may have an area of between 10
cm.sup.2 and 110 cm.sup.2 or, preferably, between 30 cm.sup.2 and
100 cm.sup.2. Based on these areas, the overall surface area of the
replaceable core component may be between 40 cm.sup.2 and 440
cm.sup.2 or, preferably, between 120 cm.sup.2 and 370 cm.sup.2.
[0327] Similarly, the absorbent structure of the replaceable core
component, e.g., an absorbent layer 34 of back panel 30, has an
inner end 238 and an outer end 239 and may be divided
longitudinally for descriptive purposes into four successive
segments 231, 232, 233, and 234 from its inner end to its outer
end, corresponding to the four segments of the replaceable core
component as a whole. Like the replaceable core component, the
absorbent structure may have two major surfaces having
substantially equal areas and, for descriptive purposes, the area
of each of the four longitudinal segments of the absorbent
structure may be expressed as the area of the portion of one of the
major surfaces falling within the segment. In some embodiments, an
absorbent layer may extend from the first segment 111 of the
replaceable core component to the fourth segment 114 of the
replaceable core component, as shown in FIG. 33. In other
embodiments, the absorbent layer may extend only from the first
segment 111 to the second segment 112 or to the third segment 113
of the replaceable core component, as shown in FIG. 34. The first
absorbent layer segment 231, or inner end segment of the absorbent
layer, includes the inner end of the absorbent layer and may have
an area less than an area of any one of the other segments of the
absorbent layer. For example, the inner end of the absorbent layer
may have a width smaller than a maximum width of the second segment
of the absorbent layer and may have converging sides, i.e., the
inner end segment may convergingly taper toward the inner end. The
absorbent layer may have an overall shape similar to the shape of
the replaceable core component, as a whole. For example, the
absorbent layer may have a shape identical to that of the
replaceable core component, but reduced in scale, so as to fit at
some distance inside the perimeter of the replaceable core
component. Alternatively, the absorbent layer and overall
replaceable core component may have different shapes. For example,
the overall replaceable core component may have a substantially
rectangular shape, while the absorbent layer inside it may have a
tapered shape.
[0328] As shown in FIG. 35 and FIG. 36, the replaceable core
component may include an extensible covering layer 300 attached to
one end segment of the replaceable core component. The extensible
covering layer is preferably permanently attached to the
replaceable core component in the outer end segment of the
replaceable core component, such as by permanent attachment means
301, and is preferably sufficiently extensible to cover the used
replaceable core component for disposal. Such an extensible
covering layer may be releasably attached to the chassis when the
replaceable core component is in the absorbent article, as shown in
FIG. 35. During the removal of the replaceable core component from
the absorbent article in the direction indicated by the arrow 321,
a portion of the extensible covering layer is temporarily held by
the releasable attachment means 302 and the extensible covering
layer is thereby extended to cover the replaceable core component
as it is withdrawn, as shown in FIG. 36. Once the replaceable core
component is fully withdrawn from the chassis, the releasable
attachment means may release the extensible covering layer from the
chassis and the extensible covering layer may then continue to
cover the replaceable core component. In some embodiments, the
extensible covering layer may be joined to an insertion tool in a
first area of joining so as to be peelably releasable and may be
non-releasably joined to the replaceable core component in a second
area of joining. In such an embodiment, the extensible covering
layer may be released from the insertion tool and releasably
attached to the chassis adjacent to the outer end of the
replaceable core component as the insertion tool is withdrawn from
the chassis. When the replaceable core component is subsequently
removed from the chassis, the extensible covering layer may remain
attached to the chassis, so as to extend to cover the outer surface
of the replaceable core component, and then may be released from
the chassis.
[0329] The extensible covering layer 300 may be constructed in a
number of ways. For example, the extensibility may be provided by
the use of an extensible, preferably low modulus material, or
alternatively by folding or pleating the extensible covering layer
so that removal of the replaceable component extends or unfolds the
extensible covering layer to cover the replaceable component, as
shown in FIG. 37 and FIG. 38. In some embodiments, the extensible
covering layer may be plastically extensible or deformable. In
exemplary embodiments including an extensible covering layer, the
extensible covering layer preferably covers less than 75% of the
area of the replaceable core component prior to extension of the
extensible covering layer and, more preferably, covers less than
50% of the area. In the embodiments in which the extensible
covering layer is unfolded to provide the extension of the
extensible covering layer, the extensible covering layer has at
least one fold, preferably at least two folds, and more preferably
at least three folds. For embodiments comprising a folded
extensible covering layer, the extensible covering layer preferably
covers less than 75% of the area of the replaceable core component
prior to extension of the extensible covering layer, more
preferably less than 50% of the area, and most preferably less than
25% of the area. A combination of folding and extensibility can
also be used to form the extensible covering layer. In such an
embodiment, the extensible covering layer may first unfold and then
extend, preferably through plastic deformation, to cover the
remainder of the replaceable core component. The extensible
covering layer should extend to cover at least the permeable liquid
transfer region of the replaceable core component and, preferably,
the extensible covering layer extends beyond the inner end of the
replaceable core component as it is withdrawn. In some embodiments,
the extensible covering layer may extend beyond the innermost end
edge of the replaceable core component and the releasable
attachment means may meet to form a partial closure of the openable
pocket formed by the extensible covering layer.
[0330] The replaceable core component may include a location
stabilizer 310, as shown in FIG. 39 and FIG. 40, adapted to
releasably retain the replaceable core component in its fully
inserted position, such as by releasably attaching the replaceable
core component to the chassis in the waist region, in the crotch
region, or in both regions. The location stabilizer may include a
mechanical surface fastener such as either a hook or a loop member
disposed on the replaceable core component and adapted to engage a
complementary member disposed on the chassis, or to engage a
non-woven surface of the chassis. In some embodiments, the location
stabilizer may include an adhesive disposed on the surface of the
replaceable core component and adapted to releasably engage a
surface of the chassis. Alternatively, the chassis may include a
location stabilizer adapted to releasably engage a surface of the
replaceable core component. In some embodiments, the location
stabilizer may include a tab adapted to be inserted into a slot and
thereby releasably retain the replaceable core component in its
fully inserted position. For example, a tab on the replaceable core
component may be insertable into a slot in the chassis or vice
versa. Such a tab disposed at the outer end segment of the
replaceable core component may be inserted into a corresponding
slot to serve as the location stabilizer 310 while the replaceable
core component is fully inserted and then may be removed from the
slot and used as the removal pull tab 46 when the replaceable core
component is removed from the chassis.
[0331] As is also shown in FIG. 39 and FIG. 40, the replaceable
core component may include a pull tab 46 that can be used to remove
the core component from the chassis.
[0332] Such a pull tab may include a gripping portion 237 to
facilitate control of the replaceable core component during its
removal. The gripping portion may include a material with a higher
coefficient of friction than the remainder of the surface of the
replaceable core component, or may have a textured surface, to
facilitate grasping the pull tab for removal. In some embodiments,
the pull tab may have various configurations, such as a
configuration including a pull ring 236 into which a finger may be
inserted to facilitate removal.
[0333] The replaceable core component may include an insertion
depth indicator 280 to provide an indication when a predetermined
position of the replaceable core component relative to the chassis
is reached. The insertion depth indicator may include a visible
indicator such as a line 281 positioned in the outer end segment of
the replaceable core component, as shown in FIG. 41, such that the
line is aligned with the waist end edge 16 of the chassis when the
predetermined position of the replaceable core component is
reached. In another example of a visible insertion depth indicator,
as shown in FIG. 42 and FIG. 43, a graphical object 282 on the
replaceable core component may align with an adjacent graphical
object 283 on the chassis to form a side-by-side composite
graphical object when the predetermined position of the replaceable
core component is reached. In yet another example of a visible
insertion depth indicator, as shown in FIG. 44 and FIG. 45, a
graphical object 282 on the replaceable core component may align
with an adjacent graphical object 283 on the chassis to form an
overlaid composite graphical object when the predetermined position
of the replaceable core component is reached. In the latter
example, the graphical object 282 on the replaceable core component
may be visible through a translucent or transparent portion of the
chassis layer coinciding with the graphical object 283 on the
chassis.
[0334] The insertion depth indicator may include a mechanical
insertion depth indicator providing tactile feedback in some
exemplary embodiments. For example, the insertion depth indicator
may include a member disposed on the replaceable core component,
for example, a mechanical surface fastener, such as either a hook
member or a loop member, adapted to engage a complementary member
disposed on the chassis or to engage a non-woven surface of the
chassis when the predetermined position of the replaceable core
component is reached. In another example of a mechanical insertion
depth indicator, an outer surface of the replaceable core component
may have a relatively higher coefficient of friction to a portion
of an adjacent surface of the chassis, such that when the
predetermined position of the replaceable core component is
reached, an increase in the coefficient of friction markedly
increases the force required to slide the replacement core
component beyond the predetermined position. Such a mechanical
insertion depth indicator may be disposed in the waist region, in
the crotch region, or in both regions. In addition, such a
mechanical insertion depth indicator may simultaneously serve as
both an insertion depth indicator and a location stabilizer. For
example, each of the location stabilizers 310 shown in FIG. 39 and
FIG. 40 may also serve as a mechanical insertion depth indicator.
Alternative forms of a mechanical insertion depth indicator are
shown in FIG. 46 and FIG. 47, in which a mechanical insertion depth
indicator 284 in the form of a protruding element prevents the
insertion of the back panel 30 beyond a predetermined depth. As can
be seen in these figures, a mechanical insertion depth indicator
can be located anywhere between the ends of a replaceable core
component. The mechanical insertion depth indicator may include a
laterally extending or protruding element, in addition to or as an
alternative to an element generally oriented in the thickness
dimension of the replaceable core component such as described
above. For example, the outer end segment of a replaceable core
component may include a laterally extending portion that prevents
the insertion of the back panel 30 beyond a predetermined depth,
thus functioning similarly to the mechanical insertion depth
indicator 284 in the form of a protruding element depicted in FIG.
46 and FIG. 47.
[0335] In some exemplary embodiments, an outer surface of the
replaceable core component or an element disposed on the outer
surface may have a directional coefficient of friction relative to
the adjacent surfaces of the chassis and thereby provide tactile
feedback related to whether or not the replaceable core component
is being inserted in the intended end-to-end orientation. In such
embodiments, a material forming the surface of the replaceable core
component and having directional frictional characteristics may be
oriented such that when the inner end of the replaceable core
component is inserted first, the coefficient of sliding friction is
relatively low, thus making the insertion of the replaceable core
component into the chassis relatively easy. On the other hand, if
the insertion of an inverted replaceable core component, i.e., a
replaceable core component oriented such that its outer end is
being inserted first, is attempted, a relatively higher coefficient
of sliding friction of the directional material may provide a
higher resistive force and, thus, make the insertion of the
inverted replaceable core component into the chassis relatively
more difficult. Such a directional frictional surface material may
include, for example, a fabric having a directional nap or grain, a
sheet having oriented protrusions or protuberances, a sheet having
oriented teeth or hooks, or any other known structure having
suitable directional frictional characteristics.
[0336] For example, in FIG. 48 and FIG. 49, the directional
coefficient of friction is illustratively represented by the angled
teeth 287 pointing toward the outer end 31 of the back panel 30 and
the perpendicular teeth 286, such that movement of the back panel
30 in one direction can be visualized as causing the angled teeth
to flex against the perpendicular teeth 286 and thereby present
relatively little resistance to the movement, while movement of the
back panel in an opposing direction can be visualized as causing
the angled teeth to jam against the perpendicular teeth and thereby
present relatively greater resistance to movement in this opposing
direction. In FIG. 48, the back panel 30 is shown as oriented in
the intended end-to-end orientation such that its inner end 32 is
being inserted first. In this figure, movement of the back panel 30
in an inward direction, i.e., in a direction from its outer end 31
toward its inner end 32, can be visualized as causing the angled
teeth 287 to flex against the perpendicular teeth 286 and thereby
present relatively little resistance to the inward movement. On the
other hand, in FIG. 49, the back panel 30 is shown as oriented
oppositely to the intended end-to-end orientation such that its
outer end 31 is being inserted first. In this figure, movement of
the back panel 30 in an inward direction, i.e., in a direction from
its inner end 32 toward its outer end 31, can be visualized as
causing the angled teeth 287 to jam against the perpendicular teeth
286 and thereby present relatively greater resistance to the inward
movement.
[0337] The directional frictional characteristics may tend to
resist the outward movement of a replaceable core component that
has been inserted in the intended end-to-end orientation in the
chassis. For example, movement of the back panel 30 in FIG. 48 in
an outward direction can be visualized as causing the angled teeth
287 to jam against the perpendicular teeth 286 and thereby present
relatively greater resistance to the outward movement. Thus, an
additional benefit of the use of such a directionally frictional
surface material is that the relatively high frictional force
resisting the outward movement of a replaceable core component
inserted in the intended predetermined orientation may tend to
assist in retaining the replaceable core component in the intended
predetermined position after its insertion and this material may
thereby serve as a location stabilizer.
[0338] In some exemplary embodiments, opposing outer surfaces of
the replaceable core component may have different coefficients of
friction relative to the adjacent surfaces of the chassis and
thereby provide tactile feedback related to whether or not the
replaceable core component is being inserted in the intended
orientation of its predetermined wearer-facing and garment-facing
surfaces. For example, in such embodiments, a material forming the
wearer-facing surface of the replaceable core component and having
directional frictional characteristics may be oriented such that
when the replaceable core component is inserted with its
predetermined wearer-facing surface oriented toward the
wearer-facing layer of the chassis and with its predetermined
garment-facing surface oriented toward the garment-facing layer of
the chassis, the coefficient of sliding friction is relatively low,
thus making the insertion of the replaceable core component into
the chassis relatively easy. On the other hand, if the insertion of
a reversed replaceable core component, i.e., a replaceable core
component oriented such that its wearer-facing and garment-facing
surfaces are reversed from its intended orientation, is attempted,
a relatively higher coefficient of sliding friction of the
directional material may provide a higher resistive force and,
thus, make the insertion of the reversed replaceable core component
into the chassis relatively more difficult. Such a directional
frictional surface material may include, for example, a fabric
having a directional nap or grain, a sheet having oriented
protrusions or protuberances, a sheet having oriented teeth or
hooks, or any other known structure having suitable directional
frictional characteristics. This directional frictional surface
material may be disposed on one or more of the major surfaces of
the replaceable core component or may be disposed on laterally
opposing edge surfaces.
[0339] For example, in FIG. 50 and FIG. 51, the directional
coefficient of friction is represented by the first angled teeth
285, pointing toward the inner end 32 of the back panel 30, the
second angled teeth 287, pointing toward the outer end 31 of the
back panel 30, and the perpendicular teeth 286, such that movement
of the back panel 30 in one direction can be visualized as causing
the angled teeth to flex against the perpendicular teeth 286 and
thereby present relatively little resistance to the movement, while
movement of the back panel in an opposing direction can be
visualized as causing the angled teeth to jam against the
perpendicular teeth and thereby present relatively greater
resistance to movement in this opposing direction. In FIG. 50, the
back panel 30 is shown as oriented in the intended orientation of
its predetermined wearer-facing and garment-facing surfaces such
that the second angled teeth 287 are oriented toward the
perpendicular teeth 286 and the first angled teeth 285 are oriented
away from the perpendicular teeth 286. In this figure, movement of
the back panel 30 in an inward direction, i.e., in a direction from
its outer end 31 toward its inner end 32, can be visualized as
causing the second angled teeth 287 to flex against the
perpendicular teeth 286 and thereby present relatively little
resistance to the inward movement. On the other hand, in FIG. 51,
the back panel 30 is shown as oriented oppositely to the intended
orientation of its predetermined wearer-facing and garment-facing
surfaces such that the first angled teeth 285 are oriented toward
the perpendicular teeth 286 and the second angled teeth 287 are
oriented away from the perpendicular teeth 286. In this figure,
movement of the back panel 30 in an inward direction, i.e., in a
direction from its outer end 31 toward its inner end 32, can be
visualized as causing the first angled teeth 285 to jam against the
perpendicular teeth 286 and thereby present relatively greater
resistance to the inward movement.
[0340] The directional frictional characteristics may tend to
resist the outward movement of a replaceable core component that
has been inserted in the intended orientation of its predetermined
wearer-facing and garment-facing surfaces. For example, movement of
the back panel 30 in FIG. 50 in an outward direction can be
visualized as causing the second angled teeth 287 to jam against
the perpendicular teeth 286 and thereby present relatively greater
resistance to the outward movement. Thus, an additional benefit of
the use of such a directionally frictional surface material is that
the relatively high frictional force resisting the outward movement
of a replaceable core component inserted in the intended
predetermined orientation may tend to assist in retaining the
replaceable core component in the intended predetermined position
after its insertion and this material may thereby serve as a
location stabilizer.
[0341] The elements having the directional frictional
characteristics described above may be combined in various ways to
provide tactile feedback related to both related to whether or not
the replaceable core component is being inserted in the intended
end-to-end orientation and whether or not the replaceable core
component is being inserted in the intended orientation of its
predetermined wearer-facing and garment-facing surfaces. For
example, as shown in FIG. 52, FIG. 53, FIG. 54, and FIG. 55, each
of the first angled teeth 285, pointing toward the inner end 32 of
the back panel 30, the second angled teeth 287, pointing toward the
outer end 31 of the back panel 30, and the perpendicular teeth 286,
again represent the directional coefficient of friction. In FIG.
52, the back panel 30 is oriented in the intended end-to-end
orientation and in the intended orientation of its predetermined
wearer-facing and garment-facing surfaces, such that movement of
the back panel 30 in the insertion direction 320 can be visualized
as causing the second angled teeth 287a to flex against the
perpendicular teeth 286 and thereby present relatively little
resistance to the movement. However, in FIG. 53, the back panel 30
is shown as oriented oppositely to the intended orientation of its
predetermined wearer-facing and garment-facing surfaces, such that
movement of the back panel 30 in the insertion direction 320 can be
visualized as causing the first angled teeth 285 to jam against the
perpendicular teeth 286 and thereby present relatively greater
resistance to the inward movement. Then, in FIG. 54, the back panel
30 is shown as oriented oppositely to the intended end-to-end
orientation such that its outer end 31 is being inserted first. In
this figure, movement of the back panel 30 in an inward direction,
i.e., in a direction from its inner end 32 toward its outer end 31,
can be visualized as causing the angled teeth 287a to jam against
the perpendicular teeth 286 and thereby present relatively greater
resistance to the inward movement. Finally, in FIG. 55, the back
panel 30 is shown as oriented oppositely to the intended end-to-end
orientation and oppositely to the intended orientation of its
predetermined wearer-facing and garment-facing surfaces. In this
figure, movement of the back panel 30 in an inward direction, i.e.,
in a direction from its inner end 32 toward its outer end 31, can
be visualized as causing the angled teeth 287b to jam against the
perpendicular teeth 286 and thereby present relatively greater
resistance to the inward movement.
[0342] As shown in FIG. 56, FIG. 57, FIG. 58, FIG. 59, FIG. 60,
FIG. 61, FIG. 62, FIG. 63, FIG. 64, and FIG. 65, the replaceable
core component may include an openable insertion pocket 260 into
which a finger or fingers or an insertion tool 270 may be inserted
for the application of a force to insert the replaceable core
component into the chassis in the intended predetermined
orientation. Such an insertion force is applied in a direction
indicated by the arrow 320 from the outer end toward the inner end
of the replaceable core component, e.g., in a direction from the
outer end 31 toward the inner end 32 of the back panel 30. For
example, the back panel 30 may have a piece of sheet material 261
joined to its outer surface by continuous linear bonds or by an
array of spot bonds, or any combination thereof, to form the
openable insertion pocket having an outer end edge 265, an inner
end 264, and an openable end 263 located at its outer end edge and
facing toward the outer end 31 of the back panel 30. The bonds 262
may be formed by any means known in the art, including ultrasonic
bonding, heat bonding, pressure bonding, or adhesive bonding. In
general, any piece of sheet material joined along at least two of
its edges to an outer surface of the replaceable core component may
form the openable insertion pocket. However, such a sheet may
alternatively be bonded elsewhere, e.g., inboard of its edges, in
any pattern that forms an openable pocket-like space that can
similarly serve as an openable insertion pocket, i.e., that can be
used in functional cooperation with the fingers or the insertion
tool inserted into this pocket-like space to exert an insertion
force in the direction 320 to insert the replaceable core component
into the chassis in the intended predetermined orientation. For
example, the bonds may have the form of the intermittent linear
bonds 262 shown in FIG. 60 or the form of the spot bonds 262 shown
in FIG. 61 and in FIG. 63. Such an openable insertion pocket may be
disposed on one major surface of the replaceable core component or
two openable insertion pockets may be disposed on the opposing
major surfaces of the replaceable core component, as shown in FIG.
64 and FIG. 65. The openable insertion pocket is preferably
disposed in the inner end segment of the replaceable core
component. In some embodiments, an insertion tool may be
predisposed inside the openable insertion pocket of the replaceable
core component.
[0343] The openable insertion pocket may be of sufficient size to
accept only a finger or fingers, of sufficient size to accept an
entire hand of a caregiver, or of sufficient size to accept an
insertion tool. A length of the insert pocket may be measured along
the longitudinal centerline of the replaceable core component from
the innermost end of the openable insertion pocket adjacent to the
inner end of the replaceable core component to the outermost end of
the openable insertion pocket. The length of the openable insertion
pocket may be at least about 10% of the length of the replaceable
core component, as shown in FIG. 56, and preferably is at least
about 20%, as shown in FIG. 62, more preferably is at least about
40%, as shown in FIG. 63, and most preferably is at least about
60%, as shown in FIG. 58, of the length of the replaceable core
component. The insertion pocket sheet material may be liquid
impervious, but preferably is liquid pervious. The insertion pocket
sheet material may be extensible to enable the openable insertion
pocket to expand to accommodate the hand of the caregiver or to be
wrapped around a folded replaceable core component for disposal, as
shown in FIG. 66, or around an end of an unfolded replaceable core
component to cover a portion of the opposing surface for disposal.
For example, the insertion pocket sheet 261 shown in FIG. 67 may be
folded around the inner end 32 of the back panel 30 to cover the
permeable liquid transfer region 246 for disposal, as shown in FIG.
68. Preferably, the insertion pocket sheet material is elastically
extensible. In some embodiments, the insertion pocket sheet 261 may
be partially detachable, such as by means of perforations or a
releasable adhesive attachment, from the surface of the replaceable
core component to allow the insertion pocket sheet to be folded
over a portion of the replaceable core component and thereby cover
the permeable liquid transfer region 246 of the replaceable core
component for disposal.
[0344] The replaceable core component may include a covering sheet
249, which may be liquid pervious or liquid impervious, covering a
portion of a first major surface 251 of the replaceable core
component and wrapping over an edge of the replaceable core
component, such as the inner end 32 of the back panel 30, to cover
at least a portion of the opposing second major surface 252 of the
replaceable core component, as shown in FIG. 69. In such an
embodiment, the wrapped over covering sheet 249 may form an
openable insertion pocket 260 and thereby serve as an insertion
pocket sheet 261 on one side of the replaceable core component, as
shown in FIG. 70, or may form openable insertion pockets on both
sides of the replaceable core component. The covering sheet 249 can
also be wrapped completely around the replaceable core component
and joined where its opposing edge margins overlap to form a
tube-like structure enveloping the replaceable core component. In
some embodiments, such a covering sheet that is liquid impervious
may form a portion of the outer end segment and/or a portion of the
pull tab, thereby preventing liquid in the absorbent layer from
wetting the outer surface of this portion of the replaceable core
component.
[0345] The openable insertion pocket 260 may also be formed
internally to the replaceable core component. For example, an
internal insertion pocket 260 may be formed in the back panel 30
between an absorbent layer 34 and a superposed absorbent layer 36,
as shown in FIG. 71, between an absorbent layer 34 and an inner
layer 266, as shown in FIG. 72, or between two inner layers 266a
and 266b, as shown in FIG. 73. In such an embodiment, a finger or
fingers or an insertion tool may be inserted into the internal
insertion pocket for the application of a force to insert the
replaceable core component into the chassis in the intended
predetermined orientation. The layers forming the internal
insertion pocket may be liquid pervious, thereby permitting the
passage of liquid from one absorbent layer of the replaceable core
component to another absorbent layer disposed on the opposing side
of the internal insertion pocket. Alternatively, one or more of the
layers forming the internal insertion pocket may be liquid
impervious and thereby act as a barrier to liquid flow between the
absorbent layer or layers and the internal insertion pocket. For
example, the inner layer 266 may be liquid pervious or liquid
impervious.
[0346] A replaceable core component having an internal insertion
pocket may include an inverting pull tab 268 disposed inside the
internal insertion pocket and extending from the inner end 264 of
the internal insertion pocket adjacent to the inner end segment of
the replaceable core component toward the outer end segment of the
replaceable core component, as shown in FIG. 74. When the inverting
pull tab is pulled toward the outer end of the replaceable core
component, the replaceable core component is inverted, i.e., turned
inside out, by drawing the inner end of the replaceable core
component into and through the internal insertion pocket, such that
the original outer layers of the replaceable core component are
drawn inside and the original inner layers of the internal
insertion pocket are drawn to the outside of the inverted
replaceable core component. In other words, when inverted, the
replaceable core component is turned inside out and wrapped within
the original inner layers 266, as shown in FIG. 75. In this
invertable embodiment, it is preferred that the inner layers be
liquid impervious, so that the inverted replaceable core component
is wrapped within these liquid impermeable layers for disposal.
Also, the outer end segment of the replaceable core component may
be releasably attached to the chassis when the replaceable core
component is in the absorbent article, such that during removal of
the replaceable core component from the absorbent article, the
outer end segment is temporarily held by the releasable attachment
means 305, thereby causing the replaceable core component to
invert, i.e., turn inside out, as it is withdrawn. Once the
replaceable core component is fully withdrawn from the chassis, the
releasable attachment means may release the outer end segment and
the original inner layers may then continue to cover the
replaceable core component. In some embodiments, the releasable
attachment means may be fastened together to secure the replaceable
core component in the inverted configuration.
[0347] The replaceable core component needs to extend only from the
crotch region to one of the waist regions of the article. However,
the replaceable core component preferably extends from the crotch
region beyond a waist end edge of one of the waist regions, so that
the outer end of the replaceable core component is exposed and
thereby visible when the absorbent article is worn. To this point
in this disclosure, the outer end 31 of the back panel 30 has been
shown extending beyond the adjacent waist end edge 16 in this
manner in FIG. 17, FIG. 18, FIG. 28, FIG. 41, FIG. 43, and FIG.
45.
[0348] A portion of the replaceable core component extending beyond
the waist end edge may include a liquid presence indicator 290
adapted to provide an indication of a wetted condition of the
replaceable core component. The liquid presence indicator may
include multiple strips 291 of wicking material, as shown in FIG.
76, which may have differing characteristics such as the lengths of
the strips, the thicknesses of the strips, the shapes and areas of
the strips, the pore sizes of the wicking materials used in the
various strips, the absorbent capacities of the strips, the degrees
of hydrophilicity of the strips, and etc. A single wicking strip
291 may also be used, as shown in FIG. 77. A suitable wicking strip
291 may have a 30 minute vertical wicking height of at least 10 cm
and, preferably, may have a 30 minute vertical wicking height of at
least 20 cm or, more preferably, of at least 30 cm. The wicking
strips may include such materials as high surface area fibers,
capillary channel filaments, open celled polymeric foams, and/or
densified cellulose substrates. The wicking strips may be disposed
within the replaceable core component, e.g., the back panel 30,
such that at least one of the wicking strips extends from the
permeable liquid transfer region of the replaceable core component
to the outer end segment. Each of the wicking strips is preferably
in capillary liquid communication with at least a portion of the
storage/redistribution member of the replaceable core component. A
portion of the wicking strip may also be isolated from the
storage/redistribution member by a liquid impermeable layer 293
disposed between the wicking strip and the absorbent layer of the
replaceable core component. The wicking strip may have a visible
liquid presence indication means 292 disposed on or adjacent to its
outer end. The visible indication means may include a pH-activated
or moisture-activated material, which may be applied to the wicking
strip in the form of a hotmelt adhesive in some exemplary
embodiments. Preferably, the visible indication means is visible
through the material forming the outer surface of the replaceable
core component, making it unnecessary for the wicking strip or
strips to extend beyond the outer end of the replaceable core
component in order to be visible.
[0349] In some exemplary embodiments, the liquid presence indicator
290 may include an indicating composition disposed on an absorbent
layer of the replaceable core component, such as a storage member
or a storage/redistribution member, as shown in FIG. 77. Such an
indicating composition may preferably be disposed on the absorbent
layer in the outer end segment of the replaceable core component.
The indicating composition may provide a visible indication and may
include a pH-activated or moisture-activated material, which may be
applied to the absorbent layer in the form of a hotmelt adhesive or
a water-soluble dye in some exemplary embodiments. The visible
liquid presence indication means 292 is preferably disposed above
the waist end edge of the chassis when the replaceable core
component is inserted to the intended predetermined depth in the
chassis.
[0350] However, in some embodiments, the visible indication means
may be disposed below the waist end edge, i.e., between the
backsheet and the wearer in the waist region of the article, when
the replaceable core component is inserted to the intended
predetermined depth. For example, a stationary absorbent strip 294
including a litmus paper-like substrate that changes color in a
wetted area 296, as shown in FIG. 78, or a series of visible liquid
presence indication means 292, as shown in FIG. 79, may undergo a
visible change in response to a liquid presence or to the pH of a
liquid contacting the indication means. As another example, a
pH-activated or moisture-activated material may be applied in a
stripe on the outer surface of the replaceable core component.
These approaches of providing a "liquid level" indication enable
the user to assess the actual level of liquid loading in the
replaceable core component, in addition to determining the presence
of liquid. In some embodiments, the visible indication means may be
visible through the backsheet when the replaceable core component
is inserted to the intended predetermined depth. The replaceable
core component may have a translucent or transparent region through
which the liquid presence indication means is visible and, in some
embodiments, a replaceable core component having a visible liquid
presence indication means may be used in a chassis having a
transparent or translucent region in the backsheet that aligns with
the visible indication means when the replaceable core component is
inserted into the article to the intended predetermined depth and
in the intended predetermined position and orientation.
[0351] Some exemplary embodiments may have a "dipstick" type
visible liquid presence indicator, as shown in FIG. 80, in which an
absorbent strip 294 can be moved through a slit 295 in an outer
layer of the replaceable core component between a fully inserted
position within the replaceable core component and a partially
inserted position, thereby exposing an inner portion of the visible
liquid presence indication absorbent strip and facilitating a
determination of the level to which the replaceable core component
has been wetted. The usage of such a "dipstick" type visible liquid
presence indication absorbent strip is similar to that of using a
dipstick to check the fluid levels in an automobile engine, the
fuel level in an aircraft fuel tank, or the level in an in-ground
storage tank. The "dipstick" type visible liquid presence
indication absorbent strip can include a litmus paper-like
substrate that changes color in a wetted area 296, as shown in FIG.
81, or can include a series of visible liquid presence indication
means 292, as shown in FIG. 82, each of which undergoes a visible
change in response to a liquid presence or to the pH of a liquid
contacting the indication means. The dipstick approach enables the
user to assess the actual level of liquid loading in the
replaceable core component, in addition to determining the presence
of liquid.
[0352] In some embodiments, the liquid presence indicator may
include a water-sensitive restraining element whose dimension,
tensile strength, resistance to compression, resistance to bending,
or resistance to buckling is altered when it is contacted by water.
The water-sensitive restraining element may include a water soluble
material or a material that weakens, but does not dissolve, when
wetted, such as cellulosic material. For example, as shown in FIG.
83 and FIG. 84, the liquid presence indicator may include a
water-sensitive restraining element 297 joined to an elongated
elastic force-generating element 298, either by joining the elastic
element directly to the water-sensitive element or by attaching the
water-sensitive element to an intermediate element that is attached
to the elastic element. In its initial dry state, the
water-sensitive element restrains the elastic element in its
elongated state. When the water-sensitive element comes into
contact with liquid as the product is loaded with bodily exudates,
the water-sensitive element dissolves and releases the elastic
element, thereby allowing the elastic element to relax by
contracting. The resultant contraction of the elastic element moves
a movable indicator strip 299 toward the inner end 32 of the back
panel 30 to expose a visible liquid presence indication means 292
and thereby indicate the presence of liquid in the replaceable core
component.
[0353] In other embodiments, the elastic force-generating element
may initially be compressed, rather than elongated, and may relax
by expanding, rather than contracting, when it is released. For
example, as shown in FIG. 85 and FIG. 86, the visible liquid
presence indication means 292 is disposed on the movable indicator
strip 299 and is initially hidden below the waist end edge 16 of
the chassis. The elastic element 298 is restrained in its initial
compressed state by the water-sensitive restraining element 297.
When the water-sensitive element comes into contact with liquid as
the product is loaded with bodily exudates, the water-sensitive
element dissolves and releases the elastic element, thereby
allowing the elastic element to relax by expanding. The resultant
expansion of the elastic element moves the movable indicator strip
299 toward the outer end 31 of the back panel 30, which outer end
extends beyond the waist end edge of the chassis, to expose the
visible liquid presence indication means 292 and thereby indicate
the presence of liquid in the replaceable core component.
[0354] In some embodiments, a liquid presence indicator having a
similar structure may provide a tactile indication of the presence
of liquid in the replaceable core component. For example, when
released, the elastic element may move a movable tactile indicator
strip to a predetermined position in which the thickness of the
strip provides the tactile impression of a raised area or a
protuberance. As another example, when released, the elastic
element may move a movable tactile indicator strip away from its
initial position in which the thickness of the strip provided the
tactile impression of a raised area or a protuberance and thereby
eliminate that tactile impression, i.e., make the initially raised
or protruding area feel smooth or flat.
The Insertion Tool
[0355] In order for the replaceable core component to be
comfortable during wear, the replaceable core component is
preferably relatively soft, relatively thin, and relatively
flexible. However, the flexibility may make the insertion of the
replaceable core component, by itself, difficult. For example, an
attempt to insert the replaceable core component by grasping its
outer end and pushing it into the chassis may result in the
replaceable core component collapsing or buckling due to the
sliding resistance between its outer surfaces and the adjacent
surfaces of the chassis. Similarly, an attempt to insert the
replaceable core component by grasping its inner end and inserting
the grasping hand into the chassis may lead to wrinkling or folding
of the replaceable core component. Also, the grasping hand may be
too large to fit into the space into which the replaceable core
component is being inserted and, therefore, only a partial
insertion may be achieved.
[0356] Thus, the use of an insertion tool having a suitable
thickness, a suitable stiffness, and a suitable buckling resistance
may facilitate the insertion of the replaceable core component.
Therefore, an absorbent article of the present invention may
include an insertion tool for use in the application of a force to
insert the replaceable core component into the chassis in the
intended predetermined orientation. The use of such an insertion
tool may obviate the need for a caregiver to insert her hand into
the absorbent article when inserting a replaceable core component.
Also, a suitable insertion tool may be significantly thinner than a
human hand and thus facilitate the deeper insertion of the
replaceable core component into the chassis, including when the
chassis, or the margin of the openable end of an openable chassis
pocket, is limited in its extensibility to accommodate the
insertion. In different embodiments, the insertion tool may be
withdrawn following the insertion of the replaceable core component
or may remain in the chassis. Also, the insertion tool may be used
without being attached to the replaceable core component, may be
attached to the replaceable core component for its insertion and
then detached from the replaceable core component, or may remain
attached to the replaceable core component.
[0357] The insertion tool 270 may be inserted into an insertion
pocket 260 attached on the outside of a replaceable core component,
such as in the exemplary embodiments shown in FIG. 87, FIG. 88,
FIG. 89, FIG. 90, FIG. 91, and FIG. 92, or it may be inserted into
an internal insertion pocket formed internally of the replaceable
core component, as described elsewhere in this disclosure. In some
embodiments, two insertion tools may be inserted into two insertion
pockets disposed on the opposing major surfaces of the replaceable
core component, as shown in FIG. 93. When used in this manner, the
two insertion tools may act as barriers preventing the exposure of
the replaceable core component, for example, to the hand of a
caregiver inserting the replaceable core component into the
absorbent article. In addition, the surfaces of the two insertion
tools may have a relatively low coefficient of friction to the
adjacent materials of the chassis and thereby facilitate the
insertion of the replaceable core component. Once it is inserted
into the insertion pocket 260, the insertion tool 270 may be used
to exert an insertion force in the direction indicated by the arrow
320 to insert the replaceable core component into the chassis.
Then, the insertion tool may be withdrawn from the chassis in the
opposing direction indicated by the arrow 321.
[0358] Such an insertion tool preferably has a planar surface area
that is sufficiently large to aid in preventing the wrinkling or
folding of the absorbent layer or layers of the replaceable core
component during its insertion. To this end, the insertion tool
preferably has a planar surface area of at least about 25% of the
planar surface area of the replaceable core component. More
preferably, the insertion tool has a planar surface area of at
least about 50% or, most preferably, at least about 75%, of the
planar surface area of the replaceable core component. The
insertion tool may also be shaped to spread the replaceable core
component and thereby prevent its wrinkling or folding during
insertion. For example, as shown in the figures, the portion of the
insertion tool adjacent to its inner end 318 is sized and shaped to
conform to the tapered shape of the inner end segment of the
absorbent layer 34 of the back panel 30.
[0359] Alternatively, the insertion tool may be releasably attached
to the replaceable core component in a manner that is suitable for
the effective insertion of the replaceable core component into the
chassis. In such an embodiment, after the replaceable core
component is inserted, the insertion tool may be released from the
replaceable core component as the insertion tool is withdrawn from
the chassis, as shown in FIG. 94, and FIG. 95. For example, the
insertion tool 270 may be affixed adjacent to its inner end 318 to
an intermediate member 315 in a first area of joining 316 and the
replaceable core component may be joined to the intermediate member
in a second area of joining 317 so as to be peelably releasable. In
such an embodiment, the intermediate member may be disposed such
that the intermediate member is subjected to a tensile force and
the first area of joining and the second area of joining are
subjected to substantially only a shear force as the insertion tool
is used to apply an insertion force in the direction indicated by
the arrow 320 to insert the replaceable core component into the
chassis. Then, when the insertion tool is withdrawn from the
chassis in the direction indicated by the arrow 321, the second
area of joining is subjected to a peel force such that the
intermediate member is released from the replaceable core
component, while remaining affixed to the insertion tool and
thereby being withdrawn with the insertion tool.
[0360] As another example, the insertion tool 270 may be joined
adjacent to its inner end 318 to the intermediate member 315 in the
first area of joining 316 so as to be peelably releasable and the
replaceable core component may be affixed to the intermediate
member in the second area of joining 317. In such an embodiment,
the intermediate member may be similarly subjected to a tensile
force and the first area of joining and the second area of joining
may similarly be subjected to substantially only a shear force as
the insertion tool is used to apply a force in the direction 320 to
insert the replaceable core component into the chassis. Then, when
the insertion tool is withdrawn from the chassis in the direction
indicated by the arrow 321, and the first area of joining is
thereby subjected to a peel force, the insertion tool may be
released from the intermediate member, which remains affixed to the
replaceable core component.
[0361] Rather than being joined or attached to the replaceable core
component either directly or through an intermediate member, the
insertion tool may have one or more protuberances, such as angled
teeth or hooks, that engage the layer forming the outer surface of
the replaceable core component when the insertion tool is slid
along the outer surface in a first direction, and that disengage or
fail to engage when the insertion tool is slid along the outer
surface in an opposing second direction. Alternatively, the
insertion tool may engage such protuberances on the outer surface
of the replaceable core component. In either configuration, the
movement of the insertion tool in the first direction applies an
insertion force to the replaceable core component, while the
movement of the insertion tool in the second direction disengages
the insertion tool from the replaceable core component, thus
leaving the replaceable core component in the inserted position. A
surface of the insertion tool having a directional coefficient of
friction relative to the outer surface layer of the replaceable
core component may perform the same function as the protuberance by
providing greater resistance when slid along the outer surface of
the replaceable core component in the insertion direction and
lesser resistance when withdrawn in the opposing direction.
[0362] In some embodiments, the extensible covering layer 300 shown
in FIG. 35, FIG. 36, FIG. 37, and FIG. 38 may serve as the
intermediate member 315 that remains attached to the replaceable
core component after the withdrawal of the insertion tool. In such
an embodiment, the extensible covering layer 300/intermediate
member 315 may be releasably attached to the insertion tool for the
insertion of the replaceable core component into the absorbent
article. As the insertion tool is withdrawn, the extensible
covering layer/intermediate member may be released from the
insertion tool and attached to the chassis, as shown in FIG. 35 and
FIG. 37. For example, in some embodiments, the extensible covering
layer/intermediate member may be releasably attached to the
insertion tool by releasable attachment means 302, which may be
exposed by the withdrawal of the insertion tool and may then become
attached to the chassis. In other embodiments, a second releasable
attachment means disposed on the surface of the extensible covering
layer/intermediate member opposite the releasable attachment means
302 may be exposed by the withdrawal of the insertion tool and may
then become attached to the chassis. Similarly, a releasable
attachment means having directional characteristics may be disposed
adjacent to the releasable attachment of the extensible covering
layer/intermediate member to the insertion tool. Such a directional
releasable attachment means may not engage the chassis when moved
in the insertion direction, but may engage the chassis when the
insertion tool is removed. When the replaceable core component is
subsequently removed from the chassis, the extensible covering
layer may remain attached to the chassis, so as to extend to cover
the outer surface of the replaceable core component as shown in
FIG. 36 and FIG. 38, and then may be released from the chassis.
[0363] The insertion tool may include an insertion depth indicator
to provide an indication when a predetermined position of the
insertion tool corresponding to a predetermined position of the
replaceable core component relative to the chassis is reached. In
general, the insertion tool may include any of the forms of an
insertion depth indicator described with regard to the replaceable
core component. For example, as shown in FIG. 88, the insertion
depth indicator may include a visible indicator such as a line 281
positioned adjacent to the outer end 319 of the insertion tool such
that the line is aligned with the waist end edge of the chassis
when the predetermined position is reached. In another example of a
visible insertion depth indicator, a graphical object on the
insertion tool may align with an adjacent graphical object on the
chassis to form a composite graphical object when the predetermined
position is reached, similarly to the way in which a similar
graphical object on the replaceable core component is herein
described as aligning.
[0364] The insertion tool's insertion depth indicator may include a
mechanical indicator providing tactile feedback in some exemplary
embodiments. For example, as shown in FIG. 89, FIG. 90, FIG. 91,
and FIG. 92, the insertion depth indicator of the insertion tool
may include a mechanical insertion depth indicator 284 in the form
of a mechanical surface fastener such as either a hook or a loop
member disposed on the insertion tool and adapted to engage a
complementary member disposed on the chassis, or to engage a
non-woven surface of the chassis, when the predetermined position
is reached. In another example of a mechanical insertion depth
indicator, an outer surface of the insertion tool may have a
relatively higher coefficient of friction to a portion of an
adjacent surface of the chassis, such that when the predetermined
position is reached, an increase in the coefficient of friction
markedly increases the force required to slide the insertion tool
farther and, thus, to insert the replaceable core component beyond
the predetermined position. In addition, such a mechanical
insertion depth indicator may simultaneously serve as both an
insertion depth indicator and a location stabilizer, in embodiments
in which the insertion tool remains in the chassis with the
replaceable core component.
[0365] In some exemplary embodiments, an outer surface of the
insertion tool may have a directional coefficient of friction
relative to the adjacent surfaces of the chassis and thereby
provide tactile feedback related to whether or not the insertion
tool and the replaceable core component are being inserted in the
intended end-to-end orientation. In general, the insertion tool may
include any of the forms of such surfaces having directional
coefficients of friction described with regard to the replaceable
core component. For example, a material forming the surface of the
insertion tool and having directional frictional characteristics
may be oriented such that when the inner end of the insertion tool
is inserted first, the coefficient of sliding friction is
relatively low, thus making the insertion of the insertion tool and
the replaceable core component into the chassis relatively easy. On
the other hand, if the insertion of an inverted insertion tool,
i.e., an insertion tool oriented such that its outer end is being
inserted first, is attempted, a relatively higher coefficient of
sliding friction of the directional material may provide a higher
resistive force and, thus, make the insertion of the inverted
insertion tool and replaceable core component into the chassis
relatively more difficult. This directional frictional surface
material may be disposed on one or more of the major surfaces of
the insertion tool or may be disposed on laterally opposing edge
surfaces.
[0366] In some exemplary embodiments, opposing outer surfaces of
the insertion tool may have different coefficients of friction
relative to the adjacent surfaces of the chassis and thereby
provide tactile feedback related to whether or not the insertion
tool and the replaceable core component are being inserted in the
intended orientation of the replaceable core component's
predetermined wearer-facing and garment-facing surfaces.
[0367] For example, a material forming the wearer-facing surface of
the insertion tool and having directional frictional
characteristics may be oriented such that when the insertion tool
is inserted with its predetermined wearer-facing surface oriented
toward the wearer-facing layer of the chassis and with its
predetermined garment-facing surface oriented toward the
garment-facing layer of the chassis, the coefficient of sliding
friction is relatively low, thus making the insertion of the
insertion tool and the replaceable core component into the chassis
relatively easy. On the other hand, if the insertion of a reversed
insertion tool, i.e., an insertion tool oriented such that its
wearer-facing and garment-facing surfaces are reversed from its
intended orientation, is attempted, a relatively higher coefficient
of sliding friction of the directional material may provide a
higher resistive force and, thus, make the insertion of the
reversed insertion tool and replaceable core component into the
chassis relatively more difficult.
[0368] The insertion tool may include a planar card-like element
271, as shown in FIG. 96. In order to be suitably thin and have a
planar surface area that is sufficiently large to aid in preventing
the wrinkling or folding of the replaceable core component during
its insertion, this card-like element preferably has a relatively
high ratio of its average width to its average thickness. For
example, the card-like element may have an average width to average
thickness ratio of at least 25:1. Preferably, the card-like element
may have an average width to average thickness ratio of at least
about 50:1 and, more preferably, at least about 100:1 and, most
preferably, at least about 300:1. In some embodiments, the
insertion tool may include two such planar card-like elements in a
superposed configuration that are separable from each other along
at least a portion of the perimeter of one or both of the
superposed planar card-like elements. The planar card-like element
may provide the desired stiffness to facilitate the insertion of
the replaceable core component into the chassis. In embodiments in
which the layers forming the insertion pocket of the replaceable
absorbent core component and/or the layers forming the openable
chassis pocket into which the replaceable core component is being
inserted provide a constraining force tending to prevent the
deflection of the replaceable core component and the insertion tool
from a smooth plane or curved planar shape during the insertion
process, this constraining force may lessen the required stiffness
of the insertion tool.
[0369] Such an insertion tool may also include a bag-like element
272 forming an openable insertion tool pocket 273, as shown in an
open state in FIG. 96. The bag like element may be joined to one
side of the planar card-like element, as in FIG. 96, or
alternatively, the bag-like element may be disposed between and
joined to two planar card-like elements, as shown in FIG. 97. The
bag-like element may be made of an extensible sheet material or may
be formed of a sheet having folds or pleats 277 so as to be
expandable for opening. The openable insertion tool pocket 273 may
be of sufficient size to accept and retain a replaceable core
component. Thus, the openable insertion tool pocket may be used to
contain an unused replaceable core component prior to use or to
accept and contain a used replaceable core component for disposal.
The bag-like structure of the insertion tool may include a closure
means, such as a tie-style closure that may include one or more
closure tabs 274, as shown in FIG. 98, a drawstring closure, a
mechanical fastener, a zipper, a button, a snap, an adhesive
closure, or another closure means known in the art. In embodiments
in which the unused replaceable core component is disposed inside
the openable insertion tool pocket, this closure means may be used
to secure the replaceable core component inside the pocket prior to
its insertion into the absorbent article. This closure means may
also be used to secure a used replaceable core component inside the
openable insertion tool pocket after its removal from the absorbent
article.
[0370] In some embodiments, an insertion tool having the form of a
card-like element 271 and an attached bag-like element 272 may be
inserted into an insertion pocket of a replaceable core component
and used in the manner described to exert an insertion force. Also,
in some embodiments, as shown in FIG. 99 and FIG. 100, a
replaceable core component, such as back panel 30, may be disposed
inside the openable insertion tool pocket 273 prior to its
insertion into the absorbent article. In such an embodiment, the
insertion tool containing the replaceable core component inside its
openable insertion tool pocket may be inserted into the absorbent
article and then withdrawn, thereby leaving the replaceable core
component in the absorbent article. When used in this manner, the
card-like element and/or the bag-like element of the insertion tool
may act as a barrier preventing the exposure of the replaceable
core component, for example, to the hand of a caregiver inserting
the replaceable core component into the absorbent article or to
potential contaminants prior to its insertion into the absorbent
article.
[0371] In some embodiments, a replaceable core component including
the extensible covering layer 300 shown in FIG. 35 and FIG. 36 may
be disposed inside the openable insertion tool pocket 273, as shown
in FIG. 99, for insertion into the absorbent article. In such an
embodiment, the releasable attachment means 302 may serve to attach
the extensible covering layer 300 to the insertion tool in the
first area of joining 316 so as to be peelably releasable. As the
insertion tool is withdrawn, it may be peelably released from the
extensible covering layer 300 and the releasable attachment means
302 may become exposed and attached to the chassis, as shown in
FIG. 35. When the replaceable core component is subsequently
removed from the chassis, the extensible covering layer may remain
attached to the chassis, so as to extend to cover the outer surface
of the replaceable core component as shown in FIG. 36, and then may
be released from the chassis.
[0372] The insertion tool may have a substantially planar portion
having a generally uniform thickness and a portion adjacent to its
inner end having a greater thickness and thereby serving as a
"plow" to separate the separable layers of the chassis as the
insertion tool in inserted into the absorbent article. The greater
thickness 276 of the insertion tool in the end portion, relative to
the generally uniform thickness 275 in the planar portion, may be
formed by folding the inner end 318 of the insertion tool 270 upon
itself, for example as shown in FIG. 101 and FIG. 102, by forming a
bend in the inner end, for example as in FIG. 103 and FIG. 104, by
adding a layer to the inner end, for example as in FIG. 105 and
FIG. 106, or by simply forming the inner end of the insertion tool
with a greater planar thickness. The greater thickness of the
insertion tool in the end portion may be at least about 5 times the
generally uniform thickness in the substantially planar portion and
is, preferably, at least about 10 times or, more preferably, at
least about 20 times the generally uniform thickness. In some
embodiments, the insertion tool may include a resilient element 278
serving to make the relatively thicker region elastically
compressible and thereby facilitate the use of the insertion tool
by allowing it to resiliently conform as it is inserted into an
insertion pocket and as it is used to exert a force to insert a
replaceable core component into a chassis.
[0373] In embodiments in which the openable chassis pocket and the
replaceable core component are "keyed" to each other, so as to
prevent the insertion of the replaceable core component in any
orientation other than a predetermined orientation contemplated in
the design of the replaceable core component, the insertion tool
may be correspondingly keyed to the openable chassis pocket and the
replaceable core component. Thus, the openable chassis pocket may
be shaped and the insertion tool may be correspondingly shaped to
fit within the shaped openable chassis pocket.
[0374] For example, in embodiments described in detail elsewhere in
this disclosure, the openable chassis pocket may include a
separator that bifurcates or partitions the openable chassis pocket
into at least two connected branches. In embodiments having such a
bifurcated openable chassis pocket, the insertion tool may include
a cooperative structure that permits the insertion of its inner end
beyond the outer end of the separator, i.e., to a point farther
from the waist end edge than the outer end of the separator. Such a
cooperative structure 227 in the insertion tool may include a slit,
a slot, or a groove formed in the insertion tool, as shown in FIG.
107, for receiving and/or bypassing the separator. The separator in
the openable chassis pocket may be formed along the longitudinal
centerline 17 of the chassis and the cooperative structure in the
insertion tool may be formed so as to coincide with the
longitudinal centerline 25 of the replaceable core component or,
alternatively, either the separator or the cooperative structure,
or both, may be offset from the respective longitudinal centerline,
as in FIG. 107. Similarly to the manner described with regard to
the cooperative structure in the replaceable core component, such
an offset configuration may serve to ensure that the insertion tool
is inserted with its inner end in the crotch region and its outer
end in the waist region and is inserted in a predetermined lateral
position, thereby ensuring that the replaceable core component
being inserted with the insertion tool is inserted with its liquid
pervious surface region in a predetermined longitudinal and/or
lateral position, and so on.
[0375] As shown in FIG. 108, in embodiments in which the openable
chassis pocket is divided into several separate connected branches
or non-interconnected sections, i.e., divided effectively into
separate openable chassis pockets, the insertion tool may have a
corresponding number of protruding finger-like sections 279. These
finger-like sections may be placed into the branches or sections of
the openable chassis pocket in a side-by-side lateral relationship
and, thus, may be used to insert a correspondingly shaped
replaceable core component or to insert multiple replaceable core
component into the respective branches or sections.
[0376] In embodiments including more than one shaping element, as
well as shaping elements other than a separator, the insertion tool
may be correspondingly shaped. For example, a shaping element may
include a slot into which a corresponding "key" fits in only a
predetermined orientation, one or more holes or depressions into
which one or more corresponding pins, bosses, or protuberances fits
in only a predetermined orientation, a partition within the
openable chassis pocket that requires the insertion tool to be
partially inserted and then rotated and/or translated in order for
the insertion to be completed, and similar configurations.
[0377] Those skilled in the art will recognize that additional
exemplary embodiments of absorbent articles providing access to a
removable and replaceable absorbent core component or absorbent
insert are possible without departing from the scope of the present
invention. Furthermore, it is contemplated that, without departing
from the scope of the present invention, additional combinations of
the absorbent core components, the absorbent core members, the
placement of the absorbent core components and members, and the
absorptive characteristics may be used, with the desired functional
requirements influencing the ultimate design. Specifically, not
only the illustrated embodiments, but all structurally feasible
combinations of the disclosed elements and configurations are
contemplated. Also, methods of use of the disposable absorbent
articles of the present invention in which the replaceable core
component is removed, inserted, and/or replaced are contemplated.
In addition, articles of commerce, such as packages, bags,
containers, display packs, and the like, in which the disposable
absorbent articles of the present invention are included with
instructions for their use are likewise contemplated.
[0378] While particular exemplary 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 present invention. It is therefore intended to
encompass in the appended claims all such changes and modifications
that are within the scope of the present invention.
* * * * *