U.S. patent application number 12/478994 was filed with the patent office on 2009-10-01 for disposable absorbent article having doubled side flaps and backsheet strips.
Invention is credited to Gary Dean LaVon, Kevin Michael Smith.
Application Number | 20090247975 12/478994 |
Document ID | / |
Family ID | 37311898 |
Filed Date | 2009-10-01 |
United States Patent
Application |
20090247975 |
Kind Code |
A1 |
LaVon; Gary Dean ; et
al. |
October 1, 2009 |
DISPOSABLE ABSORBENT ARTICLE HAVING DOUBLED SIDE FLAPS AND
BACKSHEET STRIPS
Abstract
A disposable absorbent article includes two laterally opposing
longitudinally extending backsheet strips attached to an exterior
surface of an absorbent assembly in laterally opposing attachment
zones. Each backsheet strip may include a water-impermeable layer
and may be extensible. The absorbent assembly includes a lower
covering sheet that is doubled by folding and thereby includes a
first layer and a second layer. The absorbent assembly also
includes laterally opposing side flaps which are formed by folding
doubled portions of the lower covering sheet laterally inward. A
longitudinally extending elastic gathering member is attached to
each side flap adjacent to its proximal edge. When the article is
worn, the elastic gathering members contract and raise the side
flaps to form side barriers.
Inventors: |
LaVon; Gary Dean; (Liberty
Township, OH) ; Smith; Kevin Michael; (Cincinnati,
OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY;Global Legal Department - IP
Sycamore Building - 4th Floor, 299 East Sixth Street
CINCINNATI
OH
45202
US
|
Family ID: |
37311898 |
Appl. No.: |
12/478994 |
Filed: |
June 5, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11159916 |
Jun 23, 2005 |
|
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12478994 |
|
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Current U.S.
Class: |
604/367 ;
604/378; 604/385.26; 604/385.28; 604/389 |
Current CPC
Class: |
A61F 13/49453 20130101;
A61F 13/49413 20130101; A61F 13/51474 20130101 |
Class at
Publication: |
604/367 ;
604/378; 604/385.26; 604/385.28; 604/389 |
International
Class: |
A61F 13/15 20060101
A61F013/15 |
Claims
1. A disposable diaper having a front waist region, a back waist
region, a crotch region between the waist regions, a longitudinal
axis, and a lateral axis, and comprising: an absorbent assembly
having a front edge, a back edge, laterally opposing side edges
extending between the front edge and the back edge, an exterior
surface, and an interior surface; and two laterally opposing
longitudinally extending backsheet strips attached to the exterior
surface of the absorbent assembly, the absorbent assembly
comprising an absorbent core and a water vapor-permeable lower
covering sheet disposed exteriorly of the absorbent core, laterally
opposing longitudinally extending portions of the lower covering
sheet being folded interiorly laterally inward to form the side
edges of the absorbent assembly and laterally opposing breathable
side flaps having proximal edges, the lower covering sheet being
doubled by folding and thereby having first and second layers at
least between each of the proximal edges and the respective side
edge, each of the side flaps being attached adjacent to its
longitudinally distal ends to the interior surface and having a
longitudinally extending elastic gathering member sandwiched
between the first and second layers adjacent to its proximal
edge.
2. The disposable diaper of claim 1 wherein the doubled lower
covering sheet is water-impermeable.
3. The disposable diaper of claim 2 wherein the lower covering
sheet is formed of a hydrophobic nonwoven material.
4. The disposable diaper of claim 1 wherein the absorbent assembly
further comprises an additional bottom sheet disposed between the
first layer and the second layer of the doubled lower covering
sheet.
5. The disposable diaper of claim 4 wherein the additional bottom
sheet is water-impermeable.
6. The disposable diaper of claim 5 wherein the additional bottom
sheet is water vapor-permeable.
7. The disposable diaper of claim 1 wherein the elastic gathering
member is sandwiched between the first layer and the second layer
of the doubled lower covering sheet.
8. The disposable diaper of claim 1 wherein the proximal edges of
both of the side flaps are formed by the folding of the lower
covering sheet for doubling.
9. The disposable diaper of claim 1 wherein the doubled lower
covering sheet has the first and second layers over substantially
its entire area.
10. The disposable diaper of claim 9 wherein the lower covering
sheet has two original longitudinally extending edges and the first
layer and the second layer are overlapped and attached together
adjacent to the original edges.
11. The disposable diaper of claim 1 wherein the first layer and
the second layer are attached together in laterally spaced
longitudinally extending attachment zones.
12. The disposable diaper of claim 11 wherein the laterally spaced
longitudinally extending attachment zones are disposed between the
proximal edges of the side flaps and the respective side edges of
the absorbent assembly.
13. The disposable diaper of claim 11 wherein the laterally spaced
longitudinally extending attachment zones are disposed below the
absorbent core between the side edges of the absorbent
assembly.
14. The disposable diaper of claim 1 wherein the first layer and
the second layer are attached together in laterally extending
attachment zones adjacent to the front edge and the back edge of
the absorbent assembly.
15. The disposable diaper of claim 14 wherein the laterally
extending attachment zones are laterally continuous.
16. The disposable diaper of claim 1 wherein when allowed the
elastic gathering member is allowed to relax, the elastic gathering
member contracts and lifts the proximal edge away from the interior
surface of the absorbent assembly, thereby raising the side flap to
form a side barrier.
17. A disposable diaper having a front waist region, a back waist
region, a crotch region between the waist regions, a longitudinal
axis, and a lateral axis, and comprising: an absorbent assembly
having a front edge, a back edge, laterally opposing side edges
extending between the front edge and the back edge, an exterior
surface, and an interior surface; and two laterally opposing
longitudinally extending backsheet strips attached to the exterior
surface of the absorbent assembly, the absorbent assembly
comprising an absorbent core and a water vapor-permeable lower
covering sheet disposed exteriorly of the absorbent core, the
absorbent core being attached to the lower covering sheet in a
cruciform pattern of attachment having a longitudinally extending
portion intersecting with a laterally extending portion, laterally
opposing longitudinally extending portions of the lower covering
sheet being folded interiorly laterally inward to form the side
edges of the absorbent assembly and laterally opposing breathable
side flaps having proximal edges, the lower covering sheet being
doubled by folding and thereby having first and second layers at
least between each of the proximal edges and the respective side
edge.
18. The disposable diaper of claim 17 wherein at least a portion of
the lower covering sheet lying outside the cruciform pattern is
laterally extensible.
19. A disposable diaper having a front waist region, a back waist
region, a crotch region between the waist regions, a longitudinal
axis, and a lateral axis, and comprising: an absorbent assembly
having a front edge, a back edge, laterally opposing side edges
extending between the front edge and the back edge, an exterior
surface, and an interior surface; and two laterally opposing
longitudinally extending backsheet strips attached to the exterior
surface of the absorbent assembly, each of the backsheet strips
having at least one fastening element attached to it, the fastening
element being adapted for fastening the front waist region and the
back waist region together to encircle a waist and a leg of a
wearer, the absorbent assembly comprising an absorbent core and a
water vapor-permeable lower covering sheet disposed exteriorly of
the absorbent core, laterally opposing longitudinally extending
portions of the lower covering sheet being folded interiorly
laterally inward to form the side edges of the absorbent assembly
and laterally opposing breathable side flaps having proximal edges,
the lower covering sheet being doubled by folding and thereby
having first and second layers at least between each of the
proximal edges and the respective side edge.
20. The disposable diaper of claim 19 wherein the fastening element
includes a cohesive fastening patch.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of application Ser. No.
11/159,916, filed Jun. 23, 2005, the substance of which is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to disposable absorbent articles such
as disposable diapers and other articles intended for use on
incontinent persons.
BACKGROUND OF THE INVENTION
[0003] Disposable absorbent articles are designed to absorb and
contain bodily waste in order to prevent soiling of the body and
clothing of the wearer, as well as bedding or other objects with
which the wearer comes into contact.
[0004] As the usage of disposable absorbent articles has expanded,
their complexity has increased with the incorporation of additional
features serving to enhance their performance and appearance. The
costs of the materials and the costs of the manufacturing processes
have also increased in conjunction with the increase in complexity.
As a result, the prices at which these articles are sold have risen
to levels that many potential purchasers around the world cannot
afford to pay. Thus, a need exists for a simple disposable
absorbent article.
SUMMARY OF THE INVENTION
[0005] A disposable absorbent article includes two laterally
opposing longitudinally extending backsheet strips attached to an
exterior surface of an absorbent assembly in laterally opposing
attachment zones. Each backsheet strip may include a
water-impermeable layer and may be extensible. The absorbent
assembly includes a lower covering sheet that is doubled by folding
and thereby includes a first layer and a second layer. The
absorbent assembly also includes laterally opposing side flaps
which are formed by folding doubled portions of the lower covering
sheet laterally inward. A longitudinally extending elastic
gathering member is attached to each side flap adjacent to its
proximal edge. When the article is worn, the elastic gathering
members contract and raise the side flaps to form side
barriers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] In the accompanying drawing figures, like reference numerals
identify structurally corresponding elements, which may or may not
be identical in the several exemplary embodiments that are
depicted. Some of the figures may have been simplified by the
omission of selected elements for the purpose of more clearly
showing other elements. Such omissions of elements in some figures
are not necessarily indicative of the presence or absence of
particular elements in any of the exemplary embodiments, except as
may be explicitly delineated in the corresponding written
description.
[0007] In the drawing figures and in the written description,
lowercase letters appended to reference numerals indicate generally
symmetric elements, e.g. the left and right side edges of the
absorbent assembly 200 are respectively identified by the reference
numerals 237a and 237b. A reference numeral without an appended
lowercase letter identifies all of the elements to which that
particular reference numeral applies, e.g., the same side edges as
a group are designated 237.
[0008] FIG. 1 is a plan view of an exemplary disposable diaper 20,
which is shown in its flat, uncontracted state, i.e., without the
contraction induced by elastic members. In FIG. 1, the interior
portion of the diaper 20 is shown facing the viewer.
[0009] FIG. 2 is an exterior plan view of the diaper 20 of FIG.
1.
[0010] FIG. 3, FIG. 4, and FIG. 5 are section views of the diaper
20 of FIG. 1 and FIG. 2 taken at the respective section lines 3-3,
4-4, and 5-5. In these section views, the interior portion of the
diaper 20 shown facing upward.
[0011] FIG. 6, FIG. 7, and FIG. 8 are respectively simplified side,
front, and back elevation views of the diaper 20 of FIG. 1 being
worn about the lower torso of the wearer.
[0012] FIG. 9 is a plan view of an exemplary fragment of a formed
web material.
[0013] FIG. 10 and FIG. 11 are simplified left and right side
elevation views of an exemplary diaper 20 including cohesive
fastening patches being worn about a lower torso of a wearer.
[0014] FIG. 12 is a simplified plan view of another exemplary
disposable diaper 20, which is shown in its flat, uncontracted
state and with its interior portion facing the viewer.
[0015] FIG. 13 is a simplified exterior plan view of the diaper 20
of FIG. 12.
[0016] FIG. 14 is a perspective view of an exemplary diaper 20,
which is shown in its relaxed, contracted state and with its
interior portion facing upward.
[0017] FIG. 15 is a plan view of an exemplary absorbent assembly
200, shown separately from the other portions of an exemplary
diaper and with its interior portion facing the viewer.
[0018] FIG. 16 is a view of the absorbent assembly of FIG. 15 taken
at the section line 16-16.
[0019] FIG. 17 is a view of the absorbent assembly of FIG. 15 taken
at the section line 17-17.
[0020] FIG. 18 is a section view of an exemplary absorbent assembly
200 showing details of an exemplary absorbent core having particles
of superabsorbent material contained inside pockets
[0021] FIG. 19 is a section view of an exemplary absorbent assembly
200 having an additional bottom sheet 226, taken at a section line
corresponding to the section line 4-4 in FIG. 1.
[0022] FIG. 20 is a plan view of another exemplary disposable
diaper 20, which is shown in its flat, uncontracted state and with
its interior portion facing the viewer.
[0023] FIG. 21 is a plan view of another exemplary disposable
diaper 20, which is shown in its flat, uncontracted state and with
its interior portion facing the viewer.
[0024] FIG. 22 is an exterior plan view of the diaper 20 of FIG.
21.
[0025] FIG. 23 is a section view of the diaper 20 of FIG. 21 and
FIG. 22 taken at the section line 23-23, with its interior portion
facing upward.
[0026] FIG. 24 is a plan view of another exemplary disposable
diaper 20, which is shown in its flat, uncontracted state and with
its interior portion facing the viewer.
DETAILED DESCRIPTION OF THE INVENTION
[0027] In this description, the following terms have the following
meanings:
[0028] The term "absorbent article" refers to a device that absorbs
and contains liquid, and more specifically, refers to a device that
is placed against or in proximity to the body of the wearer to
absorb and contain the various exudates discharged from the
body.
[0029] The term "diaper" refers to an absorbent article that is
generally worn by infants and incontinent persons about the lower
torso so as to encircle the waist and the legs of the wearer and
that is specifically adapted to receive and contain urinary and
fecal waste.
[0030] The term "disposable" refers to the nature of absorbent
articles that generally are not intended to be laundered or
otherwise restored or reused as an absorbent article, i.e., they
are intended to be discarded after a single use and, preferably, to
be recycled, composted or otherwise disposed of in an
environmentally compatible manner.
[0031] The term "longitudinal" refers to a direction running from a
waist edge to an opposing waist edge of the article and generally
parallel to the maximum linear dimension of the article. Directions
within 45.degree. of the longitudinal direction are considered to
be "longitudinal".
[0032] The term "lateral" refers to a direction running from a side
edge to an opposing side edge of the article and generally at a
right angle to the longitudinal direction. Directions within
45.degree. of the lateral direction are considered to be
"lateral".
[0033] The term "disposed" refers to an element being attached and
positioned in a particular place or position in a unitary structure
with other elements.
[0034] The term "attached" refers to elements being connected or
united by fastening, adhering, bonding, etc. by any method suitable
for the elements being attached together and their constituent
materials. Many suitable methods for attaching elements together
are well-known, including adhesive bonding, pressure bonding,
thermal bonding, mechanical fastening, etc. Such attachment methods
may be used to attach elements together over a particular area
either continuously or intermittently.
[0035] The term "cohesive" refers to the property of a material
that, once set, sticks to itself but does not to any significant
degree stick to other materials.
[0036] The terms "water-permeable" and "water-impermeable" refer to
the penetrability of materials in the context of the intended usage
of disposable absorbent articles. Specifically, the term
"water-permeable" refers to a layer or a layered structure having
pores, openings, and/or interconnected void spaces that permit
liquid water to pass through its thickness in the absence of a
forcing pressure. Conversely, the term "water-impermeable" refers
to a layer or a layered structure through the thickness of which
liquid water cannot pass in the absence of a forcing pressure. A
layer or a layered structure that is water-impermeable according to
this definition may be permeable to water vapor, i.e., may be
"water vapor-permeable". Such a water vapor-permeable layer or
layered structure is commonly known in the art as "breathable". As
is well known in the art, a common method for measuring the
permeability to water of the materials typically used in absorbent
articles is a hydrostatic pressure test, also called a hydrostatic
head test or simply a "hydrohead" test. Suitable well known
compendial methods for hydrohead testing are approved by INDA
(formerly the International Nonwovens and Disposables Association,
now The Association of the Nonwoven Fabrics Industry) and EDANA
(European Disposables And Nonwovens Association).
[0037] The terms "proximal" and "distal" refer respectively to the
location of an element relatively near to or far from the center of
a structure, e.g., the proximal edge of a longitudinally extending
element is located nearer to the longitudinal axis than the distal
edge of the same element is located relative to the same
longitudinal axis.
[0038] The terms "interior" and "exterior" refer respectively to
the location of an element that is intended to be placed against or
toward the body of a wearer when an absorbent article is worn and
the location of an element that is intended to be placed against or
toward any clothing that is worn over the absorbent article.
Synonyms for "interior" and "exterior" include, respectively,
"inner" and "outer", as well as "inside" and "outside". Also, when
the absorbent article is oriented such that its interior faces
upward, e.g., when it is laid out in preparation for setting the
wearer on top of it, synonyms include "upper" and "lower", "above"
and "below", "over" and "under", and "top" and "bottom",
respectively.
Description of Exemplary Diaper Embodiments
[0039] Reference is made to FIG. 1, FIG. 2, FIG. 3, FIG. 4, FIG. 5,
FIG. 6, FIG. 7, and FIG. 8 for this section of this
description.
[0040] One end portion of the exemplary diaper 20 is configured as
a front waist region 36, the longitudinally opposing end portion is
configured as a back waist region 38, and an intermediate portion
is configured as a crotch region 37.
[0041] The basic structure of the diaper 20 includes an absorbent
assembly 200, which has a front edge 236, a back edge 238,
laterally opposing side edges 237, an interior surface 202, and an
exterior surface 204. A longitudinal axis 42 extends through the
midpoints of the front edge 236 and the back edge 238 and a lateral
axis 44 extends through the midpoints of the side edges 237. The
absorbent assembly 200 has laterally opposing side flaps 247 and a
lower covering sheet 25 that are described in more detail
below.
[0042] The basic structure of the diaper 20 also includes two
laterally opposing longitudinally extending backsheet strips
designated the left backsheet strip 100a and the right backsheet
strip 100b. The backsheet strips have respective front waist edges
136, back waist edges 138, proximal edges 156, interior surfaces
102, and exterior surfaces 104. Together, the two backsheet strips
define the respective side edges 137 of the diaper 20.
[0043] The backsheet strips 100 and the lower covering sheet 25 are
attached together in laterally opposing longitudinally extending
attachment zones such as the exemplary attachment zones 220.
[0044] When the diaper 20 is worn on the lower torso of a wearer,
the front waist edges 136 of the backsheet strips, the front edge
236 of the absorbent assembly, the back waist edges 138 of the
backsheet strips, and the back edge 238 of the absorbent assembly
encircle the waist of the wearer, the side edges 137 encircle the
legs of the wearer, the crotch region 37 is generally positioned
between the legs of the wearer, and the absorbent assembly 200
extends from the front waist region 36 through the crotch region 37
to the back waist region 38.
[0045] A portion or the whole of each of the backsheet strips may
be formed of an elastically extensible material or materials.
Alternatively, or in addition, a portion or the whole of each of
the backsheet strips may be made extensible to a degree greater
than the inherent extensibility of the material or materials from
which the backsheet strip is made. Similarly, a portion of the
absorbent assembly may be formed of an elastically extensible
material or materials. Alternatively or in addition, a portion of
the absorbent assembly may be made extensible to a degree greater
than the inherent extensibility of the material or materials from
which the absorbent assembly is made. The additional extensibility
may be desirable in order to allow the diaper 20 to conform to the
body of a wearer during movement by the wearer. Additional lateral
extensibility may be particularly desirable to allow the user of a
diaper to extend the front waist region and/or the back waist
region to encircle the waist of a wearer, i.e., to tailor the waist
size and fit of a diaper to the individual wearer. Such a lateral
extension of the waist region or regions may give the diaper a
generally hourglass shape and may impart a tailored appearance to
the diaper when it is worn. In addition, the additional
extensibility may be desirable in order to minimize the cost of the
diaper, because a relatively lesser amount of material is needed
when the material is made extensible as described.
[0046] For the purpose of fitting to the waist of the wearer, in
some embodiments additional lateral extensibility in the absorbent
assembly 200 is provided only between the laterally opposing
attachment zones 220 where the absorbent assembly 200 and the
backsheet strips 100 are attached together, rather than in the
entire absorbent assembly.
[0047] Additional extensibility in the backsheet strips and/or the
absorbent assembly may be provided in a variety of ways. For
example, a material or materials from which the backsheet strips
and/or the absorbent assembly is/are made may be pleated by any of
many known methods. Alternatively, all or a portion of the
backsheet strips and/or the absorbent assembly may be made of a
formed web material or a formed laminate of web materials like
those described in U.S. Pat. No. 5,518,801 issued on 21 May 1996 in
the name of Chappell et al. An exemplary fragment 300 of such a
formed web material 305 is shown in FIG. 9. This formed web
material 305 includes distinct laterally extending regions 310 in
which the original material has been altered by embossing or
another method of deformation to create a pattern of generally
longitudinally oriented alternating ridges 312 and valleys 314. The
formed web material 305 also includes laterally extending unaltered
regions 316 located between the laterally extending altered regions
310.
[0048] Such a formed web material 305 can be laterally extended
beyond its original dimension with the application of relatively
less force than that required to extend the same material to the
same extent when undeformed. In particular, the application of
opposing divergent forces directed generally perpendicular to the
ridges 312 and valleys 314 extends such a formed web material along
an axis between the opposing forces and generates a resistive
contractive force, primarily in the unaltered regions 316. This
resistive force is relatively smaller than the resistive force that
is generated by the same material in its unaltered form when
extended to the same extent, at least up to an extension at which
the ridges and valleys in the altered regions flatten and begin to
contribute to the resistive force. Thus, such formed web materials
exhibit an extensible behavior resembling that of traditional
elastic materials in the range of extensibility that is useful in
absorbent articles, but may be made of relatively less expensive
materials that are not inherently elastic and, thus, their use may
provide an advantage in terms of the cost of manufacturing the
absorbent articles.
[0049] In addition, different portions of the backsheet strips
and/or the absorbent assembly may be formed to have different
ranges of extensibility and/or to be extensible to a greater or
lesser degree when subjected to a given level of opposing tensile
forces, i.e., to be relatively more easily or less easily
extensible. Such differential extensibility may be desirable so
that, for example, one or both of the waist regions may be
laterally extended relatively farther or relatively more easily
than the crotch region.
Description of the Backsheet Strips
[0050] The diaper 20 includes two laterally opposing longitudinally
extending backsheet strips designated the left backsheet strip 100a
and the right backsheet strip 100b as shown in FIG. 1, FIG. 2, FIG.
3, FIG. 4, and FIG. 5. The backsheet strips may be formed of a
nonwoven material, for example a synthetic nonwoven such as
spunbonded or carded polyethylene, polypropylene, polyester, or
rayon. Alternatively or in addition, each backsheet strip may
include a water-impermeable layer that is formed of a suitable
material, for example a film of polyethylene or another polyolefin,
a microporous breathable film, a hydrophobic nonwoven, or a film
formed of coextruded polyolefin layers. For example, a suitable
coextruded film is available from Clopay Plastic Products Co. of
Mason, Ohio, U.S.A. under the designation of M18-327. A multi-layer
backsheet strip, such as a laminate of a film and a nonwoven, may
also be suitable and may be oriented with the nonwoven disposed
exteriorly to provide the feel and appearance of a cloth-like
outermost layer, with the nonwoven disposed interiorly to separate
the film from the skin of the wearer, or with nonwovens disposed
both exteriorly and interiorly.
[0051] The front waist region and the back waist region can be
fastened together in many ways to form a waist opening and two leg
openings suitable for encircling the waist and the legs of the
wearer. For example, separate fastening devices such as safety
pins, separate tapes, a separate tie strap or straps, and/or a
separate belt can be used for this purpose. Alternatively or in
addition, fastening elements can be incorporated into the
disposable absorbent article to enable a user to apply the diaper
to the body of the wearer without, or in conjunction with, any
separate fastening devices. Many suitable types of such
incorporated fastening elements are well-known, including, for
example, tapes, adhesives, adhesive tape tabs, ties, buttons,
hooks, loops, snap fasteners, other forms of mechanical fasteners,
cohesive patches, etc. Some suitable mechanical fasteners may be
adapted to engage with a nonwoven, e.g., a nonwoven layer of a
laminate backsheet or the lower covering sheet.
[0052] The fastening of the front waist region and the back waist
region together may be openable and refastenable to allow for the
adjustment of the fit of the diaper on the wearer and for the
inspection of the interior of the diaper without fully removing it
from the wearer. Alternatively, the fastening may be permanent,
i.e., its opening may require the destruction of a portion of the
diaper, e.g., the tearing of a portion of the diaper or the
breaking of fused side seams.
[0053] Cohesive fastening patches may be formed by the application
of a cohesive material onto a substrate. The cohesive material may
be applied in any of a variety of patterns, such as a continuous
film, discrete dots, stripes, polygons, etc., and/or spaced and
interconnected geometric elements describing a grid. Suitable
synthetic cohesive products are available from Andover Coated
Products, Incorporated, of Salisbury, Mass., U.S.A. and are
described in U.S. Pat. No. 6,156,424 issued on 5 Dec. 2000 in the
name of Taylor.
[0054] In FIG. 1, FIG. 2, FIG. 3, FIG. 5, FIG. 10, and FIG. 11,
cohesive fastening patches 110a and 110b are shown disposed on the
exterior surfaces of the respective backsheet strips 100a and 100b
in the front waist region 36. In this exemplary embodiment,
functionally complementary cohesive fastening patches 120a and 120b
are disposed on the interior surfaces of the respective backsheet
strips 100a and 100b in the back waist region 38. When the diaper
20 is worn as shown in FIG. 10 and FIG. 11, the cohesive fastening
patches on the interior overlap the cohesive fastening patches on
the exterior and the cohesion of the overlapped cohesive fastening
patches fastens the front waist region 36 and the back waist region
38 together at the sides of the diaper 20. The configuration shown
in these figures is adapted for back-over-front fastening.
[0055] Alternatively, the front cohesive fastening patches may be
disposed on the interior of the diaper 20 and the back cohesive
fastening patches may be disposed on the exterior of the diaper 20
in order to adapt the configuration for front-over-back fastening.
Alternatively, the cohesive fastening patches may be disposed in a
reversible configuration that is adapted to provide the user of the
diaper with both options for fastening, i.e., either
back-over-front or front-over-back, according to personal
preference. For example, cohesive fastening patches that are
disposed on both the exterior and the interior of the diaper 20 may
allow a back cohesive fastening patch to overlap a front cohesive
fastening patch or the front cohesive fastening patch to overlap
the back cohesive fastening patch.
[0056] When the underlying portion of the diaper is extensible, it
is preferable that the cohesive fastening patches be similarly
extensible such that the underlying extensible portion of the
diaper is not restrained.
[0057] Alternatively, adhesive tape tabs may be attached to the
diaper 20 and may be used to fasten the back waist region 38 and
the front waist region 36 together. For example, as shown in FIG.
12 and FIG. 13, laterally opposing adhesive tape tabs 114a and 114b
may be attached to the respective backsheet strips 100a and 100b at
or adjacent to the side edges 137a and 137b of the diaper 20.
Suitable adhesive tapes are available from the 3M Corporation of
St. Paul, Minn., U.S.A., under the designation of XMF99121, and
from the Avery Dennison Corporation, Specialty Tape Division,
Mentor, Ohio, U.S.A., under the designation of F4416.
[0058] Optionally, fastening sheets may also be attached to the
diaper 20 and used in conjunction with such adhesive tape tabs. For
example, fastening sheets 116 may be attached onto the exterior
surfaces 104 of the respective backsheet strips 100 and/or the
absorbent assembly 200 as shown in FIG. 13. When a fastening sheet
is provided, the adhesive tape tabs may be adhered to the fastening
sheet to fasten the back waist region 38 and the front waist region
36 together. The fastening sheet serves to distribute the tensile
force transmitted by each of the adhesive tape tabs over an area
larger than the adhered area of the adhesive tape tab and may,
itself, bear a portion of the tensile force and thereby relieve a
portion of the force exerted on the underlying portion of the
diaper, such as the backsheet strips. Thus, for example, the
incorporation of such a fastening sheet may make it possible to use
a relatively inexpensive and relatively weak material for the
underlying portion of the diaper. When mechanical fasteners are
used instead of adhesive tape tabs, a fastening sheet can have a
surface and/or elements that engage with the mechanical fastener,
e.g., loops with which hooks may engage. When the underlying
portion of the diaper is extensible, it is preferable that the
fastening sheet be similarly extensible such that the underlying
extensible portion of the diaper is not restrained.
Description of the Absorbent Assembly
[0059] As shown in FIG. 1, FIG. 2, FIG. 3, FIG. 4, and FIG. 5, the
absorbent assembly 200 has laterally opposing side flaps 247 formed
by folding portions of the absorbent assembly toward the
longitudinal axis 42, to form both the respective side flaps 247
and the side edges 237 of the absorbent assembly 200. The absorbent
assembly 200 may simply be folded loosely or may be creased along a
portion of each of its side edges 237. For example, it may be
desirable to form creases along portions of the side edges 237 in
the crotch region 37 in order to impart a more finished appearance
to the diaper 20. Alternatively or in addition to creasing, a
portion of each of the folded side flaps 247 adjacent to the side
edges 237 may be attached to the interior surface 202 of the
absorbent assembly 200 to achieve a similar result. The side flaps
may overlap the absorbent core 250, i.e., the proximal edges 255 of
the side flaps may lie laterally inward of the respective side
edges 257 of the absorbent core 250. Alternatively, the side flaps
may not overlap the absorbent core.
[0060] In the exemplary diaper 20 shown in FIG. 1, the absorbent
assembly 200 extends the full length of the backsheet strips 100
between the front waist edges 136 and the back waist edges 138.
Such a full length configuration may be desirable in order to
minimize the amount of waste material and the difficulty associated
with the manufacture of the diaper 20, especially when the method
used to manufacture the diaper 20 requires the introduction of the
material or materials for the absorbent assembly 200 in the form of
a continuous web or multiple continuous webs. Also, such a full
length configuration may be desirable in order to isolate the skin
of the wearer from the backsheet strips. Alternatively, the
absorbent assembly 200 may be shorter and extend less than the full
length of the backsheet strips. Such a shorter configuration may be
desirable in order to minimize the total amount of material used
and the cost of the diaper 20. As another alternative, the
absorbent assembly 200 may extend longitudinally beyond the
backsheet strips. Such a longer configuration may be desirable in
order to minimize the total amount of material used in the
backsheet strips and therefore the cost of the diaper 20.
[0061] Each of the side flaps 247 is attached to the interior
surface 202 of the absorbent assembly 200 in attachment zones
located at or adjacent to the front edge 236 and the back edge 238.
For example, in the diaper 20 shown in FIG. 2, the left side flap
247a is attached to the interior surface 202 of the absorbent
assembly 200 in attachment zones 251a and 251c, while the right
side flap 247b is attached to the interior surface 202 in
attachment zones 251b and 251d. The attachment zones may have equal
areas or may be unequal in area.
[0062] Between the attachment zones, the proximal edges 255 of the
side flaps 247 remain free, i.e., are not attached to the interior
surface 202 of the absorbent assembly 200. Also between the
attachment zones, each side flap preferably includes a
longitudinally extensible flap elastic member that is attached
adjacent to the proximal edge of the side flap. For example, in the
diaper 20 shown in FIG. 1, elastic strands 267 are attached
adjacent to the respective proximal edge 255 of the side flaps. The
flap elastic member may be sandwiched between two layers of the
absorbent assembly or may be attached on a surface of the absorbent
assembly and remain exposed.
[0063] When stretched, the flap elastic members allow the proximal
edges of the side flaps to extend to the flat uncontracted length
of the absorbent assembly, as shown in FIG. 1. When allowed to
relax, the flap elastic members contract to gather the portions of
the proximal edges along which the flap elastic members are
attached. For example, when the exemplary diaper 20 is in a relaxed
condition as shown in FIG. 14, the elastic strands 267 contract to
gather the proximal edges 255 of the side flaps 247. The
contractive forces of the elastic strands pull the front waist
region 36 and the back waist region 38 toward each other and
thereby bend the absorbent assembly 200 and the entire diaper 20
into a "U" shape in which the interior of the "U" shape is formed
by the interior portions of the diaper. Because the proximal edges
remain free between the attachment zones, the contractive forces of
the elastic strands lift the proximal edges 255 of the side flaps
247 away from the interior surface 202 of the absorbent assembly
and thereby raise the side flaps into position to serve as side
barriers. The lateral spacing of the lifted proximal edges is
selected to allow the deposit of bodily wastes from the lower torso
of the wearer into the space between the raised side flaps. The
width of each of the side flaps 247 in effect becomes its height
when the free portion of its proximal edge is lifted and the side
flap is raised. This height preferably is selected to allow the
lifted proximal edges 255 to fit into the leg creases of the body
of the wearer to form seals to help prevent the leakage of
deposited bodily waste out of the diaper.
[0064] As shown in FIG. 15, FIG. 16, and FIG. 17, the absorbent
assembly 200 includes an absorbent core 250 that serves to absorb
and retain liquid bodily waste materials. The absorbent core 250
has a front edge 256, a back edge 258, laterally opposing side
edges 257, an interior surface 252, and an exterior surface
254.
[0065] The absorbent assembly 200 may include an upper covering
sheet disposed above the absorbent core 250 in addition to a lower
covering sheet is disposed below the absorbent core 250. If both
are present, such an upper covering sheet and lower covering sheet
may be attached together to contain the absorbent core 250 between
them and thereby form the absorbent assembly 200. For example, in
the exemplary absorbent assembly 200 shown in FIG. 15, FIG. 16, and
FIG. 17, an upper covering sheet 24 and a lower covering sheet 25
are attached together in the laterally opposing attachment zones
29.
[0066] An upper covering sheet, if present, is water-permeable and
allows liquid bodily waste to pass through its thickness to the
absorbent core. The upper covering sheet preferably is formed of a
soft material that will not irritate the skin of the wearer, for
example a synthetic nonwoven such as spunbonded or carded
polyethylene, polypropylene, polyester, or rayon.
[0067] The lower covering sheet 25 is doubled by folding and
thereby includes a first layer 27 and a second layer 28 at least in
the side flaps 247, i.e., at least between each side edge 237 and
the respective proximal edge 255 of the absorbent assembly 200,
both layers 27 and 28 are present, while between the side edges 237
below the absorbent core 250, only one of the layers 27 and 28
needs to be present. In some exemplary embodiments, both the first
layer 27 and the second layer 28 are present over substantially the
entire area of the lower covering sheet 25. In both of these
variations of the structure, the side flap elastic members 267 are
sandwiched between the first layer 27 and the second layer 28
adjacent to the proximal edges 255 of the side flaps 247. Doubling
by folding is a particularly easy and cost-effective way of
processing sheet materials in a manufacturing system, in part
because it obviates the need to precisely align the edges of
separate sheets when forming a doubled structure. In addition,
doubling by folding makes it unnecessary to attach the doubled
layers together, at least at the fold, although the layers can be
attached together wherever desired for certain purposes, as
explained below.
[0068] The proximal edge 255 of at least one of the side flaps 247
is formed where the lower covering sheet 25 is folded for doubling.
For example, in the exemplary embodiment shown in FIG. 15, FIG. 16,
and FIG. 17, both of the proximal edges 255 of the side flaps 247
are formed by the folding of the lower covering sheet 25 for
doubling. In this embodiment, the lower covering sheet 25 is folded
twice to form the two proximal edges 255 and the layers 27 and 28
are overlapped and attached together adjacent to the original
longitudinally extending edges 33 of the lower covering sheet 25 in
the longitudinally extending attachment zone 35 disposed below the
absorbent core 250. Alternatively, the attachment zone 35 may be
disposed laterally differently from the location shown in these
figures. For example, the attachment zone 35 may be disposed
adjacent to one of the side edges 237 of the absorbent assembly 200
or may be disposed between one of the proximal edges 255 of one of
the side flaps 247 and the respective side edge 237. As another
example, the lower covering sheet 25 may be folded only once at the
proximal edge 255 of one of the side flaps 247 and the attachment
zone 35 where the layers 27 and 28 are attached together may be
disposed adjacent to the proximal edge 255 of the laterally
opposing side flap 247 such that the original longitudinally
extending edges 33 are exposed there. As an alternative to
overlapping the original longitudinally extending edges 33, the
original edges 33 may be laterally spaced and the lower covering
sheet 25 may be attached in two laterally spaced attachment zones
35 adjacent to the two original edges 33 to one other structural
element, such as the absorbent core 250, or to two other structural
elements, such as the backsheet strips 100.
[0069] The layers 27 and 28 of the doubled lower covering sheet 25
may remain unattached to each other and thus free to contact each
other or separate from each other. Alternatively, the layers of the
doubled lower covering sheet 25 may be attached together laterally
continuously or intermittently between the proximal edges 255 of
the side flaps 247 and the side edges 237 of the absorbent assembly
200. Alternatively, or in addition, the layers of the doubled lower
covering sheet 25 may be attached together laterally continuously
or intermittently below the absorbent core 250 between the side
edges 237 of the absorbent assembly 200. For example, the layers of
the doubled lower covering sheet 25 may be attached together by
adhesives, mechanical bonds, or thermal bonds, or by a combination
of known bonding methods.
[0070] In the exemplary embodiment shown in FIG. 1, FIG. 2, and
FIG. 4, the layers 27 and 28 are attached together in laterally
spaced attachment zones 260 extending longitudinally through the
crotch region 37 and into the waist regions 36 and 38. Such
longitudinally extending attachment together prevents the layers
from separating and thereby presenting an undesirable baggy or
blousy appearance around the legs of the wearer, as well as tending
to stiffen the side flaps 247 slightly and thereby helping to
ensure their proper fit against the body.
[0071] Alternatively, or in addition, the layers 27 and 28 of the
doubled lower covering sheet 25 may be attached together in the
waist regions 36 and 38 adjacent to the front and back edges 236
and 238 of the absorbent assembly 200, for example in laterally
extending attachment zones 259 as shown in FIG. 1, FIG. 3, and FIG.
5. This lateral attachment may be laterally intermittent or
laterally continuous. When such laterally extending attachment is
continuous, it prevents the layers from separating and thereby
presenting an undesirable unfinished appearance at the waist edges,
as well as forming a barrier serving to prevent the leakage of any
liquid waste from between the layers at the front and/or back edge
of the absorbent assembly.
[0072] Exemplary materials suitable for use in the doubled lower
covering sheet 25 include breathable polyolefinic films,
microporous or other breathable formed films, breathable monolithic
films, and hydrophobic nonwovens. Suitable hydrophobic nonwovens
include SM (spunbond meltblown), SMS (spunbond meltblown spunbond),
and SMMS (spunbond meltblown meltblown spunbond) composites. The
materials of the water vapor-permeable side sheets may be selected
to balance overall product economics and function. For example, a
relatively inexpensive nonwoven having a relatively low basis
weight may provide the requisite level of water-impermeability when
it is doubled, and its relatively low cost may offset the cost
associated with the use of a greater amount of material than would
be used in a single-layer lower covering sheet made of a relatively
more expensive nonwoven material.
[0073] The absorbent assembly and the backsheet strips may be
attached together over any part or the whole of the length of the
absorbent assembly. Preferably, the second layer 28 of the lower
covering sheet 25 is attached to the backsheet strips in laterally
opposing longitudinally extending attachment zones such as the
exemplary attachment zones 220 shown in FIG. 2, FIG. 3, FIG. 4,
FIG. 5, FIG. 13, and FIG. 19. The portions of the backsheet strips
that lie outside such an attachment pattern are not restrained by
attachment to the absorbent assembly and therefore remain
extensible. For example, a relatively narrow longitudinally
extending attachment zone 220 leaves the majority of the width of
the respective backsheet strip 100 freely extensible and thereby
allows extension of that backsheet strip 100 in the lateral
direction.
[0074] Within the extent of the attachment zones, the absorbent
assembly may be attached to the backsheet strips continuously or
intermittently. For example, a film of an adhesive may be applied
continuously over the entire area of the attachment zones and then
used to continuously attach the absorbent assembly to the backsheet
strips. As an alternative example, an adhesive may be applied
discontinuously at and inside the boundaries of the attachment
zones, such as in the form of dots, stripes, beads, spirals, etc.,
and then used to attach the absorbent assembly to the backsheet
strips.
[0075] The absorbent core 250 may be attached to the first layer 27
of the lower covering sheet 25 over any part or the whole of the
area of the absorbent core. Preferably, the absorbent core is
attached on its exterior surface to the lower covering sheet in a
cruciform attachment pattern, i.e., in an attachment pattern that
forms or is arranged in a cross or "+" shape. The cruciform
attachment pattern may be contiguous, i.e., all of its portions may
be touching or connected throughout the pattern in an unbroken
sequence, or may include detached portions and thereby lack
contiguity but still be arranged such that the shape of the overall
pattern is a cruciform. An exemplary contiguous cruciform
attachment pattern 210 is shown in FIG. 15, FIG. 16, and FIG. 17.
Suitable configurations of cruciform attachment patterns are
disclosed in U.S. patent application Ser. No. 10/880,128 filed on
29 Jun. 2004.
[0076] When an adhesive is used for the attachment, less may be
necessary in a cruciform attachment pattern than in a more
extensive attachment pattern. In addition, the portions of the
lower covering sheet that lie outside such a cruciform attachment
pattern are not restrained by attachment to the absorbent core and
therefore can be extensible. In particular, a relatively narrow
longitudinally extending portion 212 of a cruciform attachment
pattern 210 like that shown in FIG. 15 and FIG. 17 leaves the
majority of the width of the lower covering sheet 25 in the front
waist region 36 and in the back waist region 38 unrestrained by the
absorbent core 250 and thereby allows extension of the lower
covering sheet 25 in the lateral direction in these regions. A
relatively wide laterally extending portion 214 of a cruciform
attachment pattern 210 like that shown in FIG. 15 and FIG. 16
prevents the portion of the lower covering sheet 25 in the crotch
region 37 to which the absorbent core 250 is attached from shifting
relative to the absorbent core 250 in that region and thereby
contributes to the effectiveness of the raised side flaps. For
example, if the lower covering sheet in the crotch region 37 were
free to shift laterally, the raised side flaps 247 might distort
and fail to maintain contact with the body or become improperly
positioned.
[0077] Within the extent of the cruciform attachment pattern, the
absorbent core may be attached to the lower covering sheet
continuously or intermittently. For example, a film of an adhesive
may be applied continuously over the entire area of the cruciform
attachment pattern and then used to continuously attach the
absorbent core to the lower covering sheet. As an alternative
example, an adhesive may be applied discontinuously at and inside
the boundaries of the cruciform attachment pattern, such as in the
form of dots, stripes, beads, spirals, etc., and then used to
attach the absorbent core to the lower covering sheet.
[0078] The absorbent core 250 includes a storage component 272 that
serves to absorb and retain liquid bodily waste materials. Suitable
known materials for the absorbent core storage component include
cellulose fibers in the form of comminuted wood pulp, which is
commonly known as "airfelt", layers or sheets of a natural or
synthetic fibrous material or materials, a superabsorbent polymer
or polymers, etc. These absorbent materials may be used separately
or in combination. Many known absorbent materials may be used in a
discrete form, i.e., in the form of fibers, granules, particles,
layers and the like. Such a discrete form of an absorbent material
may be immobilized by an adhesive that attaches the discrete pieces
together to form a coherent layer or that attaches the discrete
pieces to a substrate layer or that attaches the discrete pieces
both to each other and to the substrate layer.
[0079] The absorbent core may include an acquisition component in
addition to one or more storage components. The absorbent core
acquisition component serves to acquire deposited liquid bodily
waste material and transfer it to the absorbent core storage
component. Any porous absorbent material which will imbibe and
partition liquid bodily waste material to the storage component or
components may be used to form the acquisition component. Preferred
materials for the acquisition component include synthetic fiber
materials, open celled polymeric foam materials, fibrous nonwoven
materials, cellulosic nonwoven materials, and various combination
synthetic/cellulosic nonwoven materials. For example, the
acquisition component may be formed of a nonwoven web or webs of
synthetic fibers including polyester, polypropylene, and/or
polyethylene, natural fibers including cotton and/or cellulose,
blends of such fibers, or any equivalent materials or combinations
of materials. Examples of such acquisition materials are more fully
described in U.S. Pat. No. 4,950,264 issued to Osborn on Aug. 21,
1990. High loft nonwoven acquisition materials suitable for the
acquisition component of the present invention can be obtained from
Polymer Group, Inc., (PGI), 450 N.E. Blvd, Landisville, N.J. 08326,
U.S.A., under the material code designation of 98920.
[0080] Such an absorbent core acquisition component 290 is shown
overlying the absorbent core storage component 272 in FIG. 15, FIG.
16, and FIG. 17. A separation sheet 292 of, e.g. a tissue or a
nonwoven material, may be disposed between the absorbent core
storage component 272 and the absorbent core acquisition component
290 to help ensure that none of the gel formed by a superabsorbent
polymer reaches the skin of the wearer. This separation sheet 292
may extend laterally beyond the side edges 257 of the absorbent
core 250 and the upper covering sheet 24 may be attached to the
separation sheet 292. In this arrangement, the liquid bodily waste
material that is deposited onto the upper covering sheet 24 will
pass through the thickness of the upper covering sheet 24 to be
absorbed by the absorbent core acquisition component 290, and some
or all of it may then pass through the thickness of the separation
sheet 292 and then be absorbed and retained by the absorbent core
storage component 272.
[0081] As shown in FIG. 18, in some exemplary embodiments, an
absorbent core storage component 272 may include the discrete form
of an absorbent material that is immobilized in pockets formed by a
layer of a thermoplastic material, such as a hot melt adhesive,
that intermittently contacts and adheres to a substrate sheet,
while diverging away from the substrate sheet at the pockets.
Absorbent core components having such structures and being suitable
for the storage of liquid bodily wastes are described in co-pending
and commonly assigned U.S. patent application Ser. Nos. 10/776,839
and 10/776,851, both filed on 11 Feb. 2004. An exemplary absorbent
core storage component 272 having such a structure is shown in FIG.
18. In this absorbent core storage component 272, particles 270 of
a superabsorbent polymer are contained inside pockets 280 formed by
a layer 275 of a thermoplastic material. The absorbent core storage
component may include both particles of a superabsorbent polymer
and airfelt and both materials may be contained inside the pockets
formed by the layer of the thermoplastic material. Alternatively,
as shown in FIG. 18, an exemplary absorbent core storage component
may contain no airfelt and therefore the component can be made
relatively thinner and more flexible for the comfort of the wearer.
In addition, the particles of the superabsorbent polymer can be
immobilized relatively more easily in the absence of airfelt. As
shown in FIG. 18, the layer 275 of the thermoplastic material
intermittently contacts and adheres to a substrate sheet 274 at the
areas of attachment 282. Between the areas of attachment 282, the
layer 275 diverges away from the substrate sheet 274 to form the
pockets 280. The layer 275 may have the form of a sheet of fibers
of the thermoplastic material through which the liquid bodily waste
may pass to be absorbed by the particles 270 of the superabsorbent
polymer.
[0082] In FIG. 18, a separate thermoplastic layer covering sheet
276 is shown overlying the layer 275 of the thermoplastic material.
Alternatively, the separate thermoplastic layer covering sheet 276
may be omitted. As another alternative, two absorbent core storage
components each like that shown in FIG. 18 except for the omission
of the thermoplastic layer covering sheet 276 may be superposed
with one absorbent core storage component inverted such that the
respective substrate sheets distally oppose each other. In such a
combination of absorbent core storage components, an uppermost
substrate sheet may serve as an upper covering sheet.
[0083] The absorbent assembly may include an additional bottom
sheet to enhance the protection against leakage. Such an additional
bottom sheet may be water-impermeable and may be formed of a
suitable material, for example a film of polyethylene or another
polyolefin, a microporous breathable film, a hydrophobic nonwoven,
or a film formed of coextruded layers of polyolefin layers. For
example, a suitable coextruded film is available from Clopay
Plastic Products Co. of Mason, Ohio, U.S.A. under the designation
of M18-327. For example, as shown in FIG. 19, an additional bottom
sheet 226 may be disposed below the absorbent core 250 between the
layers 27 and 28 of lower covering sheet 25. Alternatively, the
additional bottom sheet may be attached to the absorbent assembly
either interiorly or exteriorly of the lower covering sheet. This
additional bottom sheet may extend laterally less far than either
of the side edges 237 of the absorbent assembly 200, as shown in
FIG. 19, or may extend laterally to overlap one or both of the side
edges.
[0084] When such an additional bottom sheet is attached inside the
absorbent assembly between the lower covering sheet and the
absorbent core, the additional bottom sheet may be attached to the
lower covering sheet in a cruciform attachment pattern similar to
that shown in FIG. 15, thus leaving the portions of the lower
covering sheet that lie outside the cruciform attachment pattern
unrestrained by attachment to the additional bottom sheet and
allowing these portions to be extensible.
[0085] Alternatively or in addition, the additional bottom sheet in
such an embodiment may be attached in such a cruciform attachment
pattern to the absorbent core, thus leaving the portions of the
additional bottom sheet that lie outside the cruciform attachment
pattern unrestrained by attachment to the absorbent core and
therefore allowing these portions to be extensible. In such an
embodiment, even if the additional bottom sheet is attached to the
lower covering sheet in a pattern other than a cruciform, the lower
covering sheet is not indirectly restrained by the absorbent core
and therefore is allowed to be extensible.
Description of the Shape of the Article
[0086] The finished diaper may have a generally rectangular shape,
as in the exemplary diaper 20 shown in FIG. 1 and FIG. 2. Such a
generally rectangular configuration may be desirable in order to
minimize the amount of waste material and the difficulty associated
with the manufacture of the diaper 20. Alternatively, the diaper
may have side edges 137 that are not straight, but instead are
curved and/or notched, thereby giving an overall shape in plan view
of an hourglass or of an "I" to the diaper 20. Such a
non-rectangular configuration may be desirable in order to impart a
tailored appearance to the diaper 20 when it is worn. Such a
non-rectangular configuration may also be desirable in order to
impart an impression that the diaper 20 will fit comfortably
between the legs of a wearer.
[0087] A non-rectangular configuration of the diaper may be formed
in any one of several ways. For example, laterally distal portions
may be removed from the diaper to make its lateral dimension at and
adjacent to the lateral axis 44 smaller than its lateral dimension
at and adjacent to the front waist edge 136 and smaller than its
lateral dimension at and adjacent to the back waist edge 138, i.e.,
to make the diaper narrower in the crotch region 37 than at the
waist edges. An exemplary form of such a non-rectangular
configuration of the diaper is shown in FIG. 20. As shown in this
figure, portions of the backsheet strips 100 may be removed to form
laterally opposing side notches 111, while leaving the backsheet
strips longitudinally continuous.
[0088] Alternatively, a portion of each of the backsheet strips 100
may be folded laterally inward in order to form a non-rectangular
configuration of the diaper. For example, as shown in FIG. 21, FIG.
22, and FIG. 23, laterally opposing portions 107 of the backsheet
strips 100 in the crotch region 37 may be folded laterally inward
to overlap the respective side flaps 247 and may be attached to the
side flaps, for example, in the respective attachment zones 109.
Preferably, each of the folded laterally opposing portions 107
extends laterally only a part of the way from the respective side
edge 237 of the absorbent assembly 200 toward the longitudinal axis
42, thus leaving uncovered respective exposed portions 207 of the
side flaps, which form breathable side barriers when the diaper is
worn, as described above.
[0089] As another alternative, the backsheet strips may be made
longitudinally discontinuous in order to form a non-rectangular
configuration of the diaper. For example, as shown in FIG. 24, the
backsheet strips may be separated into a left front backsheet strip
100a, a left back backsheet strip 100c, a right front backsheet
strip 100b, and a right back backsheet strip 100d, and each of
these backsheet strips may extend laterally beyond the side edges
237 of the absorbent assembly 200, thereby imparting an "I" shape
to the diaper 20.
Statements of Incorporation by Reference and Intended Scope of
Claims
[0090] Every document cited herein, including any cross referenced
or related patent or application, is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
[0091] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *