U.S. patent application number 12/820215 was filed with the patent office on 2010-10-14 for method for making reusable disposable article.
Invention is credited to Darrell Ian Brown, John Glasgow Burns, JR., Stephen Lebeuf Hardie, Clifford Theodore Papsdorf.
Application Number | 20100258242 12/820215 |
Document ID | / |
Family ID | 39232930 |
Filed Date | 2010-10-14 |
United States Patent
Application |
20100258242 |
Kind Code |
A1 |
Burns, JR.; John Glasgow ;
et al. |
October 14, 2010 |
Method for Making Reusable Disposable Article
Abstract
A method for making absorbent articles such as diapers and
training pants having a pocket for receiving a removable core
component is provided. Absorbent articles having removable
absorbent core components are further provided. A method for
manufacturing an absorbent article comprises providing a wearer
facing portion and a garment facing portion, and providing a first
absorbent core component with either the wearer facing portion or
the garment facing portion. The wearer facing portion and the
garment facing portion are associated such that an openable chassis
pocket is formed there between, the wearer facing portion and the
garment facing portion being separable to create an access opening
to the openable chassis pocket for receiving a replaceable
absorbent core component.
Inventors: |
Burns, JR.; John Glasgow;
(Springfield, OH) ; Papsdorf; Clifford Theodore;
(Miami Twp., OH) ; Brown; Darrell Ian; (Mason,
OH) ; Hardie; Stephen Lebeuf; (Deerfield Twp.,
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: |
39232930 |
Appl. No.: |
12/820215 |
Filed: |
June 22, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11598308 |
Nov 13, 2006 |
7766887 |
|
|
12820215 |
|
|
|
|
Current U.S.
Class: |
156/256 |
Current CPC
Class: |
A61F 13/15764 20130101;
A61F 13/15585 20130101; A61F 13/15804 20130101; A61F 13/505
20130101; A61F 13/15739 20130101; A61F 13/15699 20130101; Y10T
156/1062 20150115; A61F 13/15723 20130101 |
Class at
Publication: |
156/256 |
International
Class: |
B32B 38/04 20060101
B32B038/04 |
Claims
1. A method for manufacturing an absorbent article, the absorbent
article being adapted to be worn about a lower torso of a human
body, the absorbent article having a longitudinal axis and a
lateral axis and comprising a chassis forming a waist opening and a
pair of leg openings and having longitudinally opposing first and
second waist end edges, longitudinally opposing first and second
waist regions adjacent to respective waist end edges, and a crotch
region longitudinally intermediate of the first and second waist
regions, the chassis further comprising a means for receiving a
replaceable absorbent core component, the method comprising:
advancing a top carrier web in a first direction of travel, wherein
the first direction of travel corresponds with the longitudinal
axis; cutting the top carrier web into discrete wearer facing
portions, each wearer facing portion including a; advancing a
process carrier web in a second direction of travel, wherein the
second direction of travel corresponds with the lateral axis;
combining components with the process carrier web to a define a
continuous length of garment facing portions, each garment facing
portion including a backsheet and a first absorbent core component;
redirecting the discrete wearer facing portions from the first
direction of travel to the second direction of travel; and
combining the discrete wearer facing portions with the continuous
length of the garment facing portions, wherein a portion of a
periphery of the discrete wearer facing portions remain unattached
to the continuous length of garment facing portions, thereby
forming a means for accessing the means for receiving the
replaceable absorbent core component.
2. The method of claim 1, wherein the means for receiving the
replaceable absorbent core component is at least partially formed
between the first absorbent core component and the garment facing
portion.
3. The method of claim 1, wherein the means for receiving the
replaceable absorbent core component is at least partially formed
between the first absorbent core component and the wearer facing
portion.
4. The method of claim 1, wherein the first absorbent core
component comprises a plurality of layers of absorbent
material.
5. The method of claim 4, wherein the means for receiving the
replaceable absorbent core component is at least partially formed
between layers of the first absorbent core component.
6. The method of claim 1, wherein the means for accessing the means
for receiving the replaceable absorbent core component is located
at least one of the first and second waist end edges.
7. The method of claim 1, further comprising the step of disposing
the replaceable absorbent core component within the means for
receiving the replaceable absorbent core component.
8. The method of claim 7, wherein a portion of the replaceable
absorbent core component extends beyond the first or second waist
end edge of the absorbent article.
Description
CROSS REFERENCE TO A RELATED APPLICATION
[0001] This application is a continuation of application Ser. No.
11/598,308, filed Nov. 13, 2006, which is hereby incorporated by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for making
absorbent articles such as diapers and training pants. More
particularly, the present invention relates to a method for making
absorbent articles such as diapers and training pants having an
openable chassis pocket for receiving a replaceable absorbent core
component. The invention further relates to a method for making
absorbent articles having an openable chassis pocket wherein a
replaceable absorbent core component is disposed.
BACKGROUND OF THE INVENTION
[0003] Infants and other incontinent individuals wear absorbent
articles such as diapers, training pants and the like to absorb and
retain urine and other body exudates. Absorbent articles function
both to contain the discharged materials and to isolate these
materials from the body of the wearer and from the wearer's
garments and bed clothing. Disposable absorbent articles having
many different basic designs are described, for example, in U.S.
Pat. Re. 26,151 and U.S. Pat. No. 3,860,003. Typically, absorbent
articles have an absorbent core for absorbing urine and other body
exudates. Some of these articles tend to store absorbed fluids in a
discharge region of the article. This discharge region is
positioned generally within the portion of the article that fits in
the wearer's crotch region when worn. A contributing factor to
discomfort of the article to the wearer is the inability of the
article to effectively transport discharged fluids.
[0004] In addition, many absorbent articles, such as catamenial
pads, adult incontinent products, training pants and diapers, may
leak upon repeated discharges of liquid, even if the prior liquid
discharges have been effectively absorbed. Leakage due to repeated
discharges is especially prevalent during the night, when users
commonly experience multiple discharges before the absorbent
article is changed. One factor that restricts the ability of many
absorbent articles to handle multiple discharges of liquid is the
absorbent core's limitations in transporting discharged liquid away
from the discharge region once the absorbent capacity of that
region has been reached. Thus, the overall performance of the
absorbent article may be limited by the inability to transport the
liquid to the farthest reaches of the absorbent core.
[0005] An example of an absorbent material capable of providing
capillary liquid transport is open-celled polymeric foam.
Appropriately made open-celled polymeric foams can provide features
of capillary liquid acquisition, transport, and storage for use in
high performance absorbent cores for absorbent articles such as
diapers. Shaped or contoured absorbent cores made from such
open-celled foam materials are disclosed in U.S. Pat. No.
5,147,345. The '345 patent's absorbent core includes both a liquid
acquisition/distribution member and a liquid storage/redistribution
member. The liquid acquisition/distribution member is positioned
within the absorbent article in such a way as to receive or contact
aqueous bodily liquid which has been discharged into the absorbent
article by the wearer of the article. The liquid
storage/redistribution member, in turn, is positioned within the
article to be in capillary liquid communication with the liquid
acquisition/distribution member.
[0006] Absorbent cores providing the absorbent characteristics of
the '345 patent in an exemplary multi-piece configuration are
disclosed in U.S. Pat. No. 5,906,602, which describes shaped
absorbent cores having a front panel and a back panel in capillary
liquid communication with a center section. The center section
includes material generally suitable for liquid
acquisition/distribution, while the front and back panels include
material generally suitable for liquid storage/redistribution.
[0007] Despite advances in absorbent articles and in liquid
handling absorbent core materials, absorbent articles having
multiple absorbent core components as well as those having unitary
absorbent cores generally remain designed for single use wear. Once
the storage/redistribution member is saturated with bodily
discharges, such as urine, the entire absorbent article is
generally discarded and replaced. Often parts of the absorbent
article are still usable, and except for being unitary with the
absorbent core, these parts could be used further. In addition to
the added cost and waste associated with discarding reusable
materials, it is often inconvenient to remove and replace the
entire absorbent article when absorbent core components are
saturated.
[0008] Absorbent articles having removable absorbent inserts are
disclosed, for example, in U.S. Pat. No. 4,597,761, which discloses
a disposable absorbent insert for use inside an over-garment such
as a conventional reusable diaper, or a disposable diaper. Once the
absorbent insert becomes saturated it may be removed and discarded.
The absorbent article may then be reused with a fresh absorbent
insert. However, because the absorbent insert is removable only
from the body side of the article, the absorbent article is removed
from the wearer in order to remove the insert. Therefore, the
removal of the absorbent insert is often inconvenient and time
consuming.
[0009] It would be advantageous to provide an absorbent article
that provides improved fit and wearer comfort, even after the
article is wetted with body fluids, such as by reducing the
relative amount of fluid retained in the article's crotch region.
It would be further advantageous to provide an absorbent article
which has reduced bulk in the crotch region in both the dry and wet
states. Accordingly, it would be desirable to provide an absorbent
article having an openable chassis pocket for receiving a
replaceable absorbent core component wherein the replaceable
absorbent core component can be replaced without having to remove
the absorbent article from the wearer. It would also be
advantageous to provide a method of manufacturing such an absorbent
article.
SUMMARY OF THE INVENTION
[0010] A method for making absorbent articles such as diapers and
training pants having an openable chassis pocket for receiving a
replaceable absorbent core component is provided.
[0011] In accordance with one embodiment, the method of
manufacturing of an absorbent article comprises providing a first
absorbent core component disposed between a wearer facing portion
and a garment facing portion and associating the wearer facing
portion with the garment facing portion. Association of the wearer
facing portion and the garment facing portion is such that an
openable chassis pocket is formed there between, the wearer facing
portion and the garment facing portion being separable to create an
access opening to the openable chassis pocket for receiving a
replaceable absorbent core component.
[0012] In accordance with another embodiment of the present
invention the method of manufacturing of an absorbent article,
comprises providing a wearer facing portion and a garment facing
portion. The wearer facing portion includes a topsheet and has a
first direction of travel. The garment facing portion includes a
backsheet and has a second direction of travel. The method further
comprises providing a first absorbent core component, the first
absorbent core component associated with one of the garment facing
portion or the wearer facing portion. The method further comprises
changing the wearer facing portion from the first direction of
travel to the second direction of travel. The method further
comprises associating the wearer facing portion with the garment
facing portion such that an openable chassis pocket if formed there
between, the wearer facing portion and the garment facing portion
being separable to create an access opening to the openable chassis
pocket for receiving a replaceable absorbent core component.
[0013] While multiple embodiments are disclosed, still other
embodiments of the invention will become apparent to those skilled
in the art from the following detailed description, which shows and
describes illustrative embodiments of the invention. As will be
realized, the invention is capable of modifications in various
obvious aspects, all without departing from the spirit and scope of
the invention. Accordingly, the drawings and detailed description
are to be regarded as illustrative in nature, and not as
restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] While the specification concludes with claims particularly
pointing out and distinctly claiming the subject matter which is
regarded as forming the present invention, it is believed that the
invention will be better understood from the following description,
which is taken in conjunction with the accompanying drawings in
which like designations are used to designate substantially
identical elements, and in which:
[0015] FIG. 1a illustrates a plan view of a diaper in accordance
with one embodiment.
[0016] FIG. 1b illustrates an exploded view of a diaper in
accordance with one embodiment.
[0017] FIG. 2 illustrates a side cross sectional view of a
replacement core against a backsheet in accordance with one
embodiment.
[0018] FIG. 3 illustrates a side cross sectional view of a
replacement core between a backsheet and a topsheet in accordance
with one embodiment.
[0019] FIG. 4 illustrates a side cross sectional view of a
replacement core against a topsheet in accordance with one
embodiment.
[0020] FIG. 5 illustrates an exploded view of an absorbent core in
accordance with one embodiment.
[0021] FIG. 6 illustrates a side cross sectional view of a diaper
having a replaceable core component between the absorbent core and
the topsheet in accordance with one embodiment.
[0022] FIG. 7 illustrates a side cross sectional view of a diaper
having an openable chassis pocket between two absorbent core
components in accordance with one embodiment.
[0023] FIG. 8 illustrates a side cross sectional view of a diaper
having an openable chassis pocket between an absorbent core and the
backsheet in accordance with one embodiment.
[0024] FIG. 9 is a side cross sectional view of a diaper in a
closed configuration with a replaceable absorbent core being
inserted in an openable chassis pocket in accordance with one
embodiment.
[0025] FIG. 10 illustrates a front view of a diaper with a
replaceable core component positioned at the waist edge in
accordance with one embodiment.
[0026] FIG. 11 illustrates a front view of a diaper with a
replaceable core component and positioning indicia wherein the
replaceable core component is not positioned in accordance with one
embodiment.
[0027] FIG. 12 illustrates a front view of a diaper with a
replaceable core component and positioning indicia wherein the
replaceable core component is positioned in accordance with one
embodiment.
[0028] FIG. 13 illustrates a side cross sectional view of a diaper
having a replaceable core component with a fastening element in
accordance with one embodiment.
[0029] FIG. 14a illustrates a side cross sectional view of a diaper
having a chassis opening at the top waist edge in accordance with
one embodiment.
[0030] FIG. 14b illustrates a front view of a diaper having a
chassis opening at the waist region in accordance with one
embodiment.
[0031] FIG. 15 illustrates a plan view of a process carrier web
without a packet in accordance with one embodiment.
[0032] FIG. 16 illustrates a plan view of a core and chassis
combined on a process carrier web without a packet in accordance
with one embodiment.
[0033] FIG. 17 illustrates a plan view of a core and chassis
combined on a process carrier web without a packet in accordance
with another embodiment.
[0034] FIG. 18 illustrates a process carrier web with a packet in
accordance with one embodiment.
[0035] FIG. 19 illustrates a plan view of a core and chassis
combined on a process carrier web with a packet in accordance with
one embodiment.
[0036] FIG. 20 illustrates a plan view of a core and chassis
combined on a process carrier web with a packet in accordance with
another embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0037] A method for making absorbent articles such as diapers and
training pants having an openable chassis pocket for receiving a
replaceable absorbent core component is provided. Absorbent
articles having replaceable absorbent core components are further
provided.
[0038] The following definitions of terms may be useful for
understanding the disclosure of the present invention.
[0039] As used herein, the term longitudinal axis refers to an axis
of the absorbent article that extends from the midpoint of a first
waist end edge of the article in a first waist region through the
crotch region to the midpoint of a second waist end edge of the
article in a second waist region (and corresponds to the length of
the article at the midpoint).
[0040] As used herein, the term lateral axis refers to an axis of
the absorbent article that extends from the midpoint of a first
longitudinal side edge of the article in the crotch region through
the midpoint of a second longitudinal side edge of the absorbent
article in the crotch region (and corresponds to the width of the
finished article at the midpoint).
[0041] As used herein, the term "absorbent article" refers to a
device that absorbs and contains bodily exudates by means of an
absorbent core, and, more specifically, a device which is placed
against or in proximity to the body of a wearer to absorb and
contain the various exudates discharged from the body. One
embodiment of an absorbent article of the present invention is the
disposable absorbent article, or diaper, shown in the drawing
figures. It should be understood, however, that the present
invention is also applicable to other absorbent articles such as
incontinence briefs, incontinence undergarments, diaper holders and
liners, training pants, pull-on diapers, and the like.
[0042] As used herein, the term "absorbent core component" refers
to a structural constituent of an absorbent core, e.g., a piece of
an absorbent core, such as one of multiple pieces in a multi-piece
absorbent core.
[0043] As used herein, the term "absorbent insert" refers to a
device adapted for insertion into an absorbent article and to serve
as an absorbent core component when so inserted. A replaceable
absorbent core component is an absorbent insert, the latter term
being especially descriptive when referring to the device
alone.
[0044] As used herein, the term "chassis" refers to a foundational
constituent of an absorbent article upon which the remainder of the
structure of the article is built up or overlaid, e.g., in a
diaper, the structural elements that give the diaper the form of
briefs or short pants when configured for wearing, such as a
backsheet, a topsheet, or a combination of a topsheet and a
backsheet.
[0045] As used herein, the term "diaper" refers to an absorbent
article generally worn by infants and incontinent persons about the
lower torso of the wearer.
[0046] As used herein, the term "disposable" is used to describe
absorbent articles that are not intended to be laundered or
otherwise restored or reused as an absorbent article after use,
i.e., that are intended to be discarded after a single use and,
optionally, to be recycled, composted or otherwise disposed of in
an environmentally compatible manner. Note that, as described in
this disclosure, a single use of a chassis and a non-removable core
component may correspond to several uses and replacements of
replaceable core components.
[0047] As used herein, the term "capillary liquid communication"
refers to the flow of a liquid from one absorbent element to
another absorbent element by capillary transport. Also, a term used
to describe a structural disposition of absorbent elements in which
the flow of a liquid from one of the absorbent elements to the
other occurs through capillary transport of the liquid, generally
involving either the direct face-to-face contact of the absorbent
elements with each other, the direct face-to-face contact of each
of the absorbent elements with a hydrophilic intermediate layer
providing capillary conduction of the liquid from one absorbent
element to the other, or the protrusion of the fibers of a fibrous
absorbent element through a porous and/or permeable intermediate
layer into contact with the other absorbent element.
[0048] As used herein, "join," "joined," "joining," and similar
terms refer to configurations wherein an element is directly
secured to another element by affixing the element directly to the
other element, as well as configurations wherein the element is
indirectly secured to the other element by affixing the element to
an intermediate member or members which in turn is or are affixed
to the other element.
[0049] As used herein, "replaceable" describes a component of an
absorbent article that can be replaced, such as a component that
can be removed and for which a like component can be substituted in
place of the removed component, e.g., a replaceable absorbent core
component or absorbent insert.
[0050] As used herein, the term "absorbent core" is used to
describe the portions (e.g., layers) of an absorbent article that
function to acquire, distribute, transfer, store, and/or
redistribute fluid. Acquisition materials include material whose
primary function is to acquire, and optionally then relinquish,
fluids. Such materials include acquisition layers, topsheet
materials, transfer layers, flow control modules, wrap tissues, or
nonwoven sheets designed to prevent migration of hydro-gel forming
polymers, etc. As used herein, the term "distribution material"
refers to the absorbent core material(s) whose primary function is
to absorb and distribute/redistribute fluid to points away from the
point of initial fluid loading. As used herein, the term "storage
material" refers to the absorbent core material that retains a
majority of the fluid retained, on a weight basis. It should be
understood that the terms "distribution material" and "storage
material" are not mutually exclusive. In certain embodiments, a
single material may function to provide both fluid distribution and
fluid storage.
[0051] As used herein, the term "front" refers to the portion of an
article or absorbent core that is intended to be positioned
proximate the front of a wearer. The term "rear" refers to the
portion of an article or absorbent core that is intended to be
positioned proximate the back of the wearer. As such, use of the
relative term "in front of" means a position in the article or core
more toward the front of the article or core, while the term
"behind" means a position in the article or core more toward the
rear of the article or core.
[0052] As used herein, the term "z-dimension" refers to the
dimension orthogonal to the length and width of the member, core or
article. The z-dimension corresponds generally to the thickness of
the member, core, or article. As used herein, the term "x-y
dimension" refers to the plane orthogonal to the thickness of the
member, core, or article. The x- and y-dimensions correspond
generally to the width and length, respectively, of the member,
core, or article.
[0053] As used herein, the term "layers" refers to identifiable
components of the absorbent structure, and any structure referred
to as a "layer" may actually comprise a laminate or combination of
several sheets or webs of materials as hereinafter described. As
used herein, the term "layer" includes the terms "layers" and
"layered." The term "upper" refers to the layer of the absorbent
core that is nearest to and faces the article topsheet; conversely,
the term "lower" refers to the layer of the absorbent core that is
nearest to and faces the article backsheet. The various members,
layers, and structures of absorbent articles may or may not be
generally planar in nature, and may be shaped or profiled in any
desired configuration.
[0054] As used herein, the term "wearer facing portion" refers to
the elements of the chassis that form the inner surface of the
absorbent article, such as the topsheet, the inner leg cuffs, the
outer leg cuffs, the side panels, waistbands, waist shields,
fasteners, etc., when such elements are present.
[0055] As used herein, the term "garment facing portion" refers to
the elements of the chassis that form the outer surface of the
absorbent article, such as the backsheet, the side panels,
waistbands, outer leg cuffs, the fasteners, and the like, when such
elements are present.
[0056] As described below in detail, a method for manufacturing
absorbent articles suitable for absorbing and retaining aqueous
bodily liquids is provided. FIGS. 1a and 1b illustrate a diaper
such as may be used with the present teachings. FIG. 1a illustrates
a plan view of a diaper 60. FIG. 1b illustrates an exploded view of
a diaper 60 in a flat-out, uncontracted state (i.e., with any
elastic-induced contraction removed). As shown, the absorbent
articles generally include a topsheet 61, a backsheet 62, and an
absorbent core 10 positioned between the topsheet 61 and the
backsheet 62. The backsheet 62 may comprise an impermeable layer
and a nonwoven web in the form of a laminate. One example of a
suitable impermeable layer is a polyolefin film layer. As discussed
more fully below in reference to FIGS. 2-4, the absorbent core 10
may include at least one replaceable absorbent core component 20
and/or 30 disposed in capillary liquid communication with at least
one additional absorbent core component such as a non-removable,
absorbent core component 50. The diaper 60 includes a wearer facing
portion 2 and a garment facing portion 3.
[0057] As shown in FIG. 1a, the diaper 60 has a front waist region
12, a back waist region 14, a crotch region 66, and a periphery 57
that is defined by the outer edge of backsheet 62 and that has
longitudinally opposed waist end edges 16a and 16b and laterally
opposed side edges 64a and 64b, left side edge and right side edge
respectively. The waist regions 12, 14 comprise the upper portions
of the diaper 60 that, when worn, encircle the waist of the wearer.
The crotch region 66 is that portion of the diaper 60 between waist
regions 12 and 14, and comprises that portion of the diaper 60
that, when worn, is positioned between the legs of the wearer and
covers the lower torso of the wearer. Thus, the crotch region 66
may define the area of typical liquid deposition for a diaper 60 or
other disposable absorbent article.
[0058] Generally speaking, the diaper 60 includes a chassis forming
a waist opening 13 and a pair of leg openings 15 (waist opening 13
and leg openings 15 shown in FIG. 14b). The diaper 60 has a
longitudinal axis 17 and a lateral axis 18. The chassis has
longitudinally opposed waist end edges 16a and 16b, back and front
waist end edges respectively, longitudinally opposed waist regions
12 and 14, front waist region and back waist region respectively, a
crotch region 66 longitudinally intermediate of the waist regions
12, 14, and laterally opposed side edges 64a and 64b, left side and
right side respectively. The diaper 60 may also comprise first
and/or first and second absorbent core components 52 and 51 (see
FIGS. 2-4) disposed in the crotch region 66, and a replaceable
absorbent core component 20 and/or 30 (see FIGS. 2-4) disposed in
liquid communication, for example capillary liquid communication,
with the absorbent core component. Elastic members 67a, 67b may be
disposed in either or both of the waist regions 12 and 14 of the
diaper 60 to provide a waistband. Elastic members 69a, 69b, 69c,
69d may be disposed intermediate the waist regions generally along
the longitudinally extending laterally opposed side edges 64a and
64b to for elasticated leg cuffs. Fastening means, such as tape tab
fasteners 65a, 65b, may be disposed in the waistband region of the
diaper 60 for holding the diaper in position on the wearer.
Generally, the placement of any of the elements of the diaper may
be varied as suitable for the intended use. Thus, for example, the
fastening means may be disposed at either waist region and are
shown in the back waist region 14 in FIG. 1a and the front waist
region 12 in FIG. 1b.
[0059] As will be described more fully, at least one access opening
44 may be provided for placement of a removable core component.
FIG. 1b illustrates two such access openings 44, one being provided
in each the waist regions 12, 14 of the diaper.
[0060] A barrier leg cuff 240 (see FIG. 1b) including a barrier leg
cuff elastic member 241a/241b (see FIG. 1a) may be disposed
adjacent to each longitudinal edge or between the longitudinal edge
and the longitudinal axis 17 of the diaper. Suitable barrier leg
cuff materials and structures are described in U.S. Pat. Nos.
4,695,278, 4,808,178, and 4,816,025, all of which are incorporated
herein by reference.
[0061] FIGS. 2, 3 and 4 illustrate side views of layers of a diaper
in accordance with various embodiments. In this disclosure, all
description of replaceable absorbent core components, their removal
and replacement, position within the chassis or openable chassis
pocket and access to them for their removal and replacement, is
generally applicable to any of the replaceable absorbent core
components described herein and may be applied to a replaceable
core component inserted proximate the front of the absorbent
article or inserted proximate the back of the absorbent article.
The replaceable absorbent core component may be inserted into the
absorbent article prior to the application of the absorbent article
to the wearer or while the absorbent article is being worn. When
the replaceable absorbent core component is removed, a replacement
absorbent core component may be inserted in place of the removed
absorbent core component. See U.S. Pat. Nos. 6,932,800 and
6,989,006, which are both hereby incorporated by reference.
[0062] The absorbent article may include a plurality of absorbent
core components, including first and second absorbent core
components or layers 52 and 51, respectively, in capillary liquid
communication with a replaceable absorbent core component 20 or 30.
Any of the core components may have suitable liquid acquisition,
acquisition/distribution, and/or storage/redistribution
characteristics. Each of the absorbent core components may include
multiple absorbent layers. Upon saturation with bodily discharges,
the replaceable absorbent core component 30 or components may be
removed from the absorbent article. New, unsaturated replaceable
absorbent core components 20 and/or 30 may then be positioned in
place of the removed saturated replaceable absorbent core
components 20 and/or 30.
[0063] As shown, the diaper comprises a topsheet 61, a first
absorbent core component 52, a second absorbent core component 51,
and a backsheet 62. In alternative embodiments the absorbent core
component 50 may comprise a single layer of absorbent material
instead of separate absorbent layers 51 and 52 as shown. The
absorbent core 10 illustrated in FIGS. 2-4 comprise first and
second core components 52 and 51, respectively, and at least one
replaceable absorbent core component 20 and/or 30. It is understood
that the absorbent core component 50 may comprise a single layer
structure and may be a non removable absorbent core component. It
should also be noted that only one or more replaceable core
components may be disposed in the absorbent article. As will be
described, an openable chassis pocket 5 for receipt of the
replaceable absorbent core component, 20 or 30, may be disposed at
various locations in the z-dimension of the diaper. The openable
chassis pocket 5 may be formed between, for example, the absorbent
core component 50 and the topsheet 61 as illustrated in FIGS. 2 and
6, between layers of the absorbent core component 50 as illustrated
in FIGS. 3 and 7 or between the backsheet 62 and the absorbent core
component 50 as illustrated in FIGS. 4 and 8.
[0064] FIG. 5 illustrates an exploded view of an absorbent core 10
in accordance with one embodiment. As shown, the absorbent core 10
may comprise two replaceable core components 30, and an absorbent
core component 50. The absorbent core component may comprise
absorbent layers 51 and 52.
[0065] The replaceable absorbent core components 20 and/or 30 may
be inserted into an openable chassis pocket 5 formed between layers
of the diaper 60. The pocket 5 may be provided at any suitable
location on the diaper 60, such as between or within any set of
suitable layers. FIGS. 6-8 illustrates side cross sectional views
of diapers having replaceable core components between differing
layers of the diaper. Where not specifically discussed, reference
is made to FIGS. 1a-4 for description of like element numbers.
[0066] As shown in FIG. 6, the replaceable core component 30 may be
provided between the topsheet 61 and an absorbent core 50. The
absorbent core 50 may be provided proximate the backsheet 62. A
liquid pervious layer 205a may be provided associated with the
absorbent core 50. As shown, the replaceable core component 30 is
inserted in the openable chassis pocket 5 through the access
opening 44.
[0067] As shown in FIG. 7, the replaceable core component 30 may be
provided between absorbent layers 51 and 52, with one absorbent
layer 51 being provided proximate the backsheet 62 and one
absorbent layer 52 being provided proximate the topsheet 61. A
liquid pervious layer 205a, 205b may be provided associated with
each of the absorbent layers 51, 52. As shown, the replaceable core
component 30 is inserted in the openable chassis pocket 5 through
the access opening 44.
[0068] As shown in FIG. 8, the replaceable core component 30 may be
provided between the backsheet 62 and an absorbent core 50. The
absorbent core 50 may be provided proximate the backsheet 62. A
liquid pervious layer 205a may be provided associated with the
absorbent core 50. As shown, the replaceable core component 30 is
inserted in the openable chassis pocket 5 through the access
opening 44.
[0069] As discussed, a liquid pervious layer or sheet 205a or 205b
may be provided. For example, the liquid pervious layer or sheet
205a or 206b may be a tissue sheet, or a scrim layer, and may be
positioned within the core structure, such as between an
acquisition/distribution component and a storage/redistribution
component to maintain the physical integrity of the
acquisition/distribution component during processing and/or use.
This liquid pervious sheet 205a, 205b can envelop all or part of an
acquisition/distribution component of the core 10, or simply be
positioned as described above, without enveloping the
acquisition/distribution component. The liquid pervious sheet 205a,
205b may also form all or part of the openable chassis pocket
5.
[0070] The layers of the diaper 60 may be joined together at least
about a portion of the periphery 57 of the absorbent article. As
discussed with respect to FIG. 1b, an access opening 44 may be
provided for accessing the openable chassis pocket 5. In the
embodiment of FIG. 1b, the access opening 44 comprises slots
provided along the garment facing portion 3 of the diaper 50. In
alternative embodiments, such as shown in FIGS. 6-8, in a
predetermined area of the periphery 57, the wearer facing portion 2
of the diaper 60, comprising at least a topsheet 61, and the
garment facing portion 3, comprising at least an impermeable
backsheet 62, may remain non-joined to form an opening 44 along the
periphery providing access to the openable chassis pocket 5 for
receipt of the replaceable absorbent core component 20, 30.
[0071] Referring again to FIGS. 1a and 1b, the topsheet 61 may be
liquid pervious permitting liquids (e.g., urine) to penetrate there
through. Generally, the topsheet 61 may be compliant, soft feeling,
and non-irritating to the wearer's skin. A suitable topsheet 61 can
be manufactured from a wide range of materials such as woven and
nonwoven materials; polymeric materials such as apertured formed
thermoplastic films, apertured plastic films, and hydro-formed
thermoplastic films; porous foams; reticulated foams; reticulated
thermoplastic films; and thermoplastic scrims. Suitable woven and
nonwoven materials can include natural fibers, e.g., wood or cotton
fibers, synthetic fibers, e.g., polymeric fibers such as polyester,
polypropylene, or polyethylene fibers, or a combination of natural
and synthetic fibers. In one embodiment, the topsheet 61 is made of
a hydrophobic material to isolate the wearer's skin from liquids
contained in the absorbent core 10 that is treated on at least one
side with a surfactant to allow liquids to readily penetrate there
through. The topsheet 61 may comprise one or more layers.
[0072] High loft nonwoven topsheets and apertured formed film
topsheets may be used. Apertured formed films are pervious to
bodily liquids, non-absorbent, and have a reduced tendency to allow
liquids to pass through in a direction away from the absorbent core
10 and thereby rewet the wearer's skin. Thus, the surface of the
formed film that is in contact with the body remains dry, thereby
reducing bodily soiling and creating a more comfortable feel for
the wearer. The body-facing surface of the formed film topsheet can
be hydrophilic, thereby helping bodily liquids transfer through the
topsheet faster and diminishing the likelihood that liquid will
flow off the topsheet 61 rather than flowing into and being
absorbed by the absorbent core 10.
[0073] The topsheet 61 is positioned above the wearer facing
surface of the absorbent core 10. The topsheet 61 may be formed by
a single layer or more than one layer. An acquisition material may
be positioned between absorbent core 10 and topsheet 61. As will be
described below, in embodiments wherein the wearer facing portion 2
comprises at least one absorbent core component, the composite
includes the topsheet 61 and may include a second fluid pervious
layer 205a or 205b (see FIGS. 6-8) with at least a portion of the
absorbent core component 50 being disposed between the topsheet 61
and the second fluid pervious layer 205a or 205b.
[0074] The backsheet 62 may be impervious to liquids (e.g., urine),
and yet may permit vapors to escape from the absorbent core 10
(i.e., breathable). The backsheet 62 may prevent the exudates
absorbed and contained in the absorbent core from wetting articles
that contact the diaper 60, such as bed sheets and undergarments.
The backsheet 62 may comprise any suitable material, including a
woven or nonwoven material, polymeric films such as thermoplastic
films of polyethylene or polypropylene, composite materials such as
a film-coated nonwoven material, other materials, or combinations
of thereof. In the embodiments discussed, the backsheet 62 may
comprise a liquid impermeable layer and a vapor permeable layer.
The impermeable layer may comprise a poly material and the
permeable layer may comprise a carrier nonwoven web. The
impermeable layer may comprise a thermoplastic film having a
thickness of from about 0.012 mm (0.5 mils) to about 0.051 mm (2.0
mils), although other flexible liquid impervious materials can be
used. As used herein, the term "flexible" refers to materials that
are compliant and that readily conform to the general shape and
contour of the wearer's body. Suitable polymeric films for use as
the impermeable layer may contain a high content of linear low
density polyethylene. In some embodiments, the impermeable layer
may include blends comprising about 45-90% linear low density
polyethylene and about 10-55% polypropylene, or any other suitable
quantities. Exemplary films for use as the impermeable layer are
manufactured by Tredegar Industries, Inc. of Terre Haute, Ind.
under the designations X-8323, RR8220 blend for certain blown
films, and RR5475 blend for certain cast films, and are
manufactured by Monsanto Chemical Corporation and marketed in the
trade as Film No. 8020. The backsheet 62 may be embossed and/or
matte finished providing a more cloth-like appearance. In
embodiments wherein the garment facing portion comprises at least
one absorbent core component, the composite may include a liquid
pervious layer 205a or 205b (see FIGS. 6-8), a backsheet 62 for
example a substantially liquid impervious layer, and a nonwoven
cover layer. At least a portion of absorbent core component 50 may
be disposed between the backsheet 62 and the liquid pervious layer
205a or 205b.
[0075] In some embodiments, the topsheet 61 and the backsheet 62
are coextensive and have length and width dimensions generally
larger than those of the absorbent core 10. Alternatively, the
topsheet 61 may be slightly smaller than the backsheet 62.
Generally, the size of the backsheet 62 and/or topsheet 61 is
dictated by the size of the absorbent core 10 and the absorbent
article design selected.
[0076] The absorbent core 10 is provided between the topsheet 61
and the backsheet 62. As previously discussed, in some embodiments,
the absorbent core comprises first and second absorbent core
components or layers 52 and 51 and a replaceable absorbent core
component 20 or 30. The dimensions, for example, the length and
extension, of the first and second absorbent core components 52 and
51, respectively, and the replaceable absorbent core component 20
or 30 may be varied to suit the design of the particular absorbent
article. In the case of diapers, the replaceable absorbent core
component 20 and/or 30 can extend from one or both of the front or
back waist regions 12 or 14 respectively into the crotch region 66
of the diaper. The absorbent core components or layers 51, 52 can
extend from one of the waist regions 12 or 14 through the crotch
region 66 into the opposing waist region. The absorbent core
components or layers 51, 52 may not be coextensive. The front and
back waist regions 12 and 14 respectively can be determined by
measuring from the front waist end edge of the absorbent article or
back waist end edge of the absorbent article, respectively, 25% of
the total length of the absorbent article. The crotch region 66 is
the region between the front and back waist regions which
represents the remaining 50% of the total length of the diaper 60.
In alternative embodiments, the percentage length of the diaper
attributed to each of the front waist region, back waist region,
and crotch region may be varied.
[0077] The absorbent core 10 and components thereof may comprise
any absorbent material capable of absorbing and retaining liquids
such as urine and other body exudates. The absorbent core 10 can be
of any suitable shape. For example, the absorbent core 10 may be
provided in an hour glass configuration, wherein the core has
generally arcuate cutouts in its longitudinal edges, or in a
generally rectilinear configuration. The shape and configuration of
each component of the core may be varied. Generally, the absorbent
core components may be substantially rectilinear, may have
increasing width at leading and trailing edges thereof, or may have
varying widths along their length. The absorbent core component 50
may be disposed such that they are generally non-removable from the
diaper chassis. The replaceable absorbent core component 20 and/or
30 is shaped for receipt by the pocket and may be generally
rectilinear, or any other suitable shape, such as a trapezoid,
wedge, triangle, etc. The term "generally rectilinear" refers to a
center section having a generally constant width along its length.
At least one of the absorbent core components or layers, 52, 51, is
typically in liquid communication, for example capillary liquid
communication, with the replaceable absorbent core component 20 or
30, as received by the pocket 5, but need not be coextensive
therewith.
[0078] A multi-piece absorbent core 10 having discrete components
may provide benefits. First, the core may exhibit desirable
aesthetics and fit when used in an absorbent article, due to the
use of discontinuous absorbent layers or panels of absorbent
material. For example, the center section of the core may include
separate absorbent layers allowing the center section to bend and
buckle somewhat independently and thereby provide improved fit and
comfort in the crotch area.
[0079] Another potential advantage provided by a multi-piece
absorbent core 10 is the ability to independently vary selected
characteristics of the absorbent core components and members. The
characteristics that may be varied include the acquisition rates,
distribution rates, storage capacities and rates, interfacial
liquid transfer rates and efficiencies, thickness, functionality,
shape or configuration of the absorbent layers or panels, etc. For
example, an absorbent layer closest to the body of the wearer may
have relatively greater acquisition characteristics than two outer
absorbent layers having relatively greater acquisition/distribution
characteristics. In this configuration, bodily discharges such as
urine are quickly acquired by the acquisition/distribution member
and/or a storage/redistribution member.
[0080] A third potential benefit resulting from the use of a
multi-piece absorbent core 10 is the capability of removing and/or
replacing components of the absorbent core to regenerate the
storage/redistribution capacity of the absorbent core. The
provision of access to the replaceable absorbent core component 30
allows the removal and/or replacement of that absorbent core
component.
[0081] By replacing absorbent core components, particularly
absorbent core components that are primarily suited for
storage/redistribution, the use of the absorbent article, such as
the disposable diaper, may be prolonged while continuing to draw
moisture away from the wearer's skin. As core members become
saturated, they may become substantially less effective at
absorbing moisture. As an absorbent core component becomes more
saturated, its ability to absorb as much moisture away from the
wearer's skin is hindered. Once a replaceable absorbent core
component 20 or 30 is replaced, the absorption of the absorbent
core component 50 in the chassis is renewed or regenerated, and it
once again becomes capable of absorbing moisture. Therefore, the
absorbent article may be worn longer, and regeneration of the
absorbent core may be made without removal of the article from the
wearer.
[0082] Any of the core components may include multiple layers of
absorbent material, each having individual liquid acquisition,
acquisition/distribution, or storage/redistribution
characteristics, as well as individual shape, width, length, and
thickness characteristics. The number and placement of absorbent
layers may be varied to achieve desired characteristics such as
thinness, softness, flexibility, or beneficial liquid acquisition,
distribution, and storage rates, as well as capacity and storage
rates, wearer comfort, etc. The components or members of the
absorbent core may include laminates or combinations of several
sheets or webs of materials. In general, each absorbent core
component or member may be made of any absorbent material or
combination of materials having enough structural integrity to be
handled as a discrete unit.
[0083] Any suitable material or materials may be used for the
absorbent core components. For example, suitable materials include
fibrous nonwoven materials, fibrous air-laid materials, fibrous
wet-laid web materials, and combinations of fibrous materials
having absorbent gelling materials dispersed upon or within the
fibrous structure. Such absorbent core components may be formed
into an insert packet having the fibrous materials substantially
enveloped by a liquid pervious web that provides the structural
integrity for the removal and replacement into the absorbent
article. An exemplary form of a non-woven fibrous absorbent
structure that may be utilized is constructed from hydrophilic
chemically stiffened cellulosic fibers. Absorbent materials for use
as absorbent core components or members may also be foam-based. For
example, a component of the absorbent core may include a foam
material in the form of a sheet or a plurality of foam pieces or
particles, which may be adhesively bonded together or which may
simply be constrained into an unbonded aggregate held together by
an overwrapping of envelope tissue or by means of the topsheet 61
and backsheet 62 of the absorbent article. Suitable absorbent foams
for absorbent articles such as diapers have been made from High
Internal Phase Emulsions, hereafter referred to as "HIPE." The
absorbent core 10 of the absorbent articles described herein also
can include a combination of materials, such as a combination of
conventional elements or materials and one or more foam absorbent
structures. For example, the absorbent articles may utilize an
absorbent core that includes a combination, e.g., an airlaid
mixture, of particles or pieces of the foam absorbent structures
and conventional absorbent materials such as wood pulp or other
cellulosic fibers and/or particles or fibers of polymeric gelling
agents.
[0084] The absorbent core 10 may comprise acquisition components,
acquisition and transfer components, storage and redistribution
components, or any other suitable components. The acquisition
component generally is the uppermost absorbent layer or core
component and acquires the fluid and distributes the fluid away
from the wearer's body to the generally more absorptive core
components provided beneath the uppermost absorbent layer. Thus,
the uppermost absorbent layer is generally on the side
corresponding to the body side of an absorbent article, and is
generally in capillary liquid communication with the topsheet 61 of
the disposable diaper, thereby acting to quickly acquire and
partition bodily exudates. An acquisition and transfer component
acquires the fluid and transfers it to another component. An
acquisition and storage acquires and holds the fluid and may
redistribute the fluid within the component. The function of each
of the chassis absorbent core components or layers, 52 and 51, and
replaceable components, 20 or 30, may depend on the positioning of
the openable chassis pocket 5 within the layers of the diaper, as
described more fully with respect to the method of manufacturing
the diaper.
[0085] Besides acquiring bodily liquids rapidly, an absorbent
acquisition component may transfer liquid efficiently to liquid
acquisition/distribution or storage/redistribution components. This
liquid transfer function of the acquisition member may involve the
acquisition member having sufficient capillary suction to
substantially drain the liquid from the topsheet 61 and yet not
exhibit excessive liquid retention, which would make it difficult
for an underlying absorbent layer to desorb the acquisition
component. In particular, the liquid acquisition component
generally may have a suitable capillary desorption pressure
relative to the absorption pressure of other absorbent core
components, especially those intended for liquid storage. If the
liquid acquisition component of the absorbent article holds the
acquired liquid, this may inhibit the ability of these other
components to partition liquid away, and can cause the acquisition
component to remain loaded with liquid such that the absorbent
article is more susceptible to leaking.
[0086] The liquid acquisition/distribution component generally has
more distributive characteristics than the acquisition component.
Since discharged aqueous bodily liquid, e.g., urine, is frequently
discharged in gushes, the acquisition/distribution component may
acquires this liquid and transport the liquid by wicking or another
mechanism from the point of initial liquid loading to other parts
of the acquisition/distribution component for eventual desorption
to the adjacent liquid storage/redistribution component. Thus, such
materials may have a greater degree of distributive capacity than
the acquisition component materials, such that bodily exudates may
be efficiently transported from the acquisition zone to the storage
component of the absorbent core.
[0087] A suitable absorbent core includes a liquid
storage/redistribution component. The liquid storage/redistribution
component may act to store bodily exudates away from the wearer's
body, so as to leave the wearer with a feeling of dryness and to
prevent leakage. The storage/redistribution component may be
maintained in capillary liquid communication with the acquisition
and/or acquisition/distribution component(s), such that urine or
other aqueous bodily liquids can be desorbed from the acquisition
and/or acquisition/distribution component(s) and be absorbed by the
liquid storage/redistribution component.
[0088] The storage/redistribution component may include a member or
members having primarily liquid storage characteristics. Such a
storage member may have limited transport and wicking capabilities
but high storage or retention capacity, and rely upon a liquid
distribution member to distribute incoming liquid over a larger
area of the storage/redistribution member.
[0089] In some embodiments, it may be desirable to have a "biased"
absorbent core structure, wherein a portion adjacent to one surface
is capable of rapidly acquiring a liquid with reduced dispersion,
while a portion adjacent to an opposing surface is capable of
rapidly dispersing a liquid with lesser acquisition capability.
When oriented in an absorbent article such that the "acquisition
side" is oriented toward the wearer and the "distribution side" is
oriented away from the wearer, a "down and out" functionality is
provided, whereby liquid may be rapidly acquired into the absorbent
core structure with reduced dispersion on its wearer-facing side
and rapidly distributed throughout the portion of the absorbent
core structure on its garment-facing side. This functionality
allows the maintenance of a clean and dry visible and tactile
impression of the absorbent core structure, and hence the absorbent
article, while effectively utilizing the absorptive capacity of the
regions of the absorbent article oriented away from the wearer.
[0090] To provide the above-described functionality, compositions
for the absorbent core 10 may be selected such that the acquisition
side of the absorbent layer is comparatively free of small, high
surface area fibers that provide good distributive and storage
characteristics, and such that the distributive side of the
absorbent layer has a comparatively higher proportion of such
small, high surface area fibers so as to provide greater
distribution characteristics. In some embodiments, the acquisition
area may have both a relatively lower average density and lower
average basis weight per unit area than the distribution area to
establish a capillarity force gradient between them. Also, in foam
absorbent core structures, cell sizes and hole sizes are parameters
that can impact a number of important mechanical and performance
features of the foams, including their fluid wicking properties and
the capillary pressure that is developed within the foam
structure.
[0091] FIGS. 9-13 illustrate replaceable absorbent core components
being inserted or in place within an openable chassis pocket. Where
not specifically discussed, reference is made to FIGS. 1a-8 for
description of like element numbers.
[0092] As shown in FIG. 9, the replaceable absorbent core component
30 is inserted into an openable chassis pocket 5a through an access
opening 44. In the embodiment shown, the access opening 44 is shown
at the back waist region 14 at the waist opening 13. A second
openable chassis pocket 5b may be provided at the front waist
region 12. The first absorbent core component or layer 52 is shown
beginning along the back waist region 14 and the second absorbent
core component or layer 51 is shown beginning along the front waist
region 12. In the embodiment shown, the first and second absorbent
core components or layers 52, 51 are partially coextensive. FIG. 9
further illustrates elastic side panels 210a extending generally
from the waist opening 13 to the leg opening 15. Regardless of the
specific characteristics of the replaceable absorbent core
component 20 and/or 30, the replaceable absorbent core component
and/or the absorbent article may comprise indicators for indicating
proper positioning of the replaceable absorbent core component
within the article. FIGS. 10-12 illustrate various embodiments of a
diaper with a replaceable core component and positioning indicia
for indicating correct positioning of the replaceable core
component in an openable chassis pocket.
[0093] FIG. 10 illustrates a front view of a replaceable absorbent
core component 30 being inserted into an access opening 44 along
the waist opening 13. In the embodiment of FIG. 10, the indicator
comprises a visible indicator line 281 positioned in the outer end
segment of the replaceable core component 30 such that the line is
aligned with the waist end edge 16a of the chassis when the
predetermined position of the replaceable core component is
reached.
[0094] FIGS. 11 and 12 illustrate an alternative embodiment of a
visible indicator. As shown, the indicator may comprise a graphical
object 282 on the replaceable core component 30 may align with a
complementary graphical object 283 on the chassis to form a
side-by-side composite graphical object when a predetermined
position of the replaceable core component is reached. The
replaceable absorbent core component 30 may simply include a half
circle indicator 282 and the absorbent article 60 may include a
complementary half circle indicator 283, such that, when proper
positioning has been achieved, the two half circle indicators
generally form a circle. It is to be recognized that the indicators
may be any suitable shape, whether or not complementary.
[0095] Fastening members also may be included for fastening the
replaceable absorbent core component 30 in place as shown in FIG.
13. FIG. 13 illustrates the replaceable absorbent core component 30
inserted in the openable chassis pocket 5 between the topsheet 61
and the backsheet 62. In the embodiment shown, the fastening member
comprises a hook-and-loop fastener. However, other fastening
members may be used. The hook-and-loop fastener includes one member
(e.g., the hooks) 287 on the replaceable absorbent core component
30 and the other member (e.g., the loops) 286 within the operable
chassis pocket 5 of the absorbent article 60. Thus, for example,
one member of a hook-and-loop fastener 287 may be provided below
the half circle indicator of the replaceable absorbent core
component 30 and the other member of the hook-and-loop fastener 286
may be provided behind the half circle of the absorbent article.
Thus, when properly positioned, the two half circle indicators
align and/or the hook-and-loop fastener engages. Any other suitable
fastening mechanism also may be used and/or any type of indicators
for receiving portions of the fastening mechanism may be used.
[0096] In summary, the absorbent core 10 may include a plurality of
discrete components, each component having distinct liquid
acquisition, acquisition/distribution, or storage/redistribution
characteristics. So long as each of the acquisition,
acquisition/distribution, and storage/redistribution components is
in communication with an adjacent component or components, the
absorbent core components may be positioned relative to one another
in a wide variety of configurations. Any suitable positional
relationship of an acquisition component, an
acquisition/distribution component, and a storage/redistribution
component within the absorbent core may be used. These components
may be in effective liquid communication with each other, with each
component being capable of effectively holding and/or transporting
the amount of aqueous bodily liquid that is expected to be
discharged into the absorbent article. Further, an absorbent core
may not include each of a liquid acquisition component, an
acquisition/distribution component, and a storage/redistribution
component, or may include more than one of any component.
[0097] The diaper 60 may further comprise elastic members that
exert a contracting force on the diaper so that it configures more
closely and more comfortably to the wearer. Elastic members can be
assembled in a variety of well known configurations, such as those
described generally in U.S. Pat. No. 3,860,003. Leg elastic members
may be disposed adjacent to the periphery of the diaper, such as
along each longitudinal edge to form an elastically contractible
leg cuff. FIG. 1a illustrates leg elastic members 69a-69d. The
elastic members 69a-69d tend to draw and hold the diaper 60 against
the legs of the wearer. The leg elastic members 69a-69d may extend
along a portion of the length of the diaper. Alternatively, the leg
elastic members 69a-69d may generally extend the length of the
diaper, or any other length suitable to provide an elastically
contractible line. The length of the leg elastic members is guided
by the diaper design. A barrier leg cuff 240 (see FIG. 1b)
including a barrier leg cuff elastic member 241a/241b (see FIG. 1a)
may be disposed adjacent to each longitudinal edge or between the
longitudinal edge and the longitudinal axis 17 of the diaper.
Suitable barrier leg cuff materials and structures are described in
U.S. Pat. Nos. 4,695,278, 4,808,178, and 4,816,025, all of which
are incorporated herein by reference.
[0098] Again referring to FIGS. 1a and 1b, elastic members can be
disposed in either or both of the waist regions 12 and 14 of diaper
60 to provide a waistband 67a, 67b as well as disposed adjacent the
waist regions to form leg cuffs. See, for example, U.S. Pat. No.
4,515,595. The elastic members may be secured to the diaper 60 in
an elastically contractible condition so that, in a normally
unrestrained configuration, these elastic members effectively
contract or gather the diaper. The elastic members can extend
generally the length of the diaper 60 in the crotch region 66, the
length of the diaper 60, or any other length suitable to provide an
elastically contractible line. The length of these elastic members
may be guided by the diaper's design. While the waistband 67a, 67b
can comprise a separate element affixed to the body of the
disposable diaper 60, it alternatively may comprise an extension of
other elements of the disposable diaper, such as the backsheet 62
or the topsheet 61 or both the backsheet and the topsheet. In one
exemplary embodiment illustrated in the '595 patent, elastic waist
elements extend across generally the lateral width of the
disposable diaper. Similar waistbands may be useful in designs
wherein the elastic waist elements extend across only a portion of
the lateral width of the diaper. In one embodiment, the elastic
waist elements extend across a major portion of the lateral width
of the disposable diaper.
[0099] The absorbent article may have an "open" chassis
configuration, as shown in FIGS. 1a and 1b, in which the chassis is
adapted to be fastened together about the lower torso of a wearer
by the fastening means. Alternatively, the absorbent article may
have a "closed" chassis configuration, such as that of a pull-on
pant-type diaper or training pant, in which the chassis is adapted
to be pulled on over the legs and lower torso of the wearer without
any additional fastening steps. Fastening means, such as tape tab
fasteners 65 may be disposed in the waist region of the diaper 60
for holding the diaper on the wearer.
[0100] Returning to FIG. 9, a diaper 60 in a closed configuration
with the replaceable absorbent core component 30 in place is shown.
In the embodiment of FIG. 9, the diaper 60 has a closed chassis
configuration and is adapted to be pulled on. As shown, a access
opening 44 is provided along the waist edge 16 to an openable
chassis pocket 5a, with a replaceable absorbent core component 30
being disposed inside the openable chassis pocket 5a and with an
openable chassis pocket 5b being provided for receiving a second
replaceable absorbent core component. The replaceable absorbent
core component 30 is removable from and replaceable into the
openable chassis pocket 5a through the access opening 44. For
example, after the removal of a saturated replaceable absorbent
core component, a fresh, unused absorbent core component may be
inserted through the openable end 41a. In the embodiment of FIG. 9,
a first openable chassis pocket 5b is provided in the front waist
region 12 and a second openable chassis pocket 5a is provided in
the back waist region 14. This in this embodiment, the diaper 60
comprises two openable chassis pockets, 5a and 5b, adapted for
receiving replaceable absorbent core components, 20 or 30, however,
as few as one replaceable absorbent core component may be disposed
within the openable chassis pockets and only one openable chassis
pocket may be provided.
[0101] FIGS. 14a and 14b illustrate alternative embodiments of
access openings. Where not specifically discussed, reference is
made to FIGS. 1a-13 for description of like element numbers. As
shown in FIG. 14a, the access opening 44 of the openable chassis
pocket 5 may be formed along a predetermined area of the periphery
57, such as along a waist end edge 16, either in the front, in the
back, or both, where the wearer facing portion and the garment
facing portion are separable to provide access to the replaceable
absorbent core component 30. The access opening 44 is formed by the
separation of the wearer facing portion 2 and the garment facing
portion 3 and allows the removal and replacement of the replaceable
absorbent core component 30 and may be resealable to provide a
substantial degree of liquid impermeability when closed. A closing
mechanism 43, such as a hook-and-loop fastener, may thus be
provided. In the embodiment shown, one member of the closing
mechanism is provided on the backsheet 62 and a complementary
member of the closing mechanism is provided on the topsheet 51.
[0102] Alternatively, as shown in FIG. 14b, the access opening 44
of the openable chassis pocket may be formed in a waist region,
either in the front waist region 12, in the back waist region 14,
or both, where the wearer facing portion or the garment facing
portion comprises an opening 44 to provide access to the openable
chassis pocket 5. In the embodiment shown, the access opening 44 is
formed on the wearer facing portion 2, through the backsheet 62,
along the back waist region 14. The access opening 44 allows the
removal and replacement of the replaceable absorbent core
component. FIG. 14b further illustrates elastic waistband members
67 proximate the access opening 44. The elastic waistband 67 may be
disposed in the waist region between the end edge and an adjacent
end of the absorbent core.
[0103] Referring to the embodiment of FIG. 1a, when an elastic
waistband 67a, 67b is disposed adjacent to an access opening 44
formed by the separation of the wearer facing portion 2 and the
garment facing portion 3 along a waist end edge 16, the waistband
67a, 67b may serve to make the opening 44 elastically openable and
self-closing. For example, such an elastic waistband 67a, 67b,
formed as a separate element affixed to the backsheet 62 or as an
extension of the backsheet 62 in the waist region, may exert a
contractive force, tending to draw the waist end edge 16 of the
backsheet 62 at the periphery toward the topsheet 61, thus tending
to close the access opening 44 of the openable chassis pocket 5
when it is released.
[0104] Alternatively, or additionally, a contact portion may be
provided adjacent the access opening 44. The contact portion may be
used to maintain the topsheet 61 in contact with the wearer when
the access opening 44 is opened. In one embodiment, the contact
portion comprises a band extending generally from one lateral side
of the diaper 60 to another lateral side of the diaper 60 along the
topsheet 61 adjacent the access opening 44. The band may be
integral with the topsheet 61 or may be separate from and coupled
to the topsheet. The band exerts a contractive force on the
topsheet 61 to hold the waist edge of topsheet 61 against the
wearer when the garment facing portion of the diaper 60 is pulled
to open the access opening 44. Any suitable contact portion may be
used. As another example, an elastic waistband 67, formed as either
a separate element affixed to the topsheet 61 or as an extension of
the topsheet 61 in the waist region, may exert a contractive force
tending to hold the waist end edge 16 of the topsheet 61 against
the body of the wearer at all times, including when the waist end
edge 16 of the backsheet 62 or garment facing portion 3 is pulled
away from the wearer facing portion 2 to form the opening 44 and
thereby gain access into the openable chassis pocket 5. In
addition, as described, a flexible substrate forming the chassis,
such as the backsheet 62 and the topsheet 61, may be elasticized or
otherwise extensible. Thus, the layered portions of both the
topsheet 61 and the backsheet 62 in the openable area along the
waist end edge 16 may be elastically contractible, either by means
of a waistband 67 or otherwise. In such an embodiment, when the
garment facing portion 3 is pulled away for access into the
openable chassis pocket 5, the waist end edge 16 of the wearer
facing portion 2 may be held elastically against the body of the
wearer, thereby facilitating the access, and the opening 44 may
also be self-closing by means of the elastic contraction of the
waist end edge 16 of the garment facing portion 3 when it is
released. In further embodiments, a waist shield may be provided.
The waist shield may be used to prevent leakage from the front of
the diaper. Generally, the waist shield is provided over the
interior of the diaper near the waist end edge and comprises a
substantially liquid impervious material.
Method of Manufacturing
[0105] In manufacturing an article, such as the diaper 60 of FIGS.
1a-14b, having an openable chassis pocket 5 for receiving a
replaceable absorbent core component 30, a wearer facing portion 2
and a garment facing portion 3 may be separately manufactured and
then joined together about at least a portion of the peripheries
thereof, providing access to the openable chassis pocket 5.
Generally, the wearer facing portion 2 includes the topsheet 61 and
the garment facing portion 3 includes the backsheet 62. Other
layers of the diaper 60 may be allotted between the wearer facing
portion 2 and the garment facing portion 3, depending on the
desired position of the openable chassis pocket 5 within the layers
of the diaper 60 and the absorbent article design itself. Depending
on the location of the openable chassis pocket 5 the method of
manufacturing may vary. Further, the design of each of the layers,
particularly the layers of the absorbent core 10, may vary
depending on the respective position of the openable chassis pocket
5 and the position of the layers relative to the other components
of the article. While elements of the diaper 60 may be discussed in
reference to the method shown in FIGS. 15-20, reference is made to
FIGS. 1a-14b for illustration and description of such elements.
[0106] In one method of manufacture, illustrated in FIGS. 15-20,
the wearer facing portion 2 has a first direction of travel along
the article's longitudinal axis 17 and the garment facing portion 3
has a second direction of travel along the article's lateral axis
18. Although the wearer facing portion and the garment facing
portion have different directions of travel relative to the article
axis, they can have the same geographical direction of travel, e.g.
north. In this method of manufacture, the wearer facing portion 2
and the garment facing portion 3 are separately constructed from
one or more layers of material.
[0107] FIG. 15 illustrates manufacture of a garment facing portion
3. A generally continuous process carrier web 106 is provided
traveling in direction D1. The process carrier web 106 may comprise
an extensible non woven web. The garment facing portion 3,
comprising the backsheet 62 and the process carrier web 106, may be
processed using a machine-direction process or a side-saddle
process. In the embodiments of the present invention shown, a
side-saddle process is illustrated for processing of the garment
facing portion 3. Thus, a first side edge 104 of each article
backsheet 62 is processed before a second side edge 105 of the
article backsheet 62. Opposing side edges of the process carrier
web 106 may correspond with a front waist edge 16a and a rear waist
edge 16b of the article. Alternatively, the side edges of the
garment facing portion 3 may correspond to the waist edges of the
finished article or may be disposed adjacent the waist edges if the
side edges of the garment facing portion 3 are folded or trimmed
prior to a final product manufacturing step.
[0108] During manufacture of the garment facing portion 3, elements
of the garment facing portion 3 are built up over the process
carrier web. In the embodiment shown, each garment facing portion
may comprise a liquid impervious layer 107 such as a poly layer
that may be impermeable. The poly layer may be larger than the
absorbent core 10 but smaller than the nonwoven portion of the
garment facing portion 3 when such a nonwoven is present for
example in a laminate structure. The process carrier web 106
comprising at least a portion of the backsheet 62 is conceptually
divided along lines to divide the process carrier web into article
sections. Individual layers and/or elements of the garment facing
portion 3 are placed on and/or are joined to the process carrier
web 106.
[0109] FIG. 16 illustrates manufacture of a wearer facing portion
2. A generally continuous top carrier web 126 is provided traveling
in direction D2. In the embodiment shown, the front waist edge 16a
and the rear waist edge 16b of each article are provided along the
top carrier web 126. After the wearer facing portion 2 is
constructed, the top carrier web 126 is cut into discrete pieces of
wearer facing portions. More particularly, the top carrier web 126
is cut along cut lines extending in a direction generally
perpendicular to the article's longitudinal axis 17. The cut lines
of the web comprising the wearer facing portion may correspond to
the front waist edge 16a and back waist edge 16b of the finished
article. The discrete wearer facing portions may be held in an
elastically extended state and subsequently rotated to align the
cut edges with the side edges of the web comprising the garment
facing portion. In one embodiment, a portion of the top carrier web
126 may be held by vacuum in its elastically extended configuration
and then cut transverse to its direction of travel, i.e. parallel
to its lateral axis 18, along cut lines, thereby forming discrete
wearer facing portions.
[0110] After cutting of the discrete wearer facing portions 2, the
wearer facing portions 2 are placed on the garment facing portions
3, as shown in FIG. 17. Thus, FIG. 17 illustrates combining of the
wearer facing portions 2 on the garment facing portions 3 on the
process carrier web 106. The wearer facing portions 2 are spaced
laterally to correspond to the article spacing of the garment
facing portion 3. The direction of travel for the discrete wearer
facing portion is redirected from the direction of travel of the
top carrier web 126 (D2) to the direction of travel of the process
carrier web 106 (D1). Suitable means for rotating and aligning one
substrate with a second substrate are disclosed in U.S. Pat. Nos.
5,025,910 and 6,604,623, which are herein incorporated by
reference. The discrete wearer facing portions 2 are then joined
together with the process carrier web 106 the process carrier web
106 is further processed to create an absorbent articles as
described in more detail below. After the garment facing portion 3
is joined with the wearer facing portion 2, the composite web
undergoes several process transformations including, cutting,
folding and seaming in order to form separate absorbent articles as
illustrated in FIGS. 16 and 17. As will be described, a film may be
provided to form stretchable hip portions or side panels 210 and
elastic strands 67a-d may be provided to form waistbands. Cutting
may be along cut lines 109 to form leg openings 15 and side edge
cut lines 110 to separate the articles.
[0111] In an alternative method of manufacture, the wearer facing
portion 2 has a first direction of travel along the article's
longitudinal axis 17. The garment facing portion 3 has a second
direction of travel along the article's lateral axis 18. In
accordance with this method, the first direction of travel and the
second direction of travel are not the same, geographically.
Therefore the direction of travel of one of the portions is
disposed at an angle relative to the direction of travel of the
other portion. While moving in their respective directions, the
wearer facing portion and the garment facing portion are separately
constructed from one or more layers of material. Opposing side
edges of the web comprising the garment facing portion traveling in
the second direction of travel may correspond with a front waist
edge and a rear waist edge of the article as described above. After
the wearer facing portion 2 is constructed, the top carrier web is
moved into position aligning the edges of the process carrier web
with the laterally spaced garment facing portions disposed on the
process carrier web. The top carrier web is then cut to
substantially correspond to the side edges of process carrier web.
The direction of travel for the discrete wearer facing portion is
redirected from the first direction of travel to the second
direction of travel matching the direction of travel of the garment
facing potion. Suitable means for introducing and aligning the
wearer facing portion and the garment facing portion is disclosed
in U.S. Pat. No. 5,693,165, which is herein incorporated by
reference. The wearer facing portions are joined together with the
garment facing portion, and the web comprising the composite,
wearer and garment facing portion, is then further processed to
create absorbent articles as described in more detail below.
[0112] Generally absorbent articles may be manufactured using an
in-line machine-direction process wherein the primary direction of
travel is along the longitudinal axis 17 of the article, such as
the direction of travel D2 of the top carrier web 126 of FIG. 16.
Alternatively absorbent articles may be manufactured using a
side-saddle process wherein the primary direction of travel is
along the lateral axis 18 of the article, such as the direction of
travel D1 of the process carrier web 106 of FIG. 15. In one example
of a machine-direction process, the article is processed from a
first waist edge to a second waist edge along the longitudinal axis
17. Thus, for example, at a first process, the first waist edge
experiences the first process before the second waist edge. In one
example of a side-saddle process, the article is processed from a
first side edge to a second side edge along the lateral axis 18.
Thus, for example, at a first process, the first side edge
experiences the first process before the second side edge. As
alluded to above in various embodiments, methods for manufacturing
an absorbent article having an openable chassis pocket for
receiving a replaceable absorbent core component may be
manufactured using an in-line machine-direction process, a
side-saddle process, or a combination thereof. In one embodiment,
such as shown in FIG. 16, the wearer facing portion 2 comprising
the topsheet 61 may be processed in a machine direction, with a
first waist edge 16a processed before a second waist edge 16b. In
alternative embodiments, the second waist edge 16b may be processed
before the first waist edge 16a.
[0113] With any of the embodiments discussed above, the top carrier
web 126 comprising the wearer facing portion 2 is cut into discrete
single product units and associated with the garment facing portion
3 disposed on the process carrier web 106 prior to cutting the
process carrier web 106 to form separate absorbent articles, such
as diaper 60. Generally, if the process carrier web 106 is
processed in the side saddle direction, travels in a laterally
oriented direction, any portion manufactured in the machine
direction, traveling in a longitudinally oriented direction, such
as the wearer facing portion 2 in the description above, is rotated
ninety degrees prior to association with the garment facing portion
3 disposed on the process carrier web 106. The angle of rotation is
determined simply by the angle of one process transformation
relative to the other, for example the angle of the wearer facing
portion transformation relative to the garment facing portion
transformation. The wearer facing portion 2 and the garment facing
portion 3 are attached to one another around at least a portion of
their periphery, but may remain unsealed along a portion of at
least one edge, thereby forming an opening 44 to the openable
chassis pocket 5 between the wearer facing portion 2 and the
garment facing portion 3. The process carrier web 106 is cut along
the cut lines 109, thereby creating the leg openings 15 of the
absorbent articles. The process carrier web 106 is folded along the
lateral axis 18 aligning its first waist end edge 16a with the
longitudinally opposing second waist end edge 16b. Suitable seaming
techniques are employed to join the sides of the folded articles
comprised within the process carrier web 106. The articles are
subsequently cut along the side edge cut lines 110, thereby
creating individual absorbent articles.
[0114] In some embodiments, such as shown in FIGS. 18-20, a
replaceable absorbent core component 30 may be provided in the
diaper 60 during the manufacture. The removable core component 30,
provided as a packet, may be positioned on the process carrier web
106. Where not specifically discussed, reference is made to FIGS.
15-17 for description of like reference numbers. Positioning of the
packet may be done at any suitable time. In one embodiment, shown
in FIG. 18, the packet is positioned on the process carrier web,
for example, on a liquid impervious layer 107 of the garment facing
portion 3, prior to combination of the discrete wearer facing
portions 2 with the garment facing portions 3. FIG. 19 illustrates
processing of the top carrier web 126 to form discrete wearer
facing portions 2. FIG. 20 illustrates combination of the discrete
wearer facing portions 2 with the garment facing portions of the
process carrier web 106.
[0115] Whether joined prior to cutting of the garment facing
portion 3 or after cutting of the garment facing portion 3, the
wearer facing portion 2 and garment facing portion 3 are joined
together along at least a portion of the peripheries thereof. In
one embodiment, the wearer facing portion 2 and the garment facing
portion 3 are joined directly to each other by attachment means
such as an adhesive or any other suitable attachment means. For
example, a uniform continuous layer of adhesive, a patterned layer
of adhesive, or an array of separate lines or spots of adhesive may
be used to affix wearer facing portion to the garment facing
portion. Adhesives that have been found to be satisfactory are
manufactured by Century Adhesives, Inc. of Columbus, Ohio and
marketed as Century 5227; and by H. B. Fuller Company of St. Paul,
Minn. and marketed as HL-1258. The attachment means may comprise an
open pattern network of filaments of adhesive as is disclosed in
U.S. Pat. No. 4,573,986. One attachment means of an open pattern
network of filaments comprises several lines of adhesive filaments
swirled into a spiral pattern such as is illustrated by the
apparatus and methods shown in U.S. Pat. Nos. 3,911,173, 4,785,996,
and 4,842,666. Alternatively, the attachment means may comprise
heat bonds, pressure bonds, ultrasonic bonds, dynamic mechanical
bonds, or any other suitable attachment means or combinations of
these attachment means.
[0116] The topsheet 61 may be provided as part of an extensible
web, such as the top carrier web 126. A number of manufacturing
techniques may be used to manufacture the topsheet. For example,
the topsheet 61 may be formed of woven, nonwoven, spunbonded,
carded, or like materials. In nonwoven topsheets, the fibers may be
bound together by a thermal binding procedure or by a polymeric
binder such as polyacrylate. This sheet is substantially porous and
permits a liquid to readily pass therethrough into the underlying
absorbent core. When the topsheet 61 comprises a nonwoven web, the
web may be spunbonded, carded, wet laid, melt-blown,
hydro-entangled, combinations of the above, or the like. The
topsheet 61 material generally has little or no affinity for
holding aqueous bodily liquids in the area of contact between the
topsheet and the wearer's skin. In one embodiment, the topsheet 61
is carded and thermally bonded by means well known to those skilled
in the fabrics art. The topsheet 61 may comprise staple length
polypropylene fibers having a denier of about 2.2, or any other
suitable denier. As used herein, the term "staple length fibers"
refers to those fibers having a length of at least about 15.9 mm
(0.625 in), or any other suitable length. The topsheet 61 may have
a basis weight from about 18 to about 25 g/m.sup.2, or any other
suitable basis weight. A suitable topsheet is manufactured by
Veratec, Inc., a division of International Paper Company, of
Walpole, Mass., under the designation P-8. For the purposes of
description, a porous web is provided as the topsheet material. In
embodiments wherein the topsheet 61 comprises two layers, the
second topsheet layer may be adhered to the top carrier web.
[0117] At least a portion of the topsheet 61 may be subjected to
mechanical stretching in order to provide a "zero strain" stretch
laminate that forms at least a portion of the elastic side panels
210. Thus, the topsheet 61 may be elongatable, possibly drawable,
but not necessarily elastomeric, so that the topsheet 61 may, upon
mechanical stretching, be at least to a degree permanently
elongated such that it may not return to its original
configuration. The topsheet 61 can be subjected to mechanical
stretching without undue rupturing or tearing of the topsheet 61.
Thus, in one embodiment, the topsheet 61 has low cross-machine
direction (lateral direction) yield strength.
[0118] At least a portion of the backsheet 62 may be subjected to
mechanical stretching in order to provide both a "zero strain"
stretch laminate that forms the elastic side panels 210 and, if
desired, to prestrain the portion of the backsheet 62 coinciding
with the elastic waist feature or any other elastic feature. Thus,
the backsheet 62 may be elongatable, and/or may be drawable, but
not necessarily elastomeric, so that the backsheet 62 may, upon
mechanical stretching, be at least to a degree permanently
elongated such that it may not return to its original undistorted
configuration. In some embodiments, the backsheet 62 may be
subjected to mechanical stretching without undue rupturing or
tearing. Thus, the backsheet 62 may have an ultimate elongation to
break of at least about 400% to about 700% in the cross-machine
direction as measured using a method consistent with ASTM D-638.
The backsheet 62 also may have any other suitable elongation,
ranging from 0% to any desired level. Suitable polymeric films for
use as the backsheet 62 may contain a high content of linear low
density polyethylene. Example materials for the backsheet 62
include blends comprised of about 45-90% linear low density
polyethylene and about 10-55% polypropylene, or any other desired
composition. Exemplary films for use as the backsheet 62 are
manufactured by Tredegar Industries, Inc. of Terre Haute, Ind.
under the designations X-8323, RR8220 blend for certain blown
films, and RR5475 blend for certain cast films.
[0119] As discussed previously, layers of the absorbent article may
be allotted between the wearer facing portion 2 and the garment
facing portion 3. These layers may include a first absorbent core
component 52, a second absorbent core component 51. Generally, an
openable chassis pocket 5 is formed between the wearer facing
portion 2 and the garment facing portion 3 for receiving a
replaceable absorbent core component 20 or 30.
[0120] In one embodiment, the absorbent core component 50 is
provided with the garment facing portion 3. Thus, the wearer facing
portion 2 comprises the topsheet 61 and/or top carrier web 126.
More specifically, the top carrier web 126 may act as the topsheet
61. The garment facing portion 3 comprises the process carrier web
106 and the generally impermeable layer forming the backsheet 62
and an absorbent core component 50, A liquid pervious layer, or
cover layer, 205 may be provided over the first absorbent core
component. The cover layer may be a liquid permeable layer, such as
a nonwoven material or tissue that allows fluid to flow to the
absorbent core components. The openable chassis pocket 5 is thus
provided between the first absorbent core component 52 of the
garment facing portion 3 and the wearer facing portion 2.
[0121] In another embodiment, the first absorbent core component 52
is provided with the wearer facing portion 2 and the second
absorbent core component 51 is provided with the garment facing
portion 3. Thus, the wearer facing portion 2 comprises the top
carrier web 126, a first absorbent core component 52, and a second
liquid permeable layer. The garment facing portion 3 comprises the
backsheet 62, including the process carrier web 106 and the poly
impermeable layer, and a second absorbent core component 51. A
liquid pervious layer, or cover layer, 205 may be provided over the
second absorbent core component 51. The cover layer may be a liquid
permeable layer, such as a nonwoven material or tissue that allows
fluid to flow to the second absorbent core component 51. The
openable chassis pocket 5 is thus provided between the second
absorbent core component 51 of the garment facing portion 3 and the
first absorbent core component 52 of the wearer facing portion
2.
[0122] In yet a further embodiment, the absorbent core component 50
is provided with the wearer facing portion 2. Thus, the wearer
facing portion 2 comprises the topsheet, an absorbent core
component 50 and a liquid pervious layer 205. The garment facing
portion 3 comprises the backsheet 62, formed of a generally liquid
impermeable layer 107, and the process carrier web 106. The
openable chassis pocket 5 is thus provided between the impermeable
layer of the backsheet 62 of the garment facing portion 3 and the
second absorbent core component 51 of the wearer facing portion
2.
[0123] Generally, the openable chassis pocket 5 is adapted for
receiving a replaceable absorbent core component 30 and may be
provided between any layers of the absorbent article; for example
between the topsheet 61 and the backsheet 62, between the topsheet
61 and the absorbent core component 50, between layers of the
absorbent core component 50 or between the absorbent core component
50 and the backsheet 62.
[0124] Generally, the layers of an absorbent article can be
combined in any pattern, and in any sequence, such that an openable
chassis pocket 5 is formed. One openable chassis pocket 5 may be
formed, or, in other embodiments, two or more openable chassis
pockets may be formed. The openable chassis pocket(s) may be formed
by combining layers into a preassembled component group (e.g., the
wearer facing portion 2, the garment facing portion 3, or other) or
alternatively the openable chassis pocket 5 may be formed by
attaching a first component group, for example the wearer facing
portion 2, to a second component group, for example the garment
facing portion 3, in a manner wherein an openable chassis pocket 5
is formed between the two component groups. In one embodiment, each
layer of each component group is sealed together. In other
embodiments, one or more edges of one or more layers in a given
component group are not sealed together. It thus can be seen that,
by combining various groupings of layers and partially sealing some
layers together, or partially sealing all layers together except
for at one or more edges, one or more pockets may be formed during
the manufacture of the absorbent article. It also can be seen that,
by combining various layer together into a component group and
sealing each of the layers of a component group together, and then
combining that component group with a similar component group in a
manner that does not seal the component groups together around the
perimeter, a pocket also may be created. Moreover, any number of
component groups may be combined to form any desired number of
openable chassis pockets. It also can be seen that the pockets may
be oriented in any desired fashion, based on which edges are
fastened together and which edges are not fastened together. One or
more removable core components 20 and/or 30 may be provided within
each of the pockets thus formed.
[0125] Other components may be provided on the diaper, as discussed
previously. Referring to FIG. 17, waistbands 67 may be applied to
the absorbent article, generally over the process carrier web 106.
The waistbands may comprise elastic strands 67a-d. A film may be
provided to form a stretchable hip portion or side panel 210, as
shown in FIG. 17. The film may be adhered or laminated to the
nonwoven process carrier web 106. The film of the side panels 210
and the elastic strands of the waistbands 67 may be provided in any
order. As shown, the elastic strands of the waistbands 67 can be
provided substantially continuously over the process carrier web
106 while the film of the side panels 210 is provided at the waist
regions of the article. In one embodiment, the film and elastic
strands are applied to the garment facing portion 3 of the diaper.
Elastic members may be provided on the wearer facing portion 2, as
shown in FIG. 19.
[0126] Elastic members, film, and/or elastic strands may be secured
to the article in an elastically contractible condition so that in
a normally unrestrained configuration, the elastic members
effectively contract or gather portions of the diaper. The elastic
members, film, and/or elastic strands can be secured in an
elastically contractible condition in any suitable manner. For
example, the elastic members can be stretched and secured while the
article is in an extended condition. Any other suitable method also
may be used.
[0127] The topsheet 61 and the backsheet 62 may have the same size
configuration (i.e., are coextensive) such they are joined together
about at least a portion of their periphery. The size of the
backsheet 62 is dictated in part by the size of the absorbent core
and the design selected.
[0128] FIGS. 15-20 illustrate manufacture of an absorbent article
comprising a wearer facing portion 2 and a garment facing portion
3, the wearer facing portion 2 being built up on a top carrier web
126, the garment facing portion 3 being built up on a process
carrier web 106, and the wearer facing portions 2 being combined
with the garment facing portions 3 on the process carrier web 106.
The absorbent article may comprise side panels 210. The side panels
210 may be mechanically activated, as previously described, to
render the side panels 210 elastically extensible. After the
articles have been cut, the articles may be folded and seemed along
the outer edges of the side panels 210 to form a closed chassis
article. Thus, each side panel 210 may be overlapped with and
joined to a respective side panel 210 in the opposing waist region.
Thus, an absorbent article such as a training pant is formed.
Alternatively, the side panels 210 may comprise fastening members
that may be used to refastenably join the side panels 210 to one
another. In embodiments comprising fastening members, the side
panels 210 may be prefastened (fastened prior to packaging) or the
article may be packaged with the side panels unfastened.
[0129] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm".
[0130] All documents cited in the Detailed Description of the
Invention are, in relevant part, incorporated herein by reference;
the citation of any document is not to be construed as an admission
that it is prior art with respect to the present invention. 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.
[0131] 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.
* * * * *