U.S. patent application number 11/638219 was filed with the patent office on 2007-05-10 for three-piece disposable undergarment with stretchable crotch member.
This patent application is currently assigned to Kimberly-Clark Worldwide, Inc.. Invention is credited to Russell E. Thorson, Paul T. Van Gompel.
Application Number | 20070101476 11/638219 |
Document ID | / |
Family ID | 32716854 |
Filed Date | 2007-05-10 |
United States Patent
Application |
20070101476 |
Kind Code |
A1 |
Van Gompel; Paul T. ; et
al. |
May 10, 2007 |
Three-piece disposable undergarment with stretchable crotch
member
Abstract
A disposable undergarment includes a front body panel having a
pair of opposite first side edges, a first terminal edge and a
first cut edge spaced from the first terminal edge and defining a
first wave pattern and a rear body panel having a pair of opposite
second side edges, a second terminal edge and a second cut edge
spaced from the second terminal edge and defining a second wave
pattern. A crotch member includes at least one stretchable
component having an elastic material connected to the front and
rear body panels and stretchable in at least one direction. A first
maximum rise of the front body panel is aligned with and spaced
apart from a second maximum rise of the rear body panel in a
non-overlapping relationship. The crotch member is aligned with and
overlaps the first and second maximum rises of the front and rear
body panels respectively.
Inventors: |
Van Gompel; Paul T.;
(Hortonville, WI) ; Thorson; Russell E.;
(Appleton, WI) |
Correspondence
Address: |
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Assignee: |
Kimberly-Clark Worldwide,
Inc.
|
Family ID: |
32716854 |
Appl. No.: |
11/638219 |
Filed: |
December 13, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10452340 |
Jun 2, 2003 |
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11638219 |
Dec 13, 2006 |
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10261805 |
Oct 1, 2002 |
6979380 |
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10452340 |
Jun 2, 2003 |
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10325500 |
Dec 19, 2002 |
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10452340 |
Jun 2, 2003 |
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Current U.S.
Class: |
2/69 |
Current CPC
Class: |
Y10T 156/1067 20150115;
A61F 13/5148 20130101; Y10T 156/1077 20150115; A61F 2013/51322
20130101; A61F 13/513 20130101; A61F 13/51464 20130101; Y10T
156/1015 20150115; A61F 13/15764 20130101; A61F 13/496 20130101;
A61F 13/15707 20130101; Y10T 156/1008 20150115; Y10T 156/1093
20150115; Y10T 156/1095 20150115; A61F 13/51474 20130101; A41B
9/001 20130101; A61F 13/49017 20130101; A61F 13/539 20130101; Y10T
156/1051 20150115; A61F 2013/49063 20130101; Y10T 156/1097
20150115; A61F 13/15723 20130101; A61F 13/15699 20130101; Y10T
156/1066 20150115; Y10T 156/1087 20150115; Y10T 156/133 20150115;
Y10T 156/1092 20150115; A41B 2400/52 20130101; A61F 13/15804
20130101; A61F 2013/51429 20130101; Y10T 156/1049 20150115; Y10T
156/1734 20150115 |
Class at
Publication: |
002/069 |
International
Class: |
A41D 13/00 20060101
A41D013/00 |
Claims
1. A disposable undergarment comprising: a front body panel
comprising a pair of opposite first side edges, a first terminal
edge and a first cut edge spaced from said first terminal edge and
defining a first wave pattern, said first wave pattern further
defining a first maximum rise and a first minimum rise of said
front body panel along a first direction, wherein said first
maximum rise is greater than said first minimum rise such that said
first cut edge further defines a first amplitude of said first wave
pattern, and wherein said opposite first side edges are spaced
along a second direction, said second direction being substantially
perpendicular to said first direction, said opposite first side
edges defining a first pitch of said first wave pattern, and
wherein said front body panel is stretchable in at least said
second direction; a rear body panel comprising a pair of opposite
second side edges, a second terminal edge and a second cut edge
spaced from said second terminal edge and defining a second wave
pattern, said second wave pattern further defining a second maximum
rise and a second minimum rise along said first direction, wherein
said second maximum rise of said rear body panel is greater than
said second minimum rise such that said second cut edge defines a
second amplitude of said second wave pattern, and wherein said
opposite second side edges are spaced along said second direction,
said opposite second side edges defining a second pitch of said
second wave pattern, and wherein said rear body panel is
stretchable in at least said second direction; and a crotch member
comprising at least one stretchable component comprising an elastic
material connected to said front and rear body panels and
stretchable in at least said second direction, wherein said first
maximum rise of said front body panel is aligned with and spaced
apart from said second maximum rise of said rear body panel in a
non-overlapping relationship, and wherein said crotch member is
aligned with and overlaps said first and second maximum rises of
said front and rear body panels respectively.
2. The disposable undergarment of claim 1 wherein said first and
second wave patterns are substantially the same.
3. The disposable undergarment of claim 1 wherein said crotch
member comprises a back sheet connected to a top sheet and a
retention portion disposed between said back sheet and said top
sheet, wherein at least one of said back sheet and said top sheet
are stretchable and comprise said elastic material.
4. The disposable undergarment of claim 3 wherein each of said
front and rear body panels comprise one or more elastic elements
disposed adjacent said first and second terminal edges and said
first and second cut edges.
5. The disposable undergarment of claim 3 wherein said back sheet
is stretchable and comprises said elastic material.
6. The disposable undergarment of claim 5 wherein said back sheet
comprises a laminate comprising a non-woven material and said
elastic material.
7. The disposable undergarment of claim 1 wherein said front and
rear body panels are extensible in said first direction.
8. The disposable undergarment of claim 1 wherein said crotch
member is connected to a garment side surface of each of said front
and rear body panels.
9. A disposable undergarment comprising: a front body panel
comprising a pair of opposite first side edges, a first terminal
edge and a first cut edge spaced from said first terminal edge and
defining a first wave pattern, said first wave pattern further
defining a first maximum rise and a first minimum rise of said
front body panel along a first direction, wherein said first
maximum rise is greater than said first minimum rise such that said
first cut edge further defines a first amplitude of said first wave
pattern, and wherein said opposite first side edges are spaced
along a second direction, said second direction being substantially
perpendicular to said first direction, said opposite first side
edges defining a first pitch of said first wave pattern; a rear
body panel comprising a pair of opposite second side edges, a
second terminal edge and a second cut edge spaced from said second
terminal edge and defining a second wave pattern, said second wave
pattern further defining a second maximum rise and a second minimum
rise along said first direction, wherein said second maximum rise
of said rear body panel is greater than said second minimum rise
such that said second cut edge defines a second amplitude of said
second wave pattern, wherein said second wave pattern and said
first wave pattern have substantially the same shape, and wherein
said opposite second side edges are spaced along said second
direction, said opposite second side edges defining a second pitch
of said second wave pattern; and a crotch member comprising at
least one stretchable component comprising an elastic material
connected to said front and rear body panels and stretchable in at
least said second direction, wherein said first maximum rise of
said front body panel is aligned with and spaced apart from said
second maximum rise of said rear body panel in a non-overlapping
relationship, and wherein said crotch member is aligned with and
overlaps said first and second maximum rises of said front and rear
body panels respectively.
10. The disposable undergarment of claim 9 wherein said crotch
member comprises a back sheet connected to a top sheet and a
retention portion disposed between said back sheet and said top
sheet, wherein at least one of said back sheet and said top sheet
are stretchable and comprise said elastic material.
11. The disposable undergarment of claim 10 wherein said back sheet
is stretchable and comprises said elastic material.
12. The disposable undergarment of claim 11 wherein said back sheet
comprises a laminate comprising a non-woven material and said
elastic material.
13. The disposable undergarment of claim 9 wherein each of said
front and rear body panels comprise one or more elastic elements
disposed adjacent said first and second terminal edges and said
first and second cut edges.
14. The disposable undergarment of claim 9 wherein said front and
rear body panels are extensible in said first direction.
15. The disposable undergarment of claim 9 wherein said crotch
member is connected to a garment side surface of each of said front
and rear body panels.
16. The disposable undergarment of claim 9 wherein said front body
panel is stretchable in at least said second direction.
17. The disposable undergarment of claim 9 wherein said rear body
panel is stretchable in at least said second direction.
18. A disposable undergarment comprising: a front body panel
comprising a pair of opposite first side edges, a first terminal
edge and a first cut edge spaced from said first terminal edge and
defining a first wave pattern, said first wave pattern further
defining a first maximum rise and a first minimum rise of said
front body panel along a first direction, wherein said first
maximum rise is greater than said first minimum rise such that said
first cut edge further defines a first amplitude of said first wave
pattern, and wherein said opposite first side edges are spaced
along a second direction, said second direction being substantially
perpendicular to said first direction, said opposite first side
edges defining a first pitch of said first wave pattern, and
wherein said front body panel is stretchable in at least said
second direction; a rear body panel comprising a pair of opposite
second side edges, a second terminal edge and a second cut edge
spaced from said second terminal edge and defining a second wave
pattern, said second wave pattern further defining a second maximum
rise and a second minimum rise along said first direction, wherein
said second maximum rise of said rear body panel is greater than
said second minimum rise such that said second cut edge defines a
second amplitude of said second wave pattern, and wherein said
opposite second side edges are spaced along said second direction,
said opposite second side edges defining a second pitch of said
second wave pattern, and wherein said rear body panel is
stretchable in at least said second direction; and a crotch member
comprising at least one stretchable component comprising an elastic
material connected to said front and rear body panels and
stretchable in at least said second direction, wherein said first
maximum rise of said front body panel is aligned with and spaced
apart from said second maximum rise of said rear body panel in a
non-overlapping relationship, and wherein said crotch member is
aligned with and overlaps said first and second maximum rises of
said front and rear body panels respectively, wherein said crotch
member comprises a back sheet connected to a top sheet and a
retention portion disposed between said back sheet and said top
sheet, wherein at least one of said back sheet and said top sheet
are stretchable and comprise said elastic material, wherein said
back sheet is stretchable and comprises said elastic material and
wherein said back sheet comprises a laminate comprising a non-woven
material and said elastic material.
19. The disposable undergarment of claim 18 wherein said first and
second wave patterns are substantially the same.
20. The disposable undergarment of claim 18 wherein said front and
rear body panels are extensible in said first direction.
Description
[0001] This application is a divisional of U.S. application Ser.
No. 10/452,340, filed Jun. 2, 2003, which is a continuation-in-part
of U.S. application Ser. No. 10/261,805, filed Oct. 1, 2002, now
U.S. Pat. No. 6,979,380, and also is a continuation-in-part of U.S.
application Ser. No. 10/325,500, filed Dec. 19, 2002, the entire
disclosures of which are hereby incorporated herein by
reference.
BACKGROUND
[0002] The present invention relates generally to disposable
undergarments, and in particular, to a three-piece undergarment
having a folded, stretchable crotch member and to the method for
the manufacture thereof from a nested front and rear body panel
web.
[0003] Disposable undergarments can be configured in many different
forms. For example, disposable absorbent garments can be configured
as a pant-type, pull-on garment, or as a diaper-type product that
is drawn up between the legs and fastened about the waist with
various fastening systems. Often, absorbent garments include an
outer cover, which forms at least a part of a body panel that is
secured around the waist of the user. In addition, the outer cover
typically extends along a crotch region of the garment.
[0004] Often, the outer cover is made from a single piece of
material, with leg openings cut therein, for example by die
cutting. The material from the leg cut out, which can account for
as much as 20-30% of the total area of the outer cover, typically
is waste material, which must be disposed of or recycled. In
addition, the size of the leg openings formed by a die cutter in a
conventional one-piece outer cover is typically fixed. As such, it
can be expensive and time consuming, and reduces the overall
flexibility of the manufacturing line, to switch dies and alter the
process to manufacture different size garments.
[0005] In response to this problem of waste, some garments are
configured with front, rear and crotch sections formed from a
single web that is divided into two nested halves, as disclosed for
example in U.S. Pat. No. 5,858,151 and Japanese Patent Application
03-176053 A. However, the webs of the U.S. Pat. No. 5,858,151 have
overlapping crotch portions that are directly secured one to the
other. Accordingly, the overall rise of the garment is not readily
varied to accommodate different size users, and the range of sizes
is limited by the extent of the overlapping regions.
[0006] Conversely, the diaper body of Japanese Patent Application
03-176053 A is positioned over the cut-out portions of a front and
back waistband, such that the exposed portion of the waist bands
defining in part the leg holes are linear. Instead, the shape of
the leg hole is determined by the cut shape of the diaper body,
which produces excess material that must be disposed of or
recycled.
[0007] In addition, the crotch member, which is often configured as
an absorbent insert, is typically not stretchable. Often, the
non-stretchable crotch member is secured across its entire width,
which can reduce or otherwise impede the elongation of the body
panel and thereby adversely affect its ability to conform to the
body of the user.
[0008] Therefore the need remains for improved methods and
assemblies for manufacturing undergarments to reduce the waste of
materials while providing improved comfort for the user and
flexibility in manufacturing different size garments.
SUMMARY
[0009] Briefly stated, in one aspect, a method of manufacturing an
undergarment includes moving a web of body panel material in a
longitudinal machine direction and cutting the web of body panel
material along the longitudinal machine direction to thereby form a
rear body panel web and a front body panel web each having a
maximum rise and a minimum rise respectively. The maximum rise of
each of the rear and front body panel webs is greater than the
minimum rise of a corresponding one of the rear and front body
panel webs. The method further includes shifting at least one of
the rear and front body panel webs in the longitudinal machine
direction and thereby aligning the maximum rises of the rear and
front body panel webs. The method further includes aligning a
crotch member with the maximum rises of the rear and front body
panel webs and connecting the crotch member to the front and rear
body panels. The crotch member includes at least one stretchable
component including an elastic material.
[0010] In one embodiment, the cutting of the web of body panel
material along the longitudinal machine direction includes forming
a substantially sinusoidal pattern defining the maximum and minimum
rises of each of the rear and front body panel webs.
[0011] In one embodiment, the front and rear body panel webs are
cut along the lateral cross direction proximate the minimum rise of
each of the front and rear body panel webs. Also in one embodiment,
the crotch member is folded.
[0012] In another aspect, a die is used to cut the web of body
panel material. In one embodiment, the method includes forming a
cut edge along each of the front and rear body panel webs, wherein
the cut edges of the front and rear body panel webs have a first
and second shape respectively. In one embodiment, the first shape
is different than the second shape.
[0013] In another aspect, the wave pattern defining the cut edges
of the front and rear body panel webs is not symmetrical relative
to a centerline extending in the longitudinal machine direction. In
particular, the curve defining the cut edge on one side of the
centerline has a different shape than the curve defining the cut
edge on the other side of the centerline. In one example, the
curves, if continuous on both sides of the centerline, would have a
different wavelength.
[0014] In another aspect, one embodiment further includes
elongating the web of body panel material in the longitudinal
machine direction before cutting the web of body panel web. In this
way, the pitch of the garment can be easily changed simply by
varying the amount of elongation introduced into the web before the
web is cut.
[0015] In yet another aspect, one embodiment of the method further
includes varying a gap formed between the maximum rises of each of
the rear and front body panel webs. In this way, the overall rise
of the garment can be easily changed simply by varying the gap.
[0016] In various embodiments, elastic elements are positioned
along one or more of the outer lateral edges of the inner cut edge
of one or more of the webs.
[0017] In various embodiments, the stretchable crotch member is
formed of an elastic/stretchable material. In one particular
embodiment, one or both of a top sheet and backsheet, with a
retention portion disposed therebetween, are stretchable and
include an elastic material.
[0018] In another aspect, a method includes stretching at least one
of the back sheet and top sheet. In yet another aspect, a method
includes instructing a user on the user of a disposable
undergarment is provided.
[0019] The various aspects provide significant advantages over
other disposable undergarments and methods. For example and without
limitation, the nested body panels of one embodiment maximize the
area of body coverage while minimizing and virtually eliminating
the amount of waste material. In addition, the stretchable crotch
member can be stretched with the body panels to conform to the body
of the user. In addition, the elastic material of the crotch member
allows the crotch member to stretch and retract, further improving
the fit of the garment.
[0020] The foregoing paragraphs have been provided by way of
general introduction, and are not intended to limit the scope of
the following claims. The presently preferred embodiments, together
with further advantages, will be best understood by reference to
the following detailed description taken in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic illustration of a system for
manufacturing an absorbent garment.
[0022] FIG. 2 is a plan view of a web of body panel material being
cut along a longitudinal machine direction.
[0023] FIG. 3 is a plan view of a front and rear body panel web
with a plurality of absorbent inserts being applied thereto.
[0024] FIG. 4 is a plan view of one embodiment of an absorbent
garment in an unfolded configuration.
[0025] FIG. 5 is a plan view of another embodiment of an absorbent
garment in an unfolded configuration.
[0026] FIG. 6 is a plan view of a web of body panel material being
cut along a longitudinal machine direction.
[0027] FIG. 7 is a plan view of a front and rear body panel web
separated in the cross direction and aligned in the machine
direction.
[0028] FIG. 8 is a garment having a front and rear body panel web
formed from the webs shown in FIG. 7.
[0029] FIG. 9 is a plan view of one embodiment of an absorbent
garment in an unfolded configuration.
[0030] FIG. 10 is a cross sectional view of the absorbent garment
shown in FIG. 9 taken along line 10-10.
[0031] FIG. 11 is a cross sectional view of the absorbent garment
shown in FIG. 9 taken along line 11-11.
[0032] FIG. 12 is a cross-sectional view of the absorbent garment
shown in FIG. 9 taken along line 12-12.
[0033] FIG. 13 is a load v. strain graph for an exemplary
stretchable material FIG. 14 is a load v. strain graph for a second
exemplary stretchable material.
[0034] FIG. 15 is a load v. strain graph for an exemplary
non-stretchable material.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
[0035] It should be understood that the term "longitudinal," as
used herein, means of or relating to length or the lengthwise
direction 500. The term "laterally," as used herein, means situated
on, directed toward or running from side to side. The term "first
direction" generally refers to a path, line or course rather than a
vector, and includes and applies equally to opposite orientations
along the path, line or course, including for example and without
limitation movement along a path, line or course in both directions
(as indicated by the bi-directional arrows associated with the
longitudinal and lateral directions 500, 502 in FIG. 9). Likewise,
the term "second direction" generally refers to a path, line or
course rather than a vector (not orientation dependent), and
includes for example and without limitation movement along a path,
line or course in both directions. In one example, the first
direction is defined by and refers to one of the longitudinal and
lateral directions, while the second direction refers to the other
of the longitudinal and lateral directions.
[0036] The term "bodyside" should not be interpreted to mean in
contact with the body of the user, but rather simply means the side
that would face toward the body of the user, regardless of whether
an undergarment is actually being worn by the user and regardless
of whether there are or may be intervening layers between the
component and the body of the user. Likewise, the term "garment
side" should not be interpreted to mean in contact with the
garments of the user, but rather simply means the side that faces
away from the body of the user, and therefore toward any outer
garments that may be worn by the user, regardless of whether the
undergarment is actually being worn by a user, regardless of
whether any such outer garments are actually worn and regardless of
whether there may be intervening layers between the component and
any outer garment.
[0037] The term "machine direction" means the direction of flow as
the various members and webs progress along the fabrication line
and process. It should be understood that various separate members
or webs can each be traveling in a machine direction, but with the
various machine directions not necessarily being parallel or
oriented in the same direction. For example, a first component such
as a web may be traveling a first machine direction, which is
substantially perpendicular to the travel of another component,
such as an absorbent insert, in a second machine direction.
[0038] The term "cross direction" means the direction substantially
perpendicular to the machine direction.
[0039] The term "downstream" means that one item is positioned more
closely to the output or finished product end of the machine and/or
process relative to another item. Conversely, the term "upstream"
means that an item is positioned more closely to the input end of
the machine or process relative to another item. For example, the
output end is downstream of the input end, and vice versa, the
input end is upstream of the output end.
[0040] The phrases "removeably attached," "removeably attaching,"
"removeably connected," "removeably engaged," "releasably
attached," "releasably connected," or "releasably engaged," and
variations thereof, refers to two or more elements being connected
or connectable such that the elements tend to remain connected
absent a separation force applied to one, both or all of the
elements, and where the elements are capable of being separated
upon the application of a separation force. The required separation
force is typically beyond that encountered while wearing the
absorbent garment.
[0041] The phrases "fixedly secured," "fixedly engaged," "fixedly
attached," "fixedly connected," and variations thereof, refers to
two or more elements being connected or connectable such that they
are not disconnected or otherwise separated, and are not intended
to be separated or disconnected, during the normal operation and
use of the absorbent garment.
[0042] The term "web" refers to a continuous stream of material,
whether made from one or more layers or substrates, and regardless
of whether it may have non-continuous, discrete items disposed
thereon.
[0043] The terms "connecting," "coupled," "attached," and
"secured," and variations thereof, broadly covers two or more items
being directly connected one to the other, or by way of one or more
intervening members or components.
[0044] Referring to FIGS. 4, 5 and 9, an undergarment 2 includes a
first, front body panel 4 and a second, rear body panel 6. The term
"body panel" refers to the portion(s) of the undergarment, whether
made of one or more layers or substrates or of one or more pieces
or components, that is/are fitted circumferentially around at least
the waist region of the user, including for example the user's
lower back, buttock, hips and abdomen. The first and second body
panels each have an inner, bodyside surface 10 and an outer,
garment side surface 12. The first, front body panel 4 has a first
edge 14 forming a crotch portion 16 and leg opening portion 18 and
a second terminal edge 20 which, in one embodiment, is linear but
can assume other shapes. Likewise, the second, rear body panel 6
has a first edge 22 forming a crotch portion 24 and a leg opening
portion 26 and a second terminal edge 28, which is shown linear but
can assume other shapes. Each of the first and second body panels
has an outboard side edge 30, 32 formed along the outer periphery
of the opposite side portions of the first and second body panel.
It should be understood that the outboard side edges of the front
and rear body panels can have the same or different lengths
relative to each other.
[0045] Referring to FIG. 5, one or more, and in one embodiment a
plurality, meaning two or more, elastic elements 36 are secured to
each of the first and second body panels. In preferred embodiment,
a plurality of elastic elements are spaced across substantially the
entire waist portion of the front and rear body panel 4, 6,
although they may be spaced across a lesser length. For example,
elastic elements can extend along the upper waist portion and along
the lower terminal edge defining in part a leg opening 34.
[0046] In one embodiment, the front body panel has a
"non-elasticized" area wherein there are no elastic elements, or
other elastic or elastomeric backing members, incorporated therein
or making up any portion of the thickness or cross-section of the
body panel at that area. It should be understood, that in an
alternative embodiment, one or more separate waist bands, with or
without elastic elements, can be secured to one or both of the rear
and front body panels, preferably along the upper terminal edges
20, 28 thereof. Likewise, one or more separate leg bands can be
secured to one or both of the rear and front body panels along the
leg open portions 18, 26 adjacent the leg openings 34.
Alternatively, one or both of the body panels can be formed without
any elastic elements as shown in FIG. 4.
[0047] The various waist and leg elastic elements can be formed
from rubber or other elastomeric materials. One suitable material
is a LYCRA.RTM. elastic material. For example, the various elastic
elements can be formed of LYCRA.RTM. XA Spandex 540, 740 or 940
decitex T-127 or T-128 elastics available from E.I. duPont De
Nemours and Company, having an office in Wilmington, Del.
[0048] Referring to FIGS. 10 and 12, each body panel 4, 6 is
preferably formed as a composite, or laminate material, otherwise
referred to as substrates or laminates, with an elastic core 136
sandwiched therebetween. In one embodiment, the elastic core 136 is
made of an elastomeric film or nonwoven elastic or stretchable
material including for example but not limited to styrenic
copolymers of polyisoprene, polybutadiene or polyolefin, copolymers
of polyolefins, natural or styrene butadiene rubber, polyurethanes,
polyamides, polyesters, and co-extrusions/blends of the
aforementioned materials. The elastic core can be formed as a
membrane or from a plurality of elastic strands, as described
above. In one embodiment, two or more layers 40 are bonded to the
elastic core 136, and/or each other, with various adhesives, such
as hot melt, or by other techniques, including for example and
without limitation ultrasonic bonding and heat pressure sealing. In
one embodiment, the two layers are made of a non-woven material
such as a spunbond material, a bonded carded material or other
known materials. In this way, the body panels are made of a
stretchable/elastic material.
[0049] As used herein, the interchangeable terms "stretchable" and
"elastic," and variations thereof, refer to a material that can
elongate or deform (stretch) in response to the application of a
tensile force under certain test conditions herein defined below,
and upon removal of the tensile force have a length that is less
than about 128% of the original length, which corresponds to
hysteresis of less than about 28%. Thus, a stretchable or elastic
material can be stretched and upon relaxing the material, will tend
to resume its original shape. As used herein, "extensible"
materials are those materials having a length of greater than about
128% of the original length when elongated and relaxed under
certain test conditions herein defined below, which corresponds to
a hysteresis of greater than about 28%.
[0050] It should be understood that the body panels can be made of
a single layer or substrate of non-woven material, a bi-layer
substrate made of non-woven materials without an elastic core, or
more than two layers or substrates. Of course, it should be
understood that other knitted or woven fabrics, non-woven fabrics,
elastomeric materials, polymer films, laminates and the like can be
used to form one or more of the body panel layers. The term
"non-woven" web or material, as used herein, means a web having a
structure of individual fibers or filaments that are interlaid, but
not in an identifiable manner and without the aid of textile
weaving or knitting, as in a knitted or woven fabric.
[0051] In one embodiment, the body panel material can be secured to
the elastic core, such as an elastomeric layer or elastic strands
or ribbons, which have been elongated and retracted, such that the
material is gathered when the elastic element(s) are relaxed.
Alternatively, the material can be gathered and laminated to
non-elongated elastic elements. In one preferred embodiment, the
body panel includes a gathered elastic laminate made from nonwoven
base sheets bonded with elongated elastic elements sandwiched
therebetween.
[0052] In various preferred embodiments, the body panel material
may be substantially permeable to air or substantially impermeable
to air. The body panel material also may be substantially
liquid-permeable or substantially liquid-impermeable. In particular
arrangements, the body panel material may be substantially
nonelastomeric. In other aspects, the body panels can include an
elastomeric material that is elastomerically stretchable at least
along one or both of the lateral article width and the longitudinal
article length. Examples of such elastomeric composite materials
can include a continuous filament stretch bonded laminate (CFSBL),
a vertical filament laminate (VFL), neck-bonded-laminate (NBL), a
stretch-bonded-laminate (SBL), a necked-stretch bonded laminate
(NSBL) or a necked-thermal laminate, or the like, as well as
combinations thereof. Exemplary CFSBL, NBL, SBL, and NSBL materials
are described in U.S. Pat. Nos. 5,226,992, 4,981,747, 4,965,122,
5,336,545, 5,385,775, 5,414,470, 4,720,415, 4,789,699,4,781,966,
4,657,802, 4,652,487, 4,655,760, 5,116,662 and 5,114,781, and
6,323,389, all of which are hereby incorporated herein by
reference. Exemplary VFL materials are described in U.S.
Provisional Patent Application Ser. No. 60/204,307, filed May 15,
2000 and entitled "Method and Apparatus for Producing Laminated
Articles," and PCT application WO 01/88245 A2, both assigned to
Kimberly-Clark Worldwide, Inc., the Assignee of the present
application, with the entire disclosures of both being hereby
incorporated herein by reference. Such laminates can provide an
improved combination of cloth-like feel and elastomeric
stretchability. The body panels can be composed of materials that
are elastic or elastomeric and exhibit biaxial stretch
characteristics or lateral/longitudinal stretch characteristics, or
which are extensible composites. Additional waist and leg elastic
elements can be added to, but are not necessarily required by, the
body panels.
[0053] In one embodiment, the body panel material is extensible but
not elasticized. For example, the body panel can be made of a film
or non-woven that is attached, by way of adhesives or thermal
bonding, to an extensible non-woven material. Alternatively, the
body panel can be made of a low modulus film such as ethylene
methyl acrylate (EMA).
[0054] As shown in the embodiments of FIGS. 9-12, the entirety of
the body panels 4, 6, and the crotch member 50, are elasticized,
such that the entirety of each of the body panels can elongate and
conform to the body of the user without any substantial spacing
between the body panel and the user's body, and without the
attendant bulkiness of a non-elasticized material.
[0055] In one embodiment, the body panels are breathable,
cloth-like, multi-directional nonwoven laminates with stretch or
extensible properties. In one embodiment, the non-woven layers are
pre-necked, for example between about 10% and about 80%, in the
longitudinal direction, which provides extensibility in the
longitudinal direction with minimal force.
[0056] In one embodiment, the body panel members 4, 6 are made of
non-woven laminates of two layers of longitudinally extensible 0.60
osy polypropylene spunbond material with elongated strands of
Lycra.RTM. elastic sandwiched between the spunbond layers and
thereafter adhesively bonded. In particular, the body panel
material is necked in the cross direction. As used herein, the term
"necked," and variations thereof, refers to any material that has
been constricted in at least one dimension by applying a tensioning
force in a direction that is perpendicular to the desired direction
of neck-down. Processes that may be used to constrict a material in
such a manner include, for example and without limitation, drawing
processes. The elastics are then elongated in the machine direction
and secured to the body panel material. The elastics are then
allowed to retract so as to gather the necked spunbond material in
the lateral (machine) direction thereby creating an elastically
gathered non-woven body panel with longitudinal extensibility. The
term "gather," and variations thereof, as used herein means
puckered, or contracted into folds or wrinkles, which should be
understood as including micro-pleats.
[0057] In this way, the body panel can be elongated in both the
longitudinal and lateral direction to conform to the body of the
user when the garment is applied thereto. In particular, as the
user pulls the garment up over their hips, the non-woven laminate
body panels stretch in the lateral direction while the leg regions
of the front and rear body panels conform to the crotch and body
lines of the user. At the same time, the body panel material
extends in the longitudinal direction to conform to the buttocks
and stomach of the user. The extensibility of the body panels
follows the natural curvature of user's body to provide conformance
thereto. As the body panel extends in the longitudinal direction,
the spacing between the laterally extending elastic elements,
incorporated in one embodiment, will increase.
[0058] The body panel non-woven material is preferably
substantially hydrophobic, which may optionally be treated with a
surfactant or otherwise processed to impart a desired level of
wettability and hydrophilicity. In one particular embodiment of the
invention, the body panel is a nonwoven, wire-weave spunbond
polypropylene fabric composed of about 1.6 denier fibers formed
into a web having a basis weight of about 0.6 osy. One suitable
non-woven material is the Corinth 0.60 osy, 1.6 dpf wireweave,
nonwettable Metallocene (EXXON ACHIEVE 2854 PP) spunbond material
manufactured by Kimberly-Clark Corporation, the Assignee of the
present application.
[0059] The crotch member 50 of the various undergarments connecting
the front and rear body panels 4, 6 can be folded such that the
side edges 30, 32 of the front and rear body panels 4, 6 are
aligned, whereinafter they can be fixedly secured at a seam to form
the leg opening 34. The seam can be formed by bonding, sewing or
otherwise attaching the side edges. Alternatively, the product can
remain "open," wherein the body panels are releasably secured with
one or more fastening members as explained below.
[0060] In one embodiment, the garment includes a combination of
side edges that are secured to form a seam and fastening members
that allow the fit of the undergarment to be adjusted. For example,
in one embodiment, fastening members are preferably attached to the
front body panel and extend inboard relative to the outboard side
edge of the front body panel from an attachment location, which is
preferably spaced inboard from the side edge. A landing member can
be formed on or secured to the body panel to receive a refastenable
portion of the fastening member. One or more lines of weakness can
be provided along the front or rear body panel such that one or
both of the body panels are breakable. The lines of weakness can
comprise a perforation or other series of cuts, a thinning,
breakage or separation of material, or a strip of a different kind
of material bridging portions of the body panel that is more easily
torn or broken than the other material thereof, which allow a user
or the manufacturer to separate portions of the body panel. For
example, the undergarment can be broken along the lines of weakness
after the garment is applied to a user, or beforehand. In one
embodiment, the fastening members are secured to the garment-side
surface of the body panel.
[0061] It should be understood that, in other embodiments, the
fastening members can be secured to the rear body panel and engage
the front body panel or, conversely, can be secured to the front
body panel and engage the rear body panel, preferably along at
least a portion that is not elasticized. In one embodiment, the
fastening members are fixedly secured to the outer, garment-side
surface of the front and/or rear body panels, and releasably engage
the outer, garment-side surface of the front and/or rear body
panels, although it should be understood that the fastening members
could be fixedly secured to an inner body-side surface of front
and/or rear body panels and releasably engage an inner, body-side
surface of the front and/or rear body panels.
[0062] When incorporated into a disposable absorbent undergarment,
the fastening members can include a refastenable portion, such as
an array of hook members, adhesives, such as pressure sensitive
adhesives, buttons, zippers, snaps and other releasable and
reattachable fastening devices. In various embodiments, the
fastening member includes one, two or more than two tab members. In
one embodiment, the fastening members comprise a carrier member,
which is preferably fixedly secured to the side portions of the
front body panel with adhesive bonds, sonic bonds, thermal bonds,
pinning, stitching or other known types of attachment. In
alternative embodiments, the fastening members can be fixedly
secured to the rear body panel or to one or both of the front and
rear body panels, for example, at the seam, as explained above.
[0063] Referring to the embodiments of FIGS. 4-5 and 9-12, the
crotch member 50 is formed as a separate subassembly connected to
either the bodyside or garment side surface 10, 12 of the body
panel members 4, 6. In either embodiment, the crotch member 50 has
first and second opposed terminal end edges 60, 62. The crotch
member 50 bridges the gap between the terminal edges 14, 22 of the
body panels 4, 6 and is connected respectively to those body panels
at attachment locations 88. The crotch member 50 that overlaps the
body panels or body chassis member can be minimally attached
thereto with an attachment having a width of between about 10% and
about 100% of the width of the absorbent insert. For example, the
crotch member can be attached to the body panels along the
longitudinal side edges of the crotch member, or alternatively
along a centerline such that the edges of the absorbent insert are
not attached to the body panels or body chassis. In another
embodiment, the entirety of the portion of the crotch member that
overlaps the body panels can be attached thereto. The crotch member
can be secured to the body panels when they are in a stretched or
unstretched condition.
[0064] The attachment location can extend along the entire length
of the overlapping portion of the crotch member, along only a
portion of the length, or at a discrete point, for example
proximate midway between the ends 60, 62 of the crotch member. In
another embodiment (not shown), the attachment location can be
formed from a plurality of discrete attachment locations spaced
longitudinally along the centerline. In other alternatives, the
terminal edges of the crotch member 50 can be attached to the body
panels, or the crotch member can be secured to the body panels
along the terminal crotch edges 14, 22 thereof.
[0065] In one embodiment, shown in FIGS. 9-12, the crotch member is
configured as an absorbent insert 50, which includes a
substantially liquid permeable top sheet 64, or liner, and a
substantially liquid impermeable back sheet 66. A retention portion
70 is disposed or sandwiched between the topsheet and the
backsheet, which are connected. It should be understood that the
term "absorbent insert" refers to any material or assembly capable
of absorbing liquids or bodily exudates, and may be formed from a
single material or component, for example a retention portion, or
can be formed as a composite of several components. It should also
be understood that the term "crotch member" refers to any member of
any material, including for example and without limitation those
described herein with respect to the body panels and absorbent
inserts, and is no limited to absorbent inserts and/or materials.
For example, the crotch member may be made of one or more layers of
a non-woven material. It should further be understood that when the
crotch member does not include an absorbent material, it can still
be used in conjunction with various disposable absorbent pads such
as adult incontinent and/or feminine pads so as to improve the
performance and comfort of those pads by maintaining them in close
proximity to the body of the user.
[0066] Referring to FIGS. 1-9, the top sheet 64, back sheet 66 and
other components of the absorbent insert can be joined for example
with adhesive bonds, sonic bonds, thermal bonds, pinning, stitching
or any other attachment techniques known in the art, as well as
combinations thereof. For example, a uniform continuous layer of
adhesive, a patterned layer of adhesive, a sprayed pattern of
adhesive or any array of lines, swirls or spots of construction
bonds may be used to join the topsheet and backsheet, or any of the
other components described herein.
[0067] In one embodiment, one or more crotch elastic members 38 are
sandwiched between the top sheet 64 and backsheet 66 along the side
edges thereof. The elastic members 38 can extend the entire
longitudinal extent of the absorbent insert, or along only a
portion thereof.
[0068] Additional layers, including for example, a liquid
acquisition and distribution layer 72, also referred to as a surge
or transfer layer, are also preferably incorporated into the
absorbent insert. In one embodiment, the transfer layer does not
run the entire length of the absorbent insert and is shorter than
the retention portion.
[0069] In one embodiment, the retention portion 70, transfer layer
72 and other components, such as tissue layers, are free floating
(unattached) between the back sheet 64 and the top sheet 66, which
are secured along only the peripheral edges thereof. Alternatively,
the retention portion 70, transfer layer 72 and other components
are minimally attached to one or both of the back sheet 66 and top
sheet 64. For example, the retention portion can be secured to the
back sheet along an attachment location positioned along the
longitudinal centerline 108 of the retention portion.
Alternatively, or in combination with the back sheet connection,
the transfer layer or retention portion can be minimally attached
to the top sheet. In this way, the retention portion 70, transfer
layer 72 and other components do not impede or substantially affect
the lateral stretchability and extensibility of the absorbent
insert 50 and in particular the top sheet and back sheet, at least
one of which is secured to the body chassis.
[0070] In another alternative embodiment (not shown), the retention
portion is secured along the centerline at a point midway between
the two ends of the retention portion. In this embodiment, the
retention portion also does not restrict or impede the
stretchability and extensibility of the absorbent insert, and in
particular the top sheet and back sheet, in the lateral or
longitudinal directions 500, 502.
[0071] In other embodiments, the top sheet is indirectly joined to
the backsheet by affixing the topsheet to intermediate layers, such
as the surge layer or retention portion, which in turn is affixed
to the backsheet. The absorbent insert also may include barrier
cuffs, or leakage control shields, formed along the opposite
longitudinally extending edges of the absorbent composite.
[0072] In one embodiment, the back sheet 66 is a stretchable,
elastic, liquid impervious member. Alternatively, the back sheet
may be liquid permeable, e.g., when an additional barrier layer is
used with the retention portion. In one embodiment, shown in FIGS.
9-12, the back sheet 66 is a laminate structure made of a
stretchable, elastic material, such as an elastomeric film 80,
which is laminated to an extensible non-woven material layer 82. It
should be understood that the backsheet can be formed from a single
layer or substrate or more than two layers or substrates. The
backsheet can be stretchable in both the lateral and longitudinal
direction, or be stretchable in one direction and extensible in the
other.
[0073] The backsheet 66 prevents various bodily fluids and exudates
from wetting or otherwise contaminating various bedding or outer
garments worn by the user over the absorbent garment. The backsheet
can be made of the same materials described above in connection
with the body panels. In one embodiment, the backsheet can include
a film, which can be made of the various materials described
above.
[0074] The backsheet may include a micro-porous, "breathable"
material which permits gases, such as water vapor, to escape from
the absorbent garment while substantially preventing liquid
exudates from passing through the backsheet. For example, the
breathable backsheet may be composed of a microporous polymer film
or a nonwoven fabric which has been coated or otherwise modified to
impart a desired level of liquid impermeability. For example, a
suitable microporous film can be a PMP-1 material, which is
available from Mitsui Toatsu Chemicals, Inc., a company having
offices in Tokyo, Japan; or an XKO-8044 polyolefin film available
from 3M Company of Minneapolis, Minn. The backsheet may also be
embossed or otherwise provided with a pattern or matte finish to
exhibit a more aesthetically pleasing appearance.
[0075] In various embodiments, where a component, such as the
backsheet is configured to be permeable to gas while having a
resistance and limited permeability to aqueous liquid, the liquid
resistant component can have a construction which is capable of
supporting a selected hydrohead of water substantially without
leakage therethrough. A suitable technique for determining the
resistance of a material to liquid penetration is Federal Test
Method Standard FTMS 191 Method 5514, 1978, or an equivalent
thereof.
[0076] In one embodiment, the backsheet is sufficiently impermeable
to liquid and semi-liquid materials to substantially prevent the
undesired leakage of waste materials, defined as exudates,
including for example urine and feces. For example, the backsheet
member can desirably support a hydrohead of at least about 45
centimeters (cm) substantially without leakage. The backsheet
member can alternatively support a hydrohead of at least about 55
cm, and optionally, can support a hydrohead of at least about 60
cm, or more, to provide improved benefits.
[0077] In one example, the backsheet can be composed of a necked
fiber, a creped fiber, a micro-pleated fiber, polymer films or the
like, as well as combinations thereof. The fabrics may be woven or
nonwoven materials, such as spunbond fabrics. One example of a
suitable extensible material is a 60% necked, polypropylene
spunbond having a basis weight of about 1.2 osy.
[0078] Three types of backsheet materials were tested for
stretchability/extensibility.
EXAMPLE 1
VFL Material
[0079] The material is a three-ply laminate having inner and outer
facing layers of 0.46 ounces per square yard (osy) polypropylene
spunbond material (Kimberly-Clark Delta white polypropylene
spunbond) and a middle layer of 10 grams per square meter (gsm)
Kraton.RTM. 666 elastomer strands (3 mm apart) elongated to 4.5 to
5.5 times. The three piece laminate is adhesively laminated with
2.5 gsm Bostik Findley H2096 adhesive. This VFL material was tested
as explained below and as shown in FIG. 13.
EXAMPLE 2
Necked Liner Laminate
[0080] The material is made of a two-ply laminate consisting of a
soft co-extruded film laminated to a necked nonwoven material. In
particular, the material is made of a layer of 0.4 ounces per
square yard (osy) polypropylene spunbond material (Kimberly-Clark
Delta white polypropylene spunbond) that was necked 35% (to 65% of
initial width) to a final basis weight of 0.6 osy and laminated to
a Pliant Film XP-8600 0.7 mil (CaCO3 metallocene Dow Affinity and
Dowlex 2035 LLDPE co-extruded film). This material was tested as
explained below and as shown in FIG. 14.
EXAMPLE 3
Necked Liner
[0081] The material was made of a nonwoven 0.4 ounces per square
yard (osy) polypropylene spunbond material (Kimberly-Clark Delta
white polypropylene spunbond) that was necked 65% (to 35% of
initial width) to a final basis weight of 0.7 osy. This material
was tested as explained below and as shown in FIG. 15.
[0082] Referring to FIGS. 13-15, force/strain curves are shown for
each of the three exemplary backsheet materials. The stress/strain
curves were developed from a test to determine the "stretchability"
of "extensibility" of the material, as those terms are defined
above. The "Stretchability/Extensibility" test is as follows:
[0083] Test Procedure (One-Cycle Tensile Test (without hold time)):
[0084] 1. A 2 inch wide by 5 inch long specimen was cut from a
sheet of sample material. The stretchable direction of the material
was in the length direction of the specimen, which is also the test
direction. [0085] 2. The one-cycle tensile test was conducted on a
tensile tester (Model: Synergie 200 available from MTS) located in
a room where the temperature was maintained at 23 degrees C. and
with a relative humidity at 50%. [0086] 3. The distance between the
lower and upper jaws of the tensile tester were set at 3 inches.
[0087] 4. The jaws were clamped onto the specimen. [0088] 5. The
moving (upper) jaw was activated to travel at a constant rate of 5
inches/minute away from the stationary (lower) jaw. The moving jaw
was stopped at an extension of 1.8 inches (60% extension). [0089]
6. The moving jaw then returned immediately to its initial starting
position at a rate of 5 inches/minute. [0090] 7. The load v. %
strain for the tension and retraction cycle was recorded on a
computer equipped with TestWorks Version 3.10 software program
available from MTS.
[0091] As shown in FIGS. 13 and 14, the VFL and Necked Liner
Laminate materials are stretchable as that term is defined above,
meaning that they have a hysteresis strain of less than about 28%,
or a length of less than about 128% of the original length. As
shown in FIG. 15, the Necked Liner material has a hysteresis of
greater than about 28%, or a length greater than about 128%, such
that it is extensible rather than stretchable as those terms are
defined above.
[0092] In various constructions, the top sheet 64 can include
various woven or nonwoven materials and laminates, which can be
stretchable or extensible. In one embodiment, the top sheet 64,
shown in FIGS. 9-12, is an extensible material, such as a necked
spunbond material. For example, the topsheet can be composed of a
meltblown or spunbonded web of desired fibers, and may also be a
bonded-carded web. For example, the topsheet and liner can be made
of a substantially hydrophobic material, and the hydrophobic
material may optionally be treated with a surfactant or otherwise
processed to import a desired level of wettability and
hydrophilicity. In one particular embodiment of the invention, the
topsheet is a nonwoven, spunbond polypropylene fabric composed of
about 2.8-3.2 denier fibers formed into a web having a basis weight
of about 22 gsm and density of about 0.06 gm/cc. The fabric can be
surface treated with an operative amount of surfactant, such as
about 0.28% Triton X-102 surfactant. The surfactant can be applied
by any conventional means, such as spraying, printing, brush
coating or the like. In another embodiment, the top sheet can also
include an elastic material, such that it is stretchable.
[0093] The retention portion 70 is made of an absorbent material,
which can be any material that tends to swell or expand as it
absorbs exudates, including various liquids and/or fluids excreted
or exuded by the user. For example, the absorbent material can be
made of airformed, airlaid and/or wetlaid composites of fibers and
high absorbency materials, referred to as superabsorbents.
Superabsorbents typically are made of polyacrylic acids, such as
FAVOR 880 available from Stockhausen, Inc. of Greensboro, N.C. The
fibers can be fluff pulp materials, such as Alliance CR-1654, or
any combination of crosslinked pulps, hardwood, softwood, and
synthetic fibers. Airlaid and wetlaid structures typically include
binding agents, which are used to stabilize the structure. In
addition, various foams, absorbent films, and superabsorbent
fabrics can be used as an absorbent material. Various acceptable
absorbent materials are disclosed in U.S. Pat. No. 5,147,343 for
Absorbent Products Containing Hydrogels With Ability To Swell
Against Pressure, U.S. Pat. No. 5,601,542 for Absorbent Composite,
and U.S. Pat. No. 5,651,862 for Wet Formed Absorbent Composite, all
of which are hereby incorporated herein by reference. Furthermore,
the proportion of high-absorbency particles can range from about 0
to about 100%, and the proportion of fibrous material from about 0
to about 100%. Additionally, high absorbency fibers can be used
such as Oasis type 121 and type 122 superabsorbent fibers available
from Technical Absorbent Ltd., Grimsby, Lincolnshire, United
Kingdom.
[0094] The retention portion preferably can be made of a single or
dual layer of absorbent material. In one embodiment, the retention
portion has an hour-glass shape with enlarged end regions.
Alternatively, the retention portion is substantially rectangular.
The retention portion can include a folded or multi-layered
configuration. Likewise, the entire absorbent insert can have a
folded configuration, with various folds formed from one or more of
the backsheet, top sheet, retention portion or other components.
The retention portion can have a length substantially equal to, or
slightly shorter than, the length of the absorbent insert. The
retention portion can include one or more barrier layers attached
to the absorbent material. In one embodiment, an upper tissue
substrate 74 is disposed adjacent the retention portion.
Alternatively, a lower tissue substrate 75 can be disposed adjacent
an opposite side of the retention portion, or the tissue can
completely envelope the retention position.
[0095] Referring to FIGS. 3-5 and 9, the opposite garment side of
the end regions of the absorbent insert 50, and in particular, the
outer, garment side surface of the back sheet 66, are connected to
the bodyside surface of the first and second body panels 4, 6 at
attachment locations 88. It should be understood that in an
alternative embodiment, the absorbent insert, for example the body
side thereof, can be connected to the garment side surface of the
first and second body panels as explained above. It should be
understood that the absorbent insert 50 can be secured using any of
the methods of attachment described above, including for example
various adhesives, stitching or other bonding methods. The
absorbent insert can be secured to the body panels with any
configuration of attachment lines, swirls, patterns, spots, etc.,
or can be a full and continuous attachment therebetween.
[0096] In operation, the user applies the undergarment to their
body, whether by way of pulling it up around their waist as a
pant-like garment or by way of fastening it about their waist with
fasteners as a diaper-like garment. As the garment is applied or
fitted to the body of the user, the front and rear body panels 4, 6
are elongated from a first condition, preferably relaxed, to a
second condition, preferably elongated, in at least one direction,
preferably the lateral direction 502. Of course, the body panel
members can also elongate in the longitudinal direction 500 from
the crotch to the waist. In one embodiment, one or both of the body
panels 4, 6 is elongated in a lateral direction 502 between about
20% and about 300%, in another embodiment between about 50% and
about 200%, and in another embodiment between about 100% and about
150%, as it is applied to the user. The body panel members are
elongated by virtue of a tensile force being applied thereto as
they conform to the body of the user.
[0097] As one or both of the body panel members 4, 6 are elongated,
with the attendant application of a tensile force, the absorbent
insert, which includes in one embodiment an extensible top sheet 64
and a stretchable/elastic back sheet 66, stretches or elongates
with the body panels. The back sheet can be elongated in one
embodiment between about 20% and about 150%, in another embodiment
between about 40% and about 125% and in another embodiment between
about 50% and about 100%. Since, in one embodiment, the retention
portion 70 is free floating, or alternatively is minimally attached
to the stretchable top sheet and the stretchable/elastic back
sheet, e.g., along the longitudinal center line 108, the retention
portion 70 does not restrict the elongation of the back sheet 66
and top sheet 64, or the attached body panels 4, 6.
[0098] In another aspect, the manufacturer or retailer of the
afore-described absorbent garments provides instructional
information to the user, for example by way of textual or pictorial
indicia on the packaging materials, about how the garment works.
For example, the manufacturer or retailer can explain to the end
user the advantages of the stretchable/elastic absorbent insert,
and the resultant ability of the body panels to freely conform to
the body of the user without restriction from the retention
portion, thereby improving the conformance and fit of the
garment.
[0099] Referring to FIGS. 1-8, the method for fabricating one or
more embodiments of the aforedescribed refastenable absorbent
garment is illustrated. Referring to FIGS. 1, 2, 6 and 7, a web 72
of body panel material is cut in a longitudinal machine direction
74 to form a front and rear body panel web 76, 78. Preferably, the
web 72 is cut in a sinusoidal wave pattern, which should be broadly
interpreted as a pattern having peaks 54, 154 and valleys 56, 156,
with the pattern generally defined by a pitch P and an amplitude A,
A1. The pattern can be formed of undulating curves or wave
patterns, or can include or be made entirely of various linear
portions.
[0100] Each body panel web includes an outer lateral edge 80, 82
and an inner cut edge 84, 86. In one embodiment, shown for example
in FIG. 3, the inner cut edges 84, 86 of the front and rear body
panel webs correspond, or mate such that they have the same shape
and amplitude. In such an embodiment, no waste material is
generated.
[0101] In an alternative preferred embodiment, shown in FIGS. 6-8,
the wave pattern defining the first and second cut edges 84, 86 has
a first and second shape 102, 104 formed on opposite sides of a
wave baseline 100, which extends in the longitudinal machine
direction approximately half way between the peaks 54, 154 and
valleys 56, 156 of the cut edges. In this embodiment, the first
shape 102 is different from said second shape 104, with each shape
having a different curvature. In particular, the first shape 102
has a first wavelength L1 and the second shape 104 has a second
wavelength L2. Preferably, the first wavelength L1 is greater than
the second wavelength L2. In this way, as shown in FIG. 8, the
front body panel 4 can be provided with a different shape than the
rear body panel 6. For example, the undergarment can be configured
as a thong shaped undergarment with a relatively narrow rear body
panel 6.
[0102] In another preferred embodiment, a die cutter 100 is used to
cut the web. The die cutter is configured to form inner cut edges
84, 86 on the front and rear body panels having different shapes
and amplitudes A, A1, as shown for example in FIG. 2. In such an
embodiment, a minimal amount of waste material is generated, but it
allows for the front and rear body panels to be specifically shaped
to conform to the body of the user. For example, the shape of the
rear body panel web 78 cut edge 86 can be provided with lesser
amplitude A1 than the amplitude A of the front body panel web 76.
In this embodiment, a minimal amount of waste material 42 is
produced. In one embodiment, one of the body panels is formed with
a wave pattern, or substantially sinusoidal cut edge, while the
other is configured with a straight cut edge. In various
alternative embodiments, the cut edges can be formed by an
oscillating cutter, slitters, water jets, lasers and other known
cutting devices.
[0103] In the preferred embodiment, each of the front and rear body
panel webs 76, 78 has a maximum rise (Max R), measured at the peak
54, 154 and forming crotch portion lobes 16, 24 (along the
centerline of the garment), and a minimum rise (Min R), measured at
the valley 56, 156. The term "rise," as used herein, means the
measured distance between two edges, for example the outer edge 80,
82 and the inner cut edge 84, 86 of each of the front and rear body
panel webs 76, 78 respectively. The total rise of the garment is
measured between the outer edges 20, 28 of the front and rear body
panels, or body panel webs, after the crotch member is connected
thereto. Preferably, one or both of the front and rear body panel
webs are shifted in the longitudinal machine direction, as shown to
align the maximum rises, or peaks 54, 154, of the front and rear
body panels, which also results in the alignment of the minimum
rises, or valleys 56, 156, of the front and rear body panels. In a
preferred embodiment, the maximum rises, defining lobes 16, 24 of
the absorbent garment, have a profile in plan view that extends
outwardly relative to the waist edge 20, 28. As shown in FIG. 1, a
first and second conveyor 102, 104 can simply be spaced apart so as
to provide for a longer travel for one of the front and rear body
panel webs 76, 78.
[0104] Referring to FIGS. 1 and 2, the front and rear body panel
webs 76, 78 are also separated, or shifted, outwardly relative to
one another in the lateral cross-direction 94 so as to form a gap
88 between the cut edges 84, 86 of the front and rear body panel
webs 76, 78 at the maximum rise formed at the respective peaks 54,
154. In various embodiments, the spacing between the cut edges at
the maximum rise of the respective front and rear body panels
(i.e., the closest spacing between the front and rear body panels)
is preferably between about 1% and about 90% of the total rise of
the garment, more preferably between about 10% and about 60% of the
total rise of the garment, and most preferably between about 20%
and about 40% of the total rise of the garment. In addition, in
various embodiments, the spacing between the cut edges at the
maximum rise of the respective front and rear body panels is
preferably between about 10 mm and about 800 mm, more preferably
between about 50 mm and about 500 mm, and most preferably between
about 100 mm and about 300 mm. In an alternative embodiment, the
cut edges and the crotch portions of the front and rear body panels
overlap, and can be secured one to the other. In such an
embodiment, the panels can be separated slightly, or can simply be
shifted in the longitudinal direction without any lateral
separation.
[0105] In one embodiment, the front and rear body panel webs 76, 78
are separated such that no portions of either web overlap each
other. For example, and referring to FIG. 1, in one embodiment, a
first pair of rollers 106 can be angled or twisted to laterally
spread the front and rear body panel webs 76, 78 a first amount
before they are shifted in the longitudinal machine direction. A
second pair of rollers 108 can be angled or twisted to laterally
spread the front and rear body panel webs 76, 78 a second amount
after they are shifted in the longitudinal machine direction. Of
course, it should be understood that the front and rear body panels
can be first shifted in the longitudinal machine direction the
desired amount and then separated in the lateral cross direction
the entire desired amount, or they can also be first separated in
the lateral cross direction the entire desired amount and then
shifted in the longitudinal machine direction. In another
embodiment, the portions of the lobes or peaks of the body panels
overlap each other.
[0106] After the body panel webs 76, 78 are aligned and separated,
regardless of the order thereof, a plurality of crotch members 50,
for example absorbent inserts, are positioned in the lateral cross
direction so as to bridge the gaps 88 between the body panel webs
76, 78 at successive peaks 54, 154 or lobes 16, 24 where the
maximum rises of the body panel webs are aligned at the centerline
of the absorbent garment. It should be understood that the term
"gap" as used herein includes a "zero" distance between the
respective cut edges, wherein the cut edges abut but do not
overlap. The crotch members 50 are secured to the body panel webs
76, 78 as explained above. It should be understood that the crotch
members 50 are secured in one embodiment to a bodyside surface 90,
92 of the body panel webs 76, 78, although they can also be secured
to the garment side thereof as explained above with respect to
FIGS. 9-12. In one embodiment, the crotch members, for example the
absorbent inserts, are assembled offline and are then applied to
the front and rear body panel webs 76, 78 as those webs are carried
by a construction drum 110.
[0107] As shown in FIG. 1, the crotch member is preferably rotated
using an offset cam action rotator 112. The rotator includes a
plurality of transfer segments 126, which can have a vacuum applied
thereto, that engage the crotch member 50. Coupler arms 127 connect
the transfer segments and a drive ring. The coupler arm 127
includes a cam end having a cam follower that follows the profile
of a cam mechanism. The profile of the cam mechanism can be readily
changed to change the desired speed output and pitch of the crotch
member. In one preferred embodiment, the rotator is configured to
accelerate the crotch member. If the successive crotch members 50
are separated by a perforation, the transfer segment 126 breaks the
perforation as it engages one crotch member and moves away from the
next crotch member, which is engaged by a next transfer segment
126. The rotator rotates the end portion of the transfer segment,
preferably approximately 90 degrees, about a radial axis, such that
the crotch member is oriented in the machine direction as described
above as the transfer segments are rotated about a horizontal axis
128. Alternatively, the landing material and fastener material are
cut and separated by the transfer segments. The rotator, and the
method for the use thereof, is further disclosed in U.S. Pat. Nos.
5,761,478, 5,759,340, and 6,139,004, and U.S. patent application
Ser. No. 10/038,766, entitled "Apparatus For Applying Discrete
Parts to A Moving Web," filed Jan. 2, 2002, all of which are
assigned to Kimberly-Clark Worldwide, Inc., the Assignee of the
present application, and the entire disclosures of all of which are
hereby incorporated herein by reference. Alternatively, the
subassembly can be rotated using a revolving transfer roll as shown
and described in U.S. Pat. No. 4,608,115, which is assigned to
Kimberly-Clark Worldwide, Inc., the Assignee of the present
application, and which is hereby incorporated herein by reference
in its entirety.
[0108] Referring to FIGS. 1 and 4, after the crotch members 50 are
secured to the body panel webs 76, 78 across the gap 88, the
assembly is conveyed on a conveyor 114 to a helical folder 116,
wherein the undergarments, and in particular the crotch members,
are successively folded such that the front and rear body panel
webs 76, 78 are positioned in an overlapping, or overlying
relationship, preferably with the outer edges 80, 82 aligned. In
various alternative embodiments, the body panel webs 76, 78 can be
secured, for example by bonding, along a lateral cross direction at
the area of minimum rise, or valleys 56, 156 to form the side seam
48. The front and rear body panel webs 76, 78 are then cut along
the lateral cross direction along the seam 48 to form a plurality
of discrete disposable undergarments, each having a front and rear
body panel 4, 6. Alternatively, the front and rear body panel webs
76, 78 can be first cut at the area of minimum rise, or valleys 56,
156, and the crotch member 50 thereafter folded. Various
refastenable fastening members can be applied to the front and rear
body panels 4, 6 or front and rear body panel webs 76, 78 before or
after the various cutting and folding operations. In yet another
preferred embodiment, as explained above, the undergarment can be
configured with side seams which secure the front and rear body
panels, and refastenable fastening members, which bridge lines of
weakness formed in one or the other of the body panels.
[0109] The elastic elements 36 are preferably incorporated into the
web 72 of body panel material prior to cutting the web 72 to form
the front and rear body panel webs 76, 78. If leg elastics are
desired, preferably they are integrated into the web 72 along a
pattern that will follow the cut edge 84, 86 on each of the front
and rear body panel webs 76, 78. Of course, it should be understood
that the elastics could be secured to the body panel webs after
they are formed by the die cutter, or other cutting operation. In
addition, the elastics can be non-continuous and intermittently
spaced along the longitudinal direction such that they are
incorporated along only the leg opening portions 18, 26 of the body
panel webs and body panels.
[0110] The pitch (P) of the undergarment can be easily and quickly
adjusted without the need to change over to new dies. The term
"pitch" as used herein means the distance between any two adjacent
things in series, and in particular between the valleys 56, 156 or
side edges 30, 32 of the finished undergarment. In particular, the
web 72 of body panel material is simply stretched or elongated
various predetermined amounts before it is cut to form the front
and rear body panel webs 76, 78. For example, the largest waist/hip
size is provided when the web 72 of body panel material is
introduced into the cutting operation, or die cutter, with no
elongation or stretch in the longitudinal machine direction. The
smallest waist/hip size is provided when the web 72 of body panel
material is elongated or stretched to its maximum capability, such
that after the cutting operation, the front and rear body panel
webs 76, 78 retract to form a garment having a smaller pitch (P)
between the valleys. In one preferred embodiment, the elongation of
the body panel material is between about 20% and about 400%, in a
more preferred embodiment the elongation is between about 50% and
about 300%, and in a most preferred embodiment the elongation is
between about 100% and about 200%. The final size or pitch of the
undergarment is also determined by the process and positioning of
the side seams, and the distance therebetween.
[0111] The rise (R) of the undergarment, measured between the outer
edges 20, 28, also can be easily and quickly adjusted without the
need to change over to new dies. In particular, the front and rear
body panel webs are simply spaced apart in the lateral cross
direction varying amounts, preferably with the gap being less than
the length of the crotch member. For example, for a smaller garment
having a lesser rise, the front and rear body panel webs 76, 78 are
spaced closer together, with a smaller gap 88 or by overlapping the
body panels, than for a garment having a greater rise.
[0112] Preferably, the same crotch member 50 can be used in any of
the garments, regardless of the pitch and rise. In this way, the
overall simplicity and efficiency of the system and method is
greatly improved, and there is no need to maintain inserts of
different sizes in inventory, or to provide manufacturing
capabilities to produce different size inserts. Indeed, the
preferred embodiment of the method provides for a system of
manufacturing a three-piece disposable undergarment with minimal
waste, while providing flexibility to manufacture different size
garments at minimal cost.
[0113] In another use, the folded configuration of the absorbent
insert (not shown) in combination with the absorbent insert being
attached to the garment side of the body panels, allows for the
absorbent insert to expand outwardly as it is insulted by the user.
This expansion is effected without affecting the fit to the body of
the user. In addition, the lobes of the body panels 4, 6, which
extend over portions of the absorbent insert 50, provide a physical
barrier between the absorbent insert and the body of the user.
[0114] Although the present invention has been described with
reference to preferred embodiments, those skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention. As such, it
is intended that the foregoing detailed description be regarded as
illustrative rather than limiting and that it is the appended
claims, including all equivalents thereof, which are intended to
define the scope of the invention.
* * * * *