U.S. patent application number 11/200832 was filed with the patent office on 2007-02-15 for absorbent article with improved side seams.
Invention is credited to Nicole DeVittore, Edward Erdman.
Application Number | 20070038199 11/200832 |
Document ID | / |
Family ID | 37743483 |
Filed Date | 2007-02-15 |
United States Patent
Application |
20070038199 |
Kind Code |
A1 |
Erdman; Edward ; et
al. |
February 15, 2007 |
Absorbent article with improved side seams
Abstract
An absorbent article is provided that includes a top sheet and a
back sheet joined to form side seam regions. An absorbent core is
disposed between the top sheet and the back sheet; and laterally
oriented elastics are disposed between the top sheet and the back
sheet. The elastics include a first elastic region disposed
adjacent to the front end and a second elastic region disposed
adjacent the first elastic region. The second elastic region
includes one or more elastic elements that extend between the side
seam regions. The elastic elements have internal cuts adjacent the
side seams in a configuration that relieves elastic tension
adjacent the side seams regions.
Inventors: |
Erdman; Edward; (West
Chester, PA) ; DeVittore; Nicole; (West Chester,
PA) |
Correspondence
Address: |
Mark S. Leonardo, Esq.;Brown Rudnick Berlack Israels LLP
One Financial Center
Boston
MA
02111
US
|
Family ID: |
37743483 |
Appl. No.: |
11/200832 |
Filed: |
August 10, 2005 |
Current U.S.
Class: |
604/385.3 |
Current CPC
Class: |
A61F 13/15593 20130101;
A61F 13/4963 20130101; A61F 13/5633 20130101; A61F 13/496 20130101;
A61F 13/15739 20130101 |
Class at
Publication: |
604/385.3 |
International
Class: |
A61F 13/15 20060101
A61F013/15 |
Claims
1. An absorbent article defining a longitudinal axis, and a front
end and a back end disposed along said longitudinal axis, said
absorbent article comprising: (i) a body-facing surface; (ii) a
garment-facing surface, wherein said body-facing surface and said
garment-facing surface are joined to form side seam regions; (iii)
an absorbent core disposed between said body-facing surface and
said garment-facing surface; and (iv) laterally oriented elastics,
relative to said longitudinal axis, being disposed between said
body-facing surface and said garment-facing surface, said elastics
including a first elastic region disposed adjacent to said front
end and said back end, and a second elastic region disposed
adjacent said first elastic region, said second elastic region
including one or more elastic members that extend between said side
seam regions, wherein said elastic members have internal cuts
adjacent said side seam regions in a configuration that relieves
elastic tension adjacent said side seam regions.
2. The absorbent article of claim 1, wherein said front end and
said back end are each defined by two laterally-disposed side panel
regions and a medially-disposed body facing region and wherein said
internal cuts are disposed in said side panel regions.
3. The absorbent article of claim 2, wherein said side panel
regions are each defined by a medial side panel region and a
lateral side panel region and wherein said internal cuts are
disposed in said lateral side panel region.
4. The absorbent article of claim 3, wherein said elastic elements
have internal cuts in said body facing region.
5. The absorbent article of claim 1, wherein said first elastic
region includes one or more elastic members having internal cuts
adjacent to the side seam regions in a configuration that relieves
elastic tension adjacent said side seam regions.
6. The absorbent article of claim 1, wherein said second elastic
region is disposed within a laminate structure.
7. The absorbent article of claim 2, wherein said second elastic
region comprises elastic members having internal cuts in said body
facing region.
8. An absorbent article having a longitudinal axis, a front region
and a back region disposed along said longitudinal axis, wherein
said front and back regions each being characterized by a
medially-disposed body facing region and two laterally-disposed
side panels, said side panels being characterized as having a
medial region and a distal region, said absorbent article
comprising: (i) a fluid-permeable top sheet; (ii) a
fluid-impermeable back sheet, wherein said top sheet and said back
sheet are joined to form side seam regions; (iii) at least one
absorbent core disposed between said top sheet and said back sheet;
(iv) a waistband having one or more waistband elastic members
disposed perpendicular to said longitudinal axis and running
substantially the entire width of each of said front region and
said back region, and (v) a tummy band having one or more tummy
band elastic members disposed perpendicular to said longitudinal
axis, adjacent to said waist band, and running substantially the
entire width of each of said front region and said back region,
wherein said tummy band elastic members have one or more internal
cuts adjacent said side seam regions in a configuration that
relieves elastic tension in the distal regions of said side
panels.
9. The absorbent article of claim 8, wherein said internal cuts are
in the distal regions of said side panels.
10. The absorbent article of claim 8, wherein at least one of said
tummy band elastic members has internal cuts in said body facing
region.
11. The absorbent article of claim 8, wherein at least one of said
waistband elastic members has internal cuts in said body facing
region.
12. A method for manufacturing an absorbent article comprising the
steps of: (i) providing an elastic member, an upper sheet, a lower
sheet and an adhesive; (ii) applying said adhesive to at least one
side of said elastic member; (iii) assembling a laminate structure
wherein said elastic member is disposed between said upper sheet
and said lower sheet; (iv) making internal cuts in said elastic
member; (v) assembling the absorbent article wherein said laminate
structure is disposed between a body-facing surface and a
garment-facing surface which are joined to form a side seam, and
wherein said internal cuts are adjacent said side seam;
13. The method of claim 12, wherein said elastic member is under
elastic tension during assembly of said laminate structure.
14. The method of claim 12, wherein said adhesive is applied
discontinuously to said elastic member such that said elastic
member is characterized as having adhesive-containing regions and
non-adhesive-containing regions.
15. The method of claim 14, wherein said internal cuts are made in
non-adhesive-containing regions of said elastic member.
16. The method of claim 12, wherein said internal cuts are made
with a heated knife roller.
17. The method of claim 16, wherein said adhesive is further
disposed between said elastic member and said garment-facing
surface.
18. A method for manufacturing a laminate structure comprising the
steps of: (i) providing an elastic member, an upper sheet, a lower
sheet, and an adhesive; (ii) discontinuously applying said adhesive
to at least one side of said elastic member such that said elastic
member is characterized as having adhesive-containing regions and
non-adhesive-containing regions; (iii) assembling said laminate
structure wherein said elastic member is disposed between said
upper sheet and said lower sheet, and wherein said elastic member
is under elastic tension during assembly; (iv) making internal cuts
in said laminate structure wherein said internal cuts are made in
the non-adhesive-containing regions of said elastic member such
that the elastic tension of said elastic member is relieved in the
area of said internal cuts.
19. The method of claim 18, wherein said internal cuts are made
with a heated knife roller.
20. The method of claim 18, wherein said upper sheet and said lower
sheet are joined at the edges of said laminate structure.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure generally relates to absorbent
articles, and more particularly to an absorbent article having a
side seam structure including severed elastics disposed in a
configuration that is softer and more aesthetically pleasing to the
wearer for improving fit, while being low cost and easily
manufactured.
[0003] 2. Description of the Related Art
[0004] Absorbent articles such as, for example, disposable diapers,
adult incontinent pads, sanitary napkins, pantiliners, incontinent
garments and the like are generally worn, in cooperation with
garments and disposed against a body surface by infants or adult
incontinent individuals. The absorbent article is employed to
collect and absorb body fluid discharge, such as, for example,
blood, menses, urine, aqueous body fluids, mucus, cellular debris
and other forms of body discharge. For example, the absorbent
article may be disposed between the legs of an individual adjacent
a crotch area. The absorbent article is positioned with a garment
and drawn into engagement with a body surface of the crotch area to
collect body discharge.
[0005] As is known, absorbent articles typically include a fluid
permeable coverstock for engaging the body surface, a fluid
impermeable backsheet and an absorbent core supported therebetween.
The backsheet serves as a moisture barrier to prevent fluid leakage
to the garment. The absorbent core usually includes a liquid
retention material that faces the body surface. The absorbent core
can include, for example, loosely formed cellulosic fibers, such
as, for example, wood pulp, rayon, or cotton for acquiring and
storing body discharge. The absorbent core may also include tissue
wrapping or wadding, and/or super absorbent polymer.
[0006] Some absorbent article designs typically incorporate elastic
elements in the waist, stomach, and leg areas for improving the
fit, aesthetics and leakage resistance. The waist and stomach
elastic elements increase the flexibility of the absorbent article,
allowing the same article to accommodate a greater range of body
sizes. In addition, they make the article more form-fitting for the
wearer. The topsheet and backsheet are joined to support the
components of the absorbent article.
[0007] Infants, toddlers, and other incontinent individuals wear
disposable absorbent articles such as diapers and training pants,
which include "pull-on" or "pant-type" garments having fixed sides,
single-use diaper garments including front and back portions
joined, usually by an adhesive, when the diaper is initially
donned, and hybrid garments which are donned like a diaper garment
but are designed to be removed and replaced like a pant-type
garment.
[0008] Typically, the elasticized elements disposed adjacent the
side seams cause bunching at the side seam. This disadvantageous
bunching of the garment about the wearer results in many drawbacks
such as discomfort and leakage.
[0009] It would therefore be desirable to overcome the
disadvantages and drawbacks of the prior art by providing an
absorbent article having a side seam structure including severed
elastics disposed in a configuration that is softer and more
aesthetically pleasing to the wearer for improving fit. Such an
absorbent article desirably prevents leakage. It is contemplated
that the absorbent article is low cost and easy and efficient to
manufacture.
SUMMARY
[0010] Accordingly, an absorbent article having a side seam
structure, including severed elastics adjacent to the side seams,
disposed in a configuration that is softer and more aesthetically
pleasing to the wearer for improving fit is povided. Such an
absorbent article desirably prevents leakage. The absorbent article
is low cost and easy and efficient to manufacture. Objects and
advantages of the present disclosure are set forth in part herein
and in part will be obvious therefrom, or may be learned by
practice of the present disclosure that is realized and attained by
the instrumentalities and combinations pointed out in the appended
claims for the devices and methods of the present disclosure
consisting of its constituent parts, constructions, arrangements,
combinations, steps and improvements herein shown and
described.
[0011] In one particular embodiment, in accordance with the
principles of the present disclosure, an absorbent article is
provided that defines a longitudinal axis, and a front end and a
back end disposed along the longitudinal axis, comprising (i) a
garment-facing surface comprising a fluid-impermeable back sheet,
(ii) a body-facing surface comprising a fluid-permeable top sheet,
the garment-facing surface and the body-facing surface being joined
to form side seam regions; (iii) at least one absorbent core
disposed between the garment-facing surface and the body-facing
surface; and (iv) laterally oriented elastics, relative to the
longitudinal axis, being disposed between the garment-facing
surface and the body-facing surface, the elastics including a first
elastic region disposed adjacent to the ends of the article (i.e.,
the front end and the back end) and a second elastic region
disposed adjacent the first elastic region, the second elastic
region including one or more elastic elements that extend between
the side seam regions, wherein the elastic elements have internal
cuts adjacent the side seam regions in a configuration that
relieves elastic tension in the side seam regions.
[0012] The front end and the back end of the absorbent article are
each defined by two laterally-disposed side panel regions and a
medially-disposed body facing region and the internal cuts are
disposed in the side panel regions. Preferably, the internal cuts
are disposed in the lateral side panel region. It is also
contemplated that the second elastic region has internal cuts in
the body facing regions of the front and back ends.
[0013] In alternate configurations, the first elastic region
comprises one or more elastic elements and at least one of the
elastic elements has one or more internal cuts adjacent to the side
seams in a configuration that relieves elastic tension. Preferably,
these cuts are in the lateral side panel region but not in the
medial side panel region. It is also contemplated that one or more
of the elastic elements has internal cuts in the body facing
regions.
[0014] It is contemplated that the elastic elements of the first
elastic region and/or the second elastic region are disposed within
a laminate structure. The elastic elements of the first elastic
region and/or the second elastic region may be present within the
same laminate structure or within different laminate
structures.
[0015] In another embodiment, the present disclosure provides an
absorbent article having a longitudinal axis, a front region and a
back region disposed along the longitudinal axis, wherein the front
and back regions each being characterized by a medially-disposed
body facing region and two laterally-disposed side panels, the side
panels being characterized as having a medial region and a distal
region, comprising: (i) a fluid-impermeable back sheet, (ii) a
fluid-permeable top sheet, and the back sheet being joined to form
side seam regions; (iii) at least one absorbent core disposed
between the top sheet and the back sheet; and (iv) a waistband
having one or more elastic members disposed perpendicular to the
longitudinal axis running substantially the entire width of each of
the front region and the back region, and (v) a tummy band disposed
adjacent to the waistband having one or more elastic members
disposed perpendicular to the longitudinal axis and running
substantially the entire width of each of the front region and the
back region, wherein the elastic members have one or more internal
cuts adjacent the side seam regions in a configuration that
relieves elastic tension in the side seam regions. Preferably, the
internal cuts are in the distal regions of the side panels. It is
also contemplated that at least one of the elastic members of the
first elastic region and/or at least one of the elastic members of
the second elastic region has internal cuts in the body facing
region.
[0016] In another embodiment, this disclosure provides a method for
manufacturing an absorbent article comprising: (i) providing an
elastic member, a top sheet, a back sheet and an adhesive; (ii)
applying the adhesive to at least one side of the elastic member;
(iii) assembling the absorbent article having a laminate structure
wherein the adhesive is disposed between the elastic member and the
top sheet; the top sheet and the bottom sheet being joined (iv)
making internal cuts in the laminate structure adjacent the area
that will include the side seams. Preferably, the elastic member is
under elastic tension during assembly of the laminate
structure.
[0017] The adhesive may be applied continuously but is, preferably,
applied discontinuously such that the elastic member is
characterized as having adhesive-containing regions and
non-adhesive-containing regions. In the most preferred embodiment,
the internal cuts are made in non-adhesive-containing regions of
said elastic member. These internal cuts may be made using a heated
knife roller.
[0018] Adhesive may be further disposed between the elastic member
and the side seams may be joined along longitudinal edge of the
absorbent article.
[0019] In any of the foregoing embodiments, the absorbent core may
consist of wood pulp, cellulose wadding, cotton fibers, absorbent
foams, sponges, superabsorbent polymers (e.g., hydrogels),
absorbent gelling materials, or combinations thereof.
[0020] The present disclosure also provides a method for
manufacturing a laminate structure comprising: (i) providing an
elastic member, an upper sheet, a lower sheet, and an adhesive;
(ii) discontinuously applying the adhesive to at least one side of
the elastic member such that said elastic member is characterized
as having adhesive-containing regions and non-adhesive-containing
regions; (iii) assembling the absorbent article having a laminate
structure wherein the elastic member is disposed between the upper
sheet and the lower sheet, the upper sheet and the lower sheet
being joined to form a laminate structure, and wherein the elastic
member is under elastic tension during assembly; (iv) making
internal cuts in the laminate structure, wherein the internal cuts
are made in the non-adhesive-containing regions of the elastic
member such that the elastic tension of the elastic member is
relieved in the area of the internal cuts.
[0021] In one embodiment, adhesive is applied to both sides of the
elastic member. In another embodiment, the internal cuts are made
using a heated knife roller. Preferably, the cuts made in the upper
sheet and/or the lower sheet are heat-sealed by the knife
roller.
[0022] It is contemplated that the laminate structure contain
multiple elastic members. In one embodiment, the internal cuts are
made in each elastic member of the laminate structure. In another
embodiment, the internal cuts are made in fewer than all elastic
members of the laminate structure. It is further contemplated that
the laminate structure will be further cut into unitary lengths. In
preferred embodiments, at least some of the internal cuts are
adjacent to the ends of the unitary lengths.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The objects and features of the present disclosure are set
forth with particularity in the appended claims. The present
disclosure, as to its organization and manner of operation,
together with further objectives and advantages may be understood
by reference to the following description, taken in connection with
the accompanying drawings, in which:
[0024] FIG. 1A is a plan view of an absorbent article having
continuous (uncut) elastic members;
[0025] FIG. 1B is a top view of the absorbent article, shown in
FIG. 1A, in an assembled configuration;
[0026] FIG. 1C is a top view of the absorbent article, shown in
FIG. 1A, in an alternate embodiment of the assembled
configuration;
[0027] FIG. 2 is a plan view of an absorbent article having the
elastic members of the second elastic region internally cut in
distal regions of side panels;
[0028] FIG. 3 is a plan view of an absorbent article having the
elastic members of both the first and the second elastic regions
internally cut in the distal regions of the side panels;
[0029] FIG. 4 is a schematic diagram of a manufacturing method for
absorbent articles containing elastic members useful as first
elastic regions and/or second elastic regions;
[0030] FIG. 5 is a schematic diagram of a cutting apparatus, for
the method of manufacturing absorbent articles, that precuts the
elastic members within first elastic region and/or second elastic
region laminates;
[0031] FIG. 6 is a schematic diagram of a knife roller, for the
method of manufacturing absorbent articles, useful for precutting
the elastic members within first elastic region and/or second
elastic region laminates; and
[0032] FIG. 7 is a schematic diagram showing alternative
constructions of the first and second elastic regions for use in an
absorbent article.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0033] The exemplary embodiments of the absorbent article and
methods of use disclosed are discussed in terms of fluid absorbent
articles, and more particularly, in terms of an absorbent article
having a side seam region including severed elastics disposed in a
configuration that is softer and more aesthetically pleasing to the
wearer for improving fit, while being low cost and easily
manufactured. The presently disclosed absorbent article is
contemplated to be employed with, for example, training pants,
adult incontinent products, disposable diapers, and other
incontinent articles. It is contemplated that by pre-cutting the
elastic members of a second elastic region alone or the elastic
members of both the second elastic region and the first elastic
region in the distal region of the side panels of an absorbent
article, bunching and leakage is prevented at the side seam region
when the article is worn.
[0034] In the discussion that follows, the term "body-facing
surface" refers to a portion of a structure that is oriented
towards a body surface, and the "garment-facing surface" refers to
a portion of the structure that is oriented towards a garment and
is typically opposing the body-facing surface and may be referred
to as such. As used herein, the term "body surface" refers to a
portion of an individual's body that the absorbent article is
disposed with for collecting and absorbing fluid discharge from the
individual. As used herein, the term "absorbent article," or
"absorbent garment" refers to garments that absorb and contain body
waste, and more specifically, refers to garments that are placed
against or in proximity to the body of the wearer to absorb and
contain the various body discharges and wastes. As used herein, the
term "side seam region" refers to the lateral region of the
absorbent article that functionally forms and supports the side
seam. This region includes the side seam itself in addition to the
distal region of the lateral region of the absorbent article.
[0035] A non-exhaustive list of examples of absorbent articles
includes training pants, diapers, diaper covers, disposable
diapers, feminine hygiene products and adult incontinence products.
The term absorbent articles includes all variations of absorbent
garments, including disposable absorbent garments that are intended
to be discarded or partially discarded after a single use and
unitary disposable absorbent garments that have essentially a
single structure. As used herein, the term "training pants" refers
to an absorbent article generally worn by children about the lower
torso. The absorbent article may be disposable or partially
discarded after a single use. The absorbent article can be a
unitary structure or include replaceable inserts or interchangeable
parts.
[0036] Absorbent articles and diapers may have a number of
different constructions. In each of these constructions it is
generally the case that an absorbent core is disposed between a
liquid pervious, body-facing top sheet and a liquid impervious,
exterior facing back sheet. In some cases, one or both of the top
sheet and back sheet may be shaped to form a pant-like article,
such as a training pant. In other cases, the top sheet, back sheet
and absorbent core may be formed as a discrete assembly that is
placed on a main chassis layer and the chassis layer is shaped to
form a pant-like absorbent article. The absorbent article may be
provided to the consumer in the fully assembled pant-like shape or
may be partially pant-like and require the consumer to take the
final steps necessary to form the final pant-like shape. Training
pants are typically fully formed and applied by pulling the
absorbent article over a child's legs. For a diaper application, an
open article is provided and wrapped about a child's waist, such as
by manually fastening one or more fasteners or fastener tabs.
[0037] The following discussion includes a description of the
disposable absorbent article in accordance with the present
disclosure. Reference will now be made in detail to the exemplary
embodiments of the disclosure, which are illustrated in the
accompanying figures. Like components are designated by like
reference numerals throughout the several views.
[0038] As shown in FIG. 1A, an absorbent article is shown having
first 30 and second 32 elastic regions (see FIG. 2) comprised of
continuous elastic members 40 and 42, respectively, that are under
elastic tension. FIG. 1B shows a top-view of a diaper-style
absorbent article in its "donned" configuration in which the side
panels have been fastened as if around a person's waist, forming
the leg openings 18. In this configuration, the side seam region
described in more detail below, are joined to form side seams 45 in
an overlap configuration. The overlap configuration includes
joining the outer surface of the front or back end to the inner
surface of respective back or front end. In an alternate
embodiment, as shown in FIG. 1C, the side seam regions are joined
in a cross or transverse configuration to form side seams 45. The
transverse configuration includes joining the inner surfaces of the
front and back ends. It is envisioned that transverse configuration
may include joining the outer surfaces of the front and back ends.
It is envisioned that side seams 45 may be joined in various
configurations.
[0039] In an alternate embodiment, FIG. 2 illustrates an absorbent
article 10 constructed in accordance with the principals of this
disclosure. Absorbent article 10 has a longitudinal axis and
extends from a front end corresponding to a front region 12, a
crotch region 14, to back end corresponding to a back region 16
that are disposed along that axis. The crotch region 14 is further
characterized as having laterally disposed leg openings 18. The
garment-facing surface such as, for example, a fluid impermeable
back sheet, and the body-facing surface, such as, for example, a
fluid permeable top sheet, are joined to form the side seam
regions, which include side panels 22 of absorbent article 10 and
side seams 15. The garment facing surface and the body facing
surface support the absorbent core(s) 13. Although the front region
12 and the back region 16 are illustrated as being symmetrical in
shape, symmetry is not necessary.
[0040] Each of the front region 12 and back region 16 are further
characterized as having a medially-disposed body facing region 20
and two laterally-disposed side panels 22. Each laterally-disposed
side panel 22 is further characterized as having a distal region 24
and a medial region 26. It is contemplated that the side seam
regions include side panels 22 and the side seams 15, which are
supported by the junction of the garment-facing surface and the
body-facing surface, along with at least the distal region of the
side panel 24. Further, the front region 12 and back region 16 each
have a first elastic region 30 and a second elastic region 32. It
is contemplated that first elastic region 30 may be configured as a
waistband. It is further contemplated that second elastic region 32
may be configured as a tummy band.
[0041] The first elastic region 30 has at least one elastic member
40 running substantially perpendicular to the longitudinal axis and
spanning substantially the entire width of the region. The first
elastic region elastic member 40 may be contained within a laminate
structure 100 (see FIGS. 4-6) or may be affixed directly to the
garment-facing surface, body-facing surface, and/or absorbent core.
It is understood, unless specifically excluded, that a reference to
the "first elastic region elastic member 40," or more simple the
"elastic member 40" is also meant to refer to the comparable region
of a laminate structure 100 which is described in detail below. The
elastic member(s) 40 may be held in place by use of an adhesive
which may be continuous or discontinuous along the length of the
elastic member 40 or the elastic member 40 may be held in place by
fused ends between the garment-facing surface and the body-facing
surface during assembly of the absorbent article 10. In cases where
an adhesive is used, the elastic member 40 may be adhered to the
garment-facing surface, the body-facing surface, and/or the
absorbent core 13.
[0042] The second elastic region 32 is disposed, adjacent and
medially to the first elastic region 30, and has at least one
elastic member 42 (also referred to as the "second elastic region
elastic member 42") running substantially perpendicular to the
longitudinal axis and spanning substantially the entire width of
the region. The second elastic region elastic member 42 may be
contained within a laminate structure 100 (see FIGS. 4-6) or may be
affixed directly to the garment-facing surface, body-facing
surface, and/or absorbent core. It is understood, unless
specifically excluded, that a reference to the "second elastic
region elastic member 42" is also meant to refer to the comparable
region of a laminate structure 100 which is described in detail
below. During manufacture, the second elastic region elastic
member(s) 42 may be held in place by sealing the ends between the
top sheet and the back sheet. The second elastic region 32 is
further characterized as having discontinuous elastic members 45
adjacent side seams 15 in the distal region of the side panels 24
and may optionally have discontinuous elastic members 47 in the
body facing region 20 of the front and back panels 12 and 16. The
second elastic region elastic members 42 may be rendered
discontinuous by cutting following assembly of the absorbent
article 10 or they may be precut following the assembly of the
laminate structure 100 prior to final assembly of the absorbent
article 10 (see FIGS. 4-6). Second elastic region elastic member 42
cutting may be done in accordance with the principles of this
disclosure (see FIGS. 5 and 6; i.e., using a knife roller 172 that
may, preferably, be heated to seal the cuts made in the back sheet
and/or top sheet) or by any convenient method.
[0043] The discontinuous elastic members 45 relieve the elastic
tension of the second elastic region in the side panel side seam
region when the article is donned. This cutting of the second
elastic region elastic members 42 to render them discontinuous 45
reduces or eliminates side seam bunching when the article is
donned. The discontinuous elastic members 47 also serve to reduce
or eliminate bunching in the front 12 and back 16 panels and
enhance wearer comfort. Preferably, the discontinuous elastic
members 45 and 47 are not adhered to the garment-facing surface
and/or the body-facing surface and are cut in sufficiently small
pieces to relieve elastic tension. It is contemplated that the
discontinuous elastic members 45, 47 may have various dimensions,
such as, for example, less than 0.5'', less than 0.25'', or less
than 0.10''. The elastic member(s) 42 in the medial region of the
side panels 26 retain elastic tension and may be contained within a
laminate structure 100 which is assembled into the absorbent
article 10 or they may be adhered directly to the garment-facing
surface, the body-facing surface, and/or the absorbent core.
Accordingly, it is necessary to discontinuously apply an adhesive
to the tummy band elastic member(s) 42 prior to cutting such that
the adhesive is only present in the medial region of the side
panels 26. Optionally, adhesive may be applied continuously or
discontinuously to the body facing region 20 of the tummy band
elastic member(s) 42, whether or not the tummy band elastic
member(s) 42 are contained within a laminate structure 100.
[0044] FIG. 3 illustrates an alternate embodiment of the absorbent
article 10. This embodiment is similar to the one disclosed in FIG.
2 except that the first elastic region adjacent side seams 15 and
elastic members 40 are discontinuous 49 by cutting to relieve
elastic tension in the distal region of the side panels 24. As in
FIG. 2, the waistband elastic members 40 may be bonded between the
top sheet and the back sheet during assembly of the absorbent
article 10. The cutting of the elastic members 40 is typically
performed following assembly. The uncut portions of the waistband
elastic members 40 in the medial region 26 and the body facing
region 20 of each of the front 12 and back 16 regions must be
adhered to the back sheet, the top sheet, and/or the absorbent core
13. This cutting of the waistband elastic members 42 to render them
discontinuous 49 in the distal region 24 further reduces or
eliminates side seam bunching when the article is donned.
[0045] In preferred embodiments, the second elastic region elastic
members 42 and the first elastic region elastic members 40 are
contained in a laminate structure 100. It is contemplated that the
second elastic region elastic members 42 and, if desired, the first
elastic region elastic members 32 are pre-cut during the
manufacture of the laminate structure 100 but prior to the final
assembly of the absorbent article 10. The laminated structure 100,
containing both the continuous elastic members and the
discontinuous (cut) elastic members, is assembled into the final
absorbent article. The laminated structure 100 may be held in place
by fusing the ends between the garment-facing surface and
body-facing surface during final assembly, it may be held in place
using an adhesive, or both. The second elastic region 32 and the
first elastic region 30 may be contained within the same laminate
structure 100 or separate laminate structures 100.
[0046] FIG. 4 is a schematic diagram demonstrating a method for
manufacturing a laminate structure 100 suitable for use as a second
elastic region 32, a first elastic region 30, or a combination
first and second elastic regions in accordance with this
disclosure. The elastic members 110 which may be used as the first
elastic region elastic members 40 or the second elastic region
elastic members 42 or both are wound on a roller apparatus 120.
Adhesive 132 is applied by an adhesive applicator 130 in the
desired discontinuous pattern, which depends upon the final desired
configuration of the elastic members 110 in the absorbent article
10. These discontinuous patterns may vary based on whether the
laminate structure 100 will be used as a first elastic region 30 or
a second elastic region 32, or both, and whether the elastic
members will be precut in the distal region of the side panels 24
alone or also include precuts in the body facing regions 20.
Adhesive 132 may be applied to the top, lower, or both sides of the
elastic members 110. A lower sheet 142 is applied to the lower of
the elastic members 110 from a lower sheet roll stock 140. An upper
sheet 152 is applied to the top of the elastic members 110 from an
upper sheet roll stock 150. Although FIG. 3 illustrates the
application of the lower sheet 142 prior to the application of the
upper sheet 152, the order is unimportant to the configuration of
the final laminate 100. Typically, although not necessarily, the
upper sheet 152 and the lower sheet 142 are wider than the width of
the elastic members 110. In preferred embodiments, the upper sheet
152 is joined at its edges to the lower sheet 142 to enclose the
elastic members.
[0047] Next, the laminate 100 is run through compression rollers
160. The compression rollers 160 rotate at the same speed as the
top sheet roll stock 150 and the lower sheet roll stock 140 is
unwound which is, preferably, at a speed greater than the elastic
110 is unwound from the elastic roller apparatus 120. This has the
effect of creating elastic tension within the final laminate 100 as
it leaves the compression rollers 160.
[0048] FIG. 5 is a schematic diagram demonstrating a method for
precutting the second elastic region elastic members 42 and/or the
first elastic region elastic members 40 in the regions that will
correspond to the distal region of the side panels 24 and/or the
body facing region 20. As the laminate 100 exits the compression
rollers 160 (see FIG. 3), it is next passed through the cutting
rollers 170. The cutting rollers 170 typically consist of a knife
roller 172 opposed against an anvil roller 174. The knife roller
172 has raised cutting edges on a portion of its circumference such
that the laminate 100 is cut in the regions between the adhesive
132. In preferred embodiments, the circumference of the knife
roller 172 is conveniently substantially the same length as the
width of the absorbent article 10. Thus, each revolution of the
knife roller 172 precuts the elastic members 110 within the
laminate in the desired pattern as described, for example, in FIGS.
1 and 2. It is also contemplated that, in an alternative
embodiment, multiple cutting rollers 170 may be used to obtain the
desired final precut pattern. This precutting of the elastic
members 110 effectively releases the elastic tension in that region
of the laminate 100. The diameter of anvil roller 174 is usually,
but not always, larger than that of the knife roller 172. The anvil
roller 174 is substantially smooth and must be sufficient to
provide an apposing surface against which the knife roller 172 can
act. In another preferred embodiment, either one or both of the
knife roller 172 and the anvil roller 174 are heated so that the
upper sheet 152 and the lower sheet 142 are melt-sealed at each
cut. This melt-sealing aids in preventing the top sheet 152 and the
lower sheet 142 from separating and also aids in containing the
discontinuous pieces of the elastic member 110 within the laminate
100.
[0049] FIG. 6 is a schematic diagram of a preferred embodiment of
an knife roller 172. Preferably, the knife roller 172 has rows of
discontinuous raised knife edges 180 and each row of raised knife
edges 180 is longitudinally offset from the immediately adjacent
rows. The length 182 of the rows of raised knife edges 180 is
preferably greater than the width of the elastic member 110 but
less than the width of the laminate 100.
[0050] FIG. 7 is a schematic diagram showing alternate
constructions combinations of first and second elastic regions for
use with an absorbent article. In each case, the intact elastic
members are under elastic tension. FIG. 7A shows a configuration in
which the elastic tension of the elastic members of the first and
second elastic regions is maintained by the use of an adhesive 132.
The second elastic region band elastic member 42 is precut only in
the body facing region 20. This configuration causes bunching at
the side seam 15.
[0051] FIG. 7B shows an alternate configuration in which the
adhesive 132 is not present on second elastic region elastic member
in the side panel 22 region near the side seam 15. This
configuration does not reduce or prevent side seam bunching because
the second elastic region elastic member 42 remains under elastic
tension because it is anchored into the side seam 15.
[0052] FIG. 7C shows one configuration made according to the
principles of this disclosure. The second elastic region elastic
member 42 is precut, preferably multiple times, in the side panel
22 region adjacent to the side seam 15. No adhesive is used in the
precut region. This reduces the bunching problem of the prior art
by relieving elastic tension adjacent to the side seam 15.
[0053] FIG. 7D shows an alternate configuration made according to
the principles of this disclosure. In this configuration, both the
second elastic region elastic member 42 and the first elastic
region elastic member 32 are precut in the side panel 22 region
adjacent to the side seam 15. Here again, no adhesive is used in
the precut region. It is recognized that any elastic member may or
may not be precut in the body facing region, depending upon the
properties desired of the absorbent article.
[0054] Fluid permeable top sheets suitable for use with disposable
absorbent articles similar to those of the present disclosure are
well known in the art. The top sheet is sufficiently pervious to
permit liquids (e.g., urine) to readily penetrate. Suitable top
sheets may be woven or nonwoven materials, polymeric materials
(e.g., 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 include
natural fibers (e.g., wood and cotton fibers), synthetic fibers
(e.g., polymeric fibers such as polyester, polypropylene, and
polyethylene fibers). In other embodiments, the top sheet may be
treated with a surfactant to facilitate the transfer of fluid
through the top sheet into the absorbent core.
[0055] Absorbent core materials and configurations for use with
disposable absorbent articles similar to those of the present
disclosure are also well known in the art. The absorbent core may
be configured as a single continuous core or several discontinuous
cores that may or may not be connected in fluid contact. The
absorbent core may be symmetrical or asymmetrical and,
specifically, may be configured to be gender specific. The shape of
the absorbent core will depend upon the specific material used, the
specific application for which the article is used, and the desired
performance characteristics. The absorbent core(s) may consist of
either a single type of absorbent material or may contain multiple
types of absorbent materials. Suitable materials for the absorbent
core include, for example, wood pulp, cellulose wadding, cotton
fibers, absorbent foams, sponges, superabsorbent polymers (e.g.,
hydrogels), absorbent gelling materials, or combinations
thereof.
[0056] Fluid impermeable back sheets for use with disposable
absorbent articles similar to those of the present disclosure are
also well known in the art. Preferably, the back sheet is a
relatively thin (e.g., about 0.012 mm to about 0.051) plastic film.
It is particularly desirable to use back sheets which, while being
impervious to aqueous fluids, allows vapors to escape. Suitable
material for such back sheets include, for example, microporous
polyethylene and polypropylene films. In other configurations, the
back sheet may be a laminate consisting of a fluid impervious film
and a woven or nonwoven outer cover. There is no requirement that
the outer cover be fluid impervious. Frequently the outer cover is
selected for its aesthetic properties.
[0057] The disposable absorbent article of this disclosure may
include structure to fasten the front and back side panels around
the torso of the wearer. Such structure may include, for example,
hooks, snap fasteners, and unilateral or bilateral external
adhesive tabs. Alternatively, an adhesive may be applied directly
to the inside face (e.g., directly on the body facing top sheet or
by way of an adhesive-containing strip affixed to the top sheet) of
either the front or back side panel. The adhesive is exposed by
removing a protective film covering and the inner face of the
adhesive-containing side panel is adhered to the outer face (back
sheet) of the opposite side panel to form a side seam.
[0058] The assembly of the absorbent article may be performed
according to well known principles in the art and may be varied
depending upon the desired performance characteristics. For
example, the absorbent cores may be "free floating" between the top
sheet and back sheet, it may be adhered to the back sheet, or it
may be elastically supported. The top sheet and back sheet may be
joined by, for example, an adhesive or heat sealing (melting) the
materials together. This process encapsulates the absorbent cores
and all of the elastic members within the absorbent article to
provide a unitary structure that is aesthetically appealing.
[0059] Although the foregoing disclosure has been described in some
detail by way of illustration and example for purposes of clarity
of understanding, it will be readily apparent to those of ordinary
skill in the art in light of the teachings of this present
disclosure that certain changes and modifications may be made
thereto without departing from the spirit or scope of the appended
claims.
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