U.S. patent application number 13/490554 was filed with the patent office on 2012-12-27 for absorbent article with a waistband and leg cuff having gathers.
Invention is credited to Jeffrey Will Crosby, Kathleen Marie Lawson, Jeromy Thomas Raycheck.
Application Number | 20120330264 13/490554 |
Document ID | / |
Family ID | 46276042 |
Filed Date | 2012-12-27 |
United States Patent
Application |
20120330264 |
Kind Code |
A1 |
Lawson; Kathleen Marie ; et
al. |
December 27, 2012 |
Absorbent Article With A Waistband And Leg Cuff Having Gathers
Abstract
A disposable absorbent article comprising a first waist region,
a second waist region, a crotch region disposed between the first
waist region and second waist region; a first waist edge and a
second waist edge; and a first longitudinal edge and a second
longitudinal edge; the disposable absorbent article comprising a
waistband and a leg gasketing system, wherein the waistband has a
first gather count and the leg gasketing system has a second gather
count such that the ratio of the first gather count to the second
gather count is from about 0.75 to about 1.25.
Inventors: |
Lawson; Kathleen Marie;
(Mason, OH) ; Raycheck; Jeromy Thomas; (South
Lebanon, OH) ; Crosby; Jeffrey Will; (Cincinnati,
OH) |
Family ID: |
46276042 |
Appl. No.: |
13/490554 |
Filed: |
June 7, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61499298 |
Jun 21, 2011 |
|
|
|
Current U.S.
Class: |
604/385.3 ;
604/385.01 |
Current CPC
Class: |
A61F 2013/49025
20130101; A61F 2013/49092 20130101; A61F 13/49017 20130101; A61F
13/49413 20130101; A61F 13/49009 20130101; A61F 13/49011 20130101;
A61F 13/494 20130101 |
Class at
Publication: |
604/385.3 ;
604/385.01 |
International
Class: |
A61F 13/493 20060101
A61F013/493; A61F 13/496 20060101 A61F013/496; A61F 13/49 20060101
A61F013/49 |
Claims
1. A disposable absorbent article comprising: a first waist region,
a second waist region, a crotch region disposed between the first
waist region and second waist region; a first waist edge and a
second waist edge; and a first longitudinal edge and a second
longitudinal edge; the disposable absorbent article comprising a
waistband and a leg gasketing system, wherein the leg gasketing
system has a first gather count and the waistband has a second
gather count such that the ratio of the first gather count to the
second gather count is from about 0.75 to about 1.25 and the outer
leg cuff gather count is greater than about 13.
2. A disposable absorbent article comprising: a first waist region,
a second waist region, a crotch region disposed between the first
waist region and second waist region; a first waist edge and a
second waist edge; and a first longitudinal edge and a second
longitudinal edge; the disposable absorbent article comprising a
waistband and a leg gasketing system, wherein the leg gasketing
system has a first gather count and the waistband has a second
gather count such that the ratio of the first gather count to the
second gather count is from about 0.75 to about 1.25 and the
waistband gather count is greater than about 12.
3. A disposable absorbent article comprising: a first waist region,
a second waist region, a crotch region disposed between the first
waist region and second waist region; a first waist edge and a
second waist edge; and a first longitudinal edge and a second
longitudinal edge; the disposable absorbent article comprising a
waistband and a leg gasketing system, wherein the leg gasketing
system has a first gather count and the waistband has a second
gather count such that the ratio of the first gather count to the
second gather count is from about 0.75 to about 1.25 and both the
waistband and leg gasketing system are comprised of the same
laminate structure and have a similar color, bond pattern, or
texture.
4. The disposable absorbent article of claim 1, wherein the ratio
of the first gather count to the second gather count is about
1.00.
5. The disposable absorbent article of claim 2, wherein the ratio
of the first gather count to the second gather count is about
1.00.
6. The disposable absorbent article of claim 1, wherein the
waistband has greater than about 10 gathers per 30 mm section.
7. The disposable absorbent article of claim 1, wherein the leg
gasketing system has greater than about 10 gathers per 30 mm
section.
8. The disposable absorbent article of claim 1, wherein the
waistband is present in the first waist edge and the second waist
edge and the leg gasketing system is present in the first
longitudinal edge and the second longitudinal edge.
9. The disposable absorbent article of claim 1, wherein the
waistband and the leg gasketing system have a similar color, bond
pattern, or texture.
10. The disposable absorbent article of claim 1, wherein the
waistband is comprised of a laminate comprising a nonwoven material
and at least one elastic strand, wherein the nonwoven material and
the least one elastic strand are combined under a first strain and
the waistband is attached to the disposable absorbent article under
a an applied waistband strain, wherein the waistband has a Full
Waistband Consolidation of greater than about 95%.
11. The disposable absorbent article of claim 8, wherein the
waistband in the first waist edge and the waistband in the second
waist edge have a Front-to-Back Delta Chassis Contraction greater
than about 9.0%.
12. The disposable absorbent article of claim 1, wherein the leg
gasketing system comprises an inner cuff and an outer cuff; wherein
the inner cuff comprises an inner cuff folded edge and an inner
cuff material edge; wherein the outer cuff comprises an outer cuff
folded edge and an outer cuff material edge such that the web of
material is folded laterally inward to form the outer cuff folded
edge and folded laterally outward to form the inner cuff material
edge.
13. The disposable absorbent article of claim 1, wherein the leg
gasketing system extends from the first waist edge to the second
waist edge.
14. The disposable absorbent article of claim 1, wherein the
article is a taped diaper.
15. The disposable absorbent article of claim 1, wherein the
article is a pant-type diaper.
16. The disposable absorbent article of claim 1 further comprising
an apertured topsheet.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/499,298, filed Jun. 21, 2011, which is herein
incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] This invention relates to absorbent articles such as diapers
having improved waistband properties that yield a more garment-like
article. The absorbent article may have improved functional
characteristics and communicative properties.
BACKGROUND OF THE INVENTION
[0003] Many diapers on the market today have waistbands or waist
stretch elements in which a laminate of nonwovens and elastics
strands are combined with the chassis under some tension. Elastic
strands are the most cost effective way to get stretch that
exhibits little relax or set over time. Nonwovens are preferred for
the exterior of the waist material because it is breathable and
softer than film alternatives. Some executions of applied waistband
consist of elastics stretched in the process and applied
transversely to the length of the product sandwiched in between
some body-facing and some garment-facing material.
[0004] Other executions create a laminate of elastic strands and
nonwoven and apply the laminate to the chassis under contraction
transversely to the length of the product on the body-facing side
such that the only material between the elastics and the body
surface is a nonwoven in the waistband region. It is known that
contraction around the waist will improve the perceived fit of the
product by closing gaps at the back of the diaper, therefore,
closing of these gaps could positively impact real or perceived
leakage/containment. It is also known that when strands of elastic
are combined under strain with other often non-extensible materials
and then allowed to relax, they will create a laminate that has
gathers of a certain frequency and a resulting basis weight that is
higher than the starting materials laid flat. Since waistbands or
stretch elements around the waist are added at full strain, when
pulled tight during application, the waistbands fully extend or
flatten around the waist area resulting in a basis weight around
the waist similar to the starting materials. Therefore, a need
exists to improve waist and leg band construction and application
to the chassis to improve fit and leakage containment.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a disposable absorbent
article comprising: a first waist region, a second waist region, a
crotch region disposed between the first waist region and second
waist region; a first waist edge and a second waist edge; a first
longitudinal edge and a second longitudinal edge, the disposable
absorbent article comprising at least one waistband.
[0006] In one embodiment, the waistband is comprised of a laminate
comprising a nonwoven material and at least one elastic strand,
wherein the nonwoven material and the elastic strand are combined
under a first strain and the waistband is attached to the
disposable absorbent article under an applied waistband strain,
such that the waistband has a Full Waistband Consolidation of
greater than about 95% and/or an Extended Waistband Consolidation
of greater than about 35%.
[0007] In one embodiment, the disposable absorbent article
comprises a first waistband near the first waist edge and a second
waistband near the second waist edge, wherein the Front-to-Back
Delta Chassis Contraction is greater than about 9.0%.
[0008] In one embodiment, the disposable absorbent article
comprises a leg gasketing system, wherein the waistband has a first
gather count and the leg gasketing system has a second gather count
such that the ratio of the first gather count to the second gather
count is from about 0.75 to about 1.25.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a plan view of an exemplary absorbent article.
[0010] FIG. 2 is a plan view of a waistband laminate suitable in
one embodiment of the invention.
[0011] FIG. 3 is a plan view of an absorbent article suitable in
one embodiment of the invention.
[0012] FIG. 4 is a schematic cross section view of an example of a
folded outer leg cuff suitable in one embodiment of the
invention.
[0013] FIG. 5 is a schematic cross section view of an example of a
folded outer leg cuff suitable in one embodiment of the
invention.
[0014] FIG. 6 is a schematic cross section view of an example of an
absorbent core suitable in one embodiment of the invention.
[0015] FIG. 7 is a schematic cross section view of another example
of an absorbent core suitable in one embodiment of the
invention.
[0016] FIG. 8 is a schematic cross section view of another example
of an absorbent core suitable in one embodiment of the
invention.
[0017] FIGS. 9a-d are schematic cross section views of waistband
laminates suitable in embodiments of the invention.
[0018] FIG. 10 is a schematic representation of a template.
DETAILED DESCRIPTION OF THE INVENTION
[0019] As used herein, the following terms shall have the meaning
specified thereafter:
[0020] "Disposable," in reference to absorbent articles, means that
the absorbent articles are generally not intended to be laundered
or otherwise restored or reused as absorbent articles (i.e., they
are intended to be discarded after a single use and, preferably, to
be recycled, composted or otherwise discarded in an environmentally
compatible manner).
[0021] "Absorbent article" refers to devices which absorb and
contain body exudates and, more specifically, refers to devices
which are placed against or in proximity to the body of the wearer
to absorb and contain the various exudates discharged from the
body. Exemplary absorbent articles include diapers, training pants,
pull-on pant-type diapers (i.e., a diaper having a pre-formed waist
opening and leg openings such as illustrated in U.S. Pat. No.
6,120,487), refastenable diapers or pant-type diapers, incontinence
briefs and undergarments, diaper holders and liners, feminine
hygiene garments such as panty liners, absorbent inserts, and the
like.
[0022] "Proximal" and "Distal" refer respectively to the location
of an element relatively near to or far from the longitudinal or
lateral centerline of a structure (e.g., the proximal edge of a
longitudinally extending element is located nearer to the
longitudinal centerline than the distal edge of the same element is
located relative to the same longitudinal centerline).
[0023] "Body-facing" and "garment-facing" refer respectively to the
relative location of an element or a surface of an element or group
of elements. "Body-facing" implies the element or surface is nearer
to the wearer during wear than some other element or surface.
"Garment-facing" implies the element or surface is more remote from
the wearer during wear than some other element or surface (i.e.,
element or surface is proximate to the wearer's garments that may
be worn over the disposable absorbent article).
[0024] "Longitudinal" refers to a direction running substantially
perpendicular from a waist edge to an opposing waist edge of the
article and generally parallel to the maximum linear dimension of
the article. Directions within 45 degrees of the longitudinal
direction are considered to be "longitudinal"
[0025] "Lateral" refers to a direction running from a longitudinal
edge to an opposing longitudinal edge of the article and generally
at a right angle to the longitudinal direction. Directions within
45 degrees of the lateral direction are considered to be
"lateral."
[0026] "Disposed" refers to an element being located in a
particular place or position.
[0027] "Joined" refers to configurations whereby an element is
directly secured to another element by affixing the element
directly to the other element and to configurations whereby an
element is indirectly secured to another element by affixing the
element to intermediate member(s) which in turn are affixed to the
other element.
[0028] "Film" refers to a sheet-like material wherein the length
and width of the material far exceed the thickness of the material.
Typically, films have a thickness of about 0.5 mm or less.
[0029] "Water-permeable" and "water-impermeable" refer to the
penetrability of materials in the context of the intended usage of
disposable absorbent articles. Specifically, the term
"water-permeable" refers to a layer or a layered structure having
pores, openings, and/or interconnected void spaces that permit
liquid water, urine, or synthetic urine to pass through its
thickness in the absence of a forcing pressure. Conversely, the
term "water-impermeable" refers to a layer or a layered structure
through the thickness of which liquid water, urine, or synthetic
urine cannot pass in the absence of a forcing pressure (aside from
natural forces such as gravity). A layer or a layered structure
that is water-impermeable according to this definition may be
permeable to water vapor, i.e., may be "vapor-permeable."
[0030] "Extendibility" and "extensible" mean that the width or
length of the component in a relaxed state can be extended or
increased.
[0031] "Elasticated" and "elasticized" mean that a component
comprises at least a portion made of elastic material.
[0032] "Elongatable material," "extensible material," or
"stretchable material" are used interchangeably and refer to a
material that, upon application of a biasing force, can stretch to
an elongated length of at least about 110% of its relaxed, original
length (i.e. can stretch to 10 percent more than its original
length), without rupture or breakage, and upon release of the
applied force, shows little recovery, less than about 20% of its
elongation without complete rupture or breakage as measured by
EDANA method 20.2-89. In the event such an elongatable material
recovers at least 40% of its elongation upon release of the applied
force, the elongatable material will be considered to be "elastic"
or "elastomeric." For example, an elastic material that has an
initial length of 100 mm can extend at least to 150 mm, and upon
removal of the force retracts to a length of at least 130 mm (i.e.,
exhibiting a 40% recovery). In the event the material recovers less
than 40% of its elongation upon release of the applied force, the
elongatable material will be considered to be "substantially
non-elastic" or "substantially non-elastomeric". For example, an
elongatable material that has an initial length of 100 mm can
extend at least to 150 mm, and upon removal of the force retracts
to a length of at least 145 mm (i.e., exhibiting a 10%
recovery).
[0033] "Elastomeric material" is a material exhibiting elastic
properties. Elastomeric materials may include elastomeric films,
scrims, nonwovens, and other sheet-like structures.
[0034] "Pant" refers to disposable absorbent articles having a
pre-formed waist and leg openings. A pant may be donned by
inserting a wearer's legs into the leg openings and sliding the
pant into position about the wearer's lower torso. Pants are also
commonly referred to as "closed diapers", "prefastened diapers",
"pull-on diapers", "training pants" and "diaper-pants."
[0035] FIG. 1 is a plan view of an exemplary, non-limiting
embodiment of an absorbent article 20 of the present invention in a
flat, uncontracted state (i.e., without elastic induced
contraction). The garment-facing surface 120 of the absorbent
article 20 is facing the viewer. The absorbent article 20 includes
a longitudinal centerline 100 and a lateral centerline 110. The
absorbent article 20 may comprise a chassis 22. The absorbent
article 20 and chassis 22 are shown to have a first waist region
36, a second waist region 38 opposed to the first waist region 36,
and a crotch region 37 located between the first waist region 36
and the second waist region 38. The waist regions 36 and 38
generally comprise those portions of the absorbent article 20
which, when worn, encircle the waist of the wearer. The waist
regions 36 and 38 may include elastic elements such that they
gather about the waist of the wearer to provide improved fit and
containment. The waist regions 36 and 38 may include a first
waistband 1000 and a second waistband 2000. The crotch region 37 is
that portion of the absorbent article 20 which, when the absorbent
article 20 is worn, is generally positioned between the legs of the
wearer. The outer periphery of chassis 22 is defined by
longitudinal edges 12 and lateral edges 14.
[0036] The longitudinal edges 12 may be subdivided into a front
longitudinal edge 12a, which is the portion of the longitudinal
edge 12 in the first waist region 36, and a rear longitudinal edge
12b, which is the portion of the longitudinal edge 12 in the rear
waist region 38. The chassis 22 may have opposing longitudinal
edges 12 that are oriented generally parallel to the longitudinal
centerline 100. However, for better fit, longitudinal edges 12 may
be curved or angled to produce, for example, an "hourglass" shape
diaper when viewed in a plan view. The chassis 22 may have opposing
lateral edges 14 that are oriented generally parallel to the
lateral centerline 110.
[0037] The chassis 22 may comprise a liquid permeable topsheet 24,
a backsheet 26, and an absorbent core 28 between the topsheet 24
and the backsheet 26. The absorbent core 28 may have a body-facing
surface and a garment facing-surface. The topsheet 24 may be joined
to the core 28 and/or the backsheet 26. The backsheet 26 may be
joined to the core 28 and/or the topsheet 24. It should be
recognized that other structures, elements, or substrates may be
positioned between the core 28 and the topsheet 24 and/or backsheet
26. In certain embodiments, the chassis 22 comprises the main
structure of the absorbent article 20 with other features may added
to form the composite diaper structure. While the topsheet 24, the
backsheet 26, and the absorbent core 28 may be assembled in a
variety of well-known configurations, preferred diaper
configurations are described generally in U.S. Pat. Nos. 3,860,003;
5,151,092; 5,221,274; 5,554,145; 5,569,234; 5,580,411; and
6,004,306.
[0038] The topsheet 24 is generally a portion of the absorbent
article 20 that may be positioned at least in partial contact or
close proximity to a wearer. Suitable topsheets 24 may be
manufactured from a wide range of materials, such as porous foams;
reticulated foams; apertured plastic films; or woven or nonwoven
webs of natural fibers (e.g., wood or cotton fibers), synthetic
fibers (e.g., polyester or polypropylene fibers), or a combination
of natural and synthetic fibers. The topsheet 24 is generally
supple, soft feeling, and non-irritating to a wearer's skin.
Generally, at least a portion of the topsheet 24 is liquid
pervious, permitting liquid to readily penetrate through the
thickness of the topsheet 24. The topsheet 24 may include
apertures. One topsheet 24 useful herein is available from BBA
Fiberweb, Brentwood, Tenn. as supplier code 055SLPV09U.
[0039] Any portion of the topsheet 24 may be coated with a lotion
or skin care composition as is known in the art. Examples of
suitable lotions include those described in U.S. Pat. Nos.
5,607,760; 5,609,587; 5,635,191; and 5,643,588. The topsheet 24 may
be fully or partially elasticized or may be foreshortened so as to
provide a void space between the topsheet 24 and the core 28.
Exemplary structures including elasticized or foreshortened
topsheets are described in more detail in U.S. Pat. Nos. 4,892,536;
4,990,147; 5,037,416; and 5,269,775.
[0040] The absorbent core 28 may comprise a wide variety of
liquid-absorbent materials commonly used in disposable diapers and
other absorbent articles. Examples of suitable absorbent materials
include comminuted wood pulp, which is generally referred to as air
felt creped cellulose wadding; melt blown polymers, including
co-form; chemically stiffened, modified or cross-linked cellulosic
fibers; tissue, including tissue wraps and tissue laminates;
absorbent foams; absorbent sponges; superabsorbent polymers;
absorbent gelling materials; or any other known absorbent material
or combinations of materials. In one embodiment, at least a portion
of the absorbent core is substantially cellulose free and contains
less than 10% by weight cellulosic fibers, less than 5% cellulosic
fibers, less than 1% cellulosic fibers, no more than an immaterial
amount of cellulosic fibers or no cellulosic fibers. It should be
understood that an immaterial amount of cellulosic material does
not materially affect at least one of the thinness, flexibility,
and absorbency of the portion of the absorbent core that is
substantially cellulose free. Among other benefits, it is believed
that when at least a portion of the absorbent core is substantially
cellulose free, this portion of the absorbent core is significantly
thinner and more flexible than a similar absorbent core that
includes more than 10% by weight of cellulosic fibers. The amount
of absorbent material, such as absorbent particulate polymer
material present in the absorbent core may vary, but in certain
embodiments, is present in the absorbent core in an amount greater
than about 80% by weight of the absorbent core, or greater than
about 85% by weight of the absorbent core, or greater than about
90% by weight of the absorbent core, or greater than about 95% by
weight of the core. Non-limiting examples of suitable absorbent
cores are described in greater details below.
[0041] Exemplary absorbent structures for use as the absorbent core
28 are described in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,834,735;
4,888,231; 5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207;
5,397,316; and 5,625,222.
[0042] The backsheet 26 is generally positioned such that it may be
at least a portion of the garment-facing surface 120 of the
absorbent article 20. Backsheet 26 may be designed to prevent the
exudates absorbed by and contained within the absorbent article 20
from soiling articles that may contact the absorbent article 20,
such as bed sheets and undergarments. In certain embodiments, the
backsheet 26 is substantially water-impermeable. Suitable backsheet
26 materials include films such as those manufactured by Tredegar
Industries Inc. of Terre Haute, Ind. and sold under the trade names
X15306, X10962, and X10964. Other suitable backsheet 26 materials
may include breathable materials that permit vapors to escape from
the absorbent article 20 while still preventing exudates from
passing through the backsheet 26. Exemplary breathable materials
may include materials such as woven webs, nonwoven webs, composite
materials such as film-coated nonwoven webs, and microporous films
such as manufactured by Mitsui Toatsu Co., of Japan under the
designation ESPOIR NO and by EXXON Chemical Co., of Bay City, Tex.,
under the designation EXXAIRE. Suitable breathable composite
materials comprising polymer blends are available from Clopay
Corporation, Cincinnati, Ohio under the name HYTREL blend P18-3097.
Such breathable composite materials are described in greater detail
in PCT Application No. WO 95/16746 and U.S. Pat. No. 5,865,823.
Other breathable backsheets including nonwoven webs and apertured
formed films are described in U.S. Pat. No. 5,571,096. An
exemplary, suitable backsheet is disclosed in U.S. Pat. No.
6,107,537. Other suitable materials and/or manufacturing techniques
may be used to provide a suitable backsheet 26 including, but not
limited to, surface treatments, particular film selections and
processing, particular filament selections and processing, etc.
[0043] Backsheet 26 may also consist of more than one layer. The
backsheet 26 may comprise an outer cover and an inner layer. The
outer cover may be made of a soft, non-woven material. The inner
layer may be made of a substantially liquid-impermeable film. The
outer cover and an inner layer may be joined together by adhesive
or any other suitable material or method. A particularly suitable
outer cover is available from Corovin GmbH, Peine, Germany as
supplier code A18AH0, and a particularly suitable inner layer is
available from RKW Gronau GmbH, Gronau, Germany as supplier code
PGBR4WPR. While a variety of backsheet configurations are
contemplated herein, 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.
[0044] The absorbent article 20 may include front ears 40 and/or
back ears 42. The ears 40, 42 may be extensible, inextensible,
elastic, or inelastic. The ears 40, 42 may be formed from nonwoven
webs, woven webs, knitted fabrics, polymeric and elastomeric films,
apertured films, sponges, foams, scrims, and combinations and
laminates thereof. In certain embodiments the ears 40, 42 may be
formed of a stretch laminate such as a nonwoven/elastomeric
material laminate or a nonwoven/elastomeric material/nonwoven
laminate. Stretch laminates may be formed by any method known in
the art. For example, the ears 40, 42 may be formed as a zero
strain stretch laminate, which includes at least a layer of
non-woven material and an elastomeric element. The elastomeric
element is attached to the layer of non-woven material while in a
relaxed or substantially relaxed state, and the resulting laminate
is made stretchable (or more stretchable over a further range) by
subjecting the laminate to an activation process which elongates
the nonwoven layer permanently, but the elastomeric element
temporarily. The nonwoven layer may be integral with at least a
portion of the chassis 22, in which case the elastomeric element
may be attached to the nonwoven layer and the non-woven/elastomeric
element laminate is subsequently activated. Alternatively, the
nonwoven layer may be a separate component, in which case the
elastomeric element is attached to the nonwoven layer to form the
laminate, which is then coupled to the main portion. If one or more
layers of the side panel are provided separately, the laminate may
be activated either before or after attachment to the main portion.
The zero strain activation processes is further disclosed in U.S.
Pat. Nos. 5,167,897 and 5,156,793. A suitable elastic ear may be an
activated laminate comprising an elastomeric film (such as is
available from Tredegar Corp, Richmond, Va., as supplier code
X25007) disposed between two nonwoven layers (such as is available
from BBA Fiberweb, Brentwood, Tenn. as supplier code FPN332).
[0045] The ears 40, 42 may be discrete or integral. A discrete ear
is formed as separate element which is joined to the chassis 22. An
integral ear is a portion of the chassis 22 that projects laterally
outward from the longitudinal edge 12. The integral ear may be
formed by cutting the chassis form to include the shape of the ear
projection.
[0046] The absorbent article 20 may also include a fastening system
50. When fastened, the fastening system 50 interconnects the first
waist region 36 and the second waist region 38 resulting in a waist
circumference that may encircle the wearer during wear of the
absorbent article 20. The fastening system 50 may comprises a
fastener such as tape tabs, hook and loop fastening components,
interlocking fasteners such as tabs & slots, buckles, buttons,
snaps, and/or hermaphroditic fastening components, although any
other known fastening means are generally acceptable. Some
exemplary surface fastening systems are disclosed in U.S. Pat. Nos.
3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092;
and 5,221,274. An exemplary interlocking fastening system is
disclosed in U.S. Pat. No. 6,432,098. The fastening system 50 may
also provide a means for holding the article in a disposal
configuration as disclosed in U.S. Pat. No. 4,963,140. The
fastening system 50 may also include primary and secondary
fastening systems, as disclosed in U.S. Pat. No. 4,699,622. The
fastening system 50 may be constructed to reduce shifting of
overlapped portions or to improve fit as disclosed in U.S. Pat.
Nos. 5,242,436; 5,499,978; 5,507,736; and 5,591,152.
[0047] Waistbands of the present invention may result in absorbent
articles having increased comfort, fit, and improved leakage
performance for the wearer. Certain waistbands may also provide
improved product durability and strength. The waistbands of the
present invention may also result an easier and improved absorbent
article changing experience.
[0048] One object of the present invention is to deliver an
absorbent article having improved gap closure in the first and/or
second waist regions of the absorbent article than what is
currently known in the art today. Having gap closure in the waist
regions may create an article with better fit and containment,
resulting in improved leakage performance. One way to achieve gap
closure is to provide a waistband that is flush coterminous with
the rear lateral edge of the absorbent article. Because there is
variation in the application process, in some embodiments, a
waistband may be present in both the first and second waist regions
of the absorbent article. However, while a highly contracted
waistband is desirable for the back waist region to provide
stretch, it may be more desirable to have a less contracted
waistband in the front waist region to aid in application.
Therefore, one embodiment of the present invention is directed to
"differential contraction" or waistband laminates having different
installed elongation strands in the front versus the back, such
that only one waistband laminate is cut. Cutting of the waistband
laminate is subsequent to the waistband application to the article;
the waistband is applied such that it spans the intended article
separation (cut) zone. Thus, the same waistband laminate can
deliver different levels of contraction in the back and front,
resulting in higher contraction in the back to help close the gap
and lower contraction in the front.
[0049] In one embodiment, the first (1000) and second waistbands
(2000) are comprised of a waistband laminate (3000). In one
embodiment, the waistband laminate is comprised of a nonwoven
material (3100). In one embodiment, the waistband laminate is
comprised of a film. In one embodiment, the waistband laminate is
comprised of at least two elastic strands (3200), at least four
elastic strands, at least six elastic strands, at least eight
elastic strands, at least ten elastic strands, at least twelve
elastic strands.
[0050] In one embodiment, the first and second waistbands are
applied to the article at the same applied waistband strain. In one
embodiment, the first waistband and the second waistband are
applied to the disposable absorbent article at a strain of greater
than about 30%, greater than about 50%, greater than about 70% as
compared to the relaxed length. In one embodiment, the first
waistband and the second waistband are applied to the disposable
absorbent article at a strain of less than about 150%, less than
about 125%, less than about 100%, less than about 75% as compared
to the relaxed length. In one embodiment, the first waistband and
the second waistband are applied to the disposable absorbent
article at a strain of from about 70% to about 75% as compared to
the relaxed length.
[0051] In one embodiment, the waistband laminate is comprised of a
nonwoven material and at least two elastic strands, wherein each of
the at least two elastic strands are different elastic materials.
In one embodiment, the elastic strands have different diameters or
cross-sectional geometry.
[0052] In one embodiment, the waistband laminate is cut after
application to the article between the elastic strands such that a
waistband laminate comprised of at least two elastic strands
results in two waistbands each having one elastic strand; a
waistband laminate comprised of at least four elastic strands
results in two waistbands each having two elastic strands. As shown
in FIG. 2, a waistband laminate 3000 comprised of at least six
elastic strands results in two waistbands (1000, 2000) each having
three elastic strands when cut (cut line 4000). Further, a
waistband laminate comprised of at least eight elastic strands
results in two waistbands each having four elastic strands, a
waistband laminate comprised of at least ten elastic strands
results in two waistbands each having five elastic strands, a
waistband laminate comprised of at least twelve elastic strands
results in two waistbands each having six elastic strands. In one
embodiment, the waistband laminate is cut such that the two
resulting waistbands have an unequal distribution of elastic
strands or having no elastic strands on one side of the cut. For
example, a waistband laminate having ten elastic strands may result
in one waistband having six elastics and one waistband having four
elastics. In another example, a waistband laminate having ten
elastic strands may result in one waistband having ten elastics and
one waistband having no elastics. In one embodiment, the waistband
laminate is cut in the center to create the two waistbands. In one
embodiment, the waistband laminate is cut off-center. In one
embodiment, the waistband laminate may have elastic strands spaced
equally apart. In one embodiment, the waistband laminate may have
strands spaced closer together or further apart as compared to the
other elastic strands in the laminate.
[0053] In one embodiment, the waistband has a length in the
direction parallel to the longitudinal axis of the article of
greater than about 12 mm, greater than about 15 mm, greater than
about 20 mm. In one embodiment, the waistband has a length in the
direction parallel to the longitudinal axis of the article f less
than about 50 mm, less than about 45 mm, less than about 40 mm. In
one embodiment, the waistband in a relaxed product has a length in
the direction parallel to the lateral axis of the article of
greater than about 50 mm, greater than about 75 mm, greater than
about 100 mm. In one embodiment, the length in the direction
parallel to the lateral axis of the article of the waistband in a
relaxed product is less than about 300 mm, less than about 250 mm,
less than about 200 mm.
[0054] In one embodiment, the CD Length Ratio of the waistband
compared to the distance from one tape to the other tape is less
than about 2, less than about 1.5, about 1.
[0055] In one embodiment, the waistband is on the body-facing
surface of the article. In one embodiment, the waistband is on the
garment-facing surface of the article. In one embodiment, the
waistband is sandwiched in between the layers of the absorbent
article. In one embodiment, the waistband is on the garment-facing
surface in either the first or second waist regions and on the
body-facing surface in either the first or second waist regions. In
one embodiment, the waistband is on both the body-facing surface
and the garment-facing surface. In one embodiment, the waistband is
on either the body-facing surface or the garment-facing surface and
the surface not comprising the waistband is printed with a printed
waistband feature.
[0056] In one embodiment, the distance from one tape edge to the
other tape edge is at least about 50% the average length of the
baby waist circumference for an average baby that wears the size of
absorbent article; at least about 60% the average length; at least
about 65% the average length.
[0057] In one embodiment, the elastic strands of the waistband
laminate may have different installed elongations within one
laminate, thus, after being cut, resulting in a first waistband
having a first installed elongation and a second waistband having a
second installed elongation; both the first and second waistbands
have the same applied waistband strain. The installed elongation is
the strain at which the elastic is under relative to the second
material that it is combined with (e.g. low basis weight nonwoven).
For example, if the elastic is stretched from 100 mm to 250 mm when
it is combined with the nonwoven, it would be said to be 150%
installed elongation or ((250 mm/100 mm)-1).times.100%. This
laminate can then be allowed to relax and will return to about the
original 100 mm, but with 250 mm of nonwoven. There can be more
than one installed elongation within one waistband laminate if the
elastics are strained to a different degree. For example, strand
(1) is stretched from 100 mm to 250 mm when combined with the
nonwoven or has 150% installed elongation while strand (2) is
stretched from 90 mm to 250 mm when combined with the NW or has an
installed elongation of about 178%.
[0058] The Applied Waistband Strain is the strain that the
waistband laminate is under when combined with the absorbent
article. For example if 100 mm of laminate is stretched to 170 mm
when applied it would be considered to be 70% applied waistband
strain or ((170 mm-100 mm)/100 mm.times.100%). In one embodiment,
the first installed elongation of any number of elastic strands is
about 100%, about 125%, about 140%, about 150%, about 160%, about
175%, about 200%. In one embodiment the second installed elongation
of any number of elastic strands is about 100%, about 125%, about
140%, about 150%, about 160%, about 175%, about 200%.
[0059] In one embodiment, the delta between the first installed
elongation and the second installed elongation is greater than
about 20%, greater than about 30%, greater than about 40%.
[0060] In one embodiment, the resulting Front-to-Back Delta Chassis
Contraction is greater than about 5.0%, greater than about 9.0%,
greater than about 9.5%, greater than about 12.5%, greater than
about 15%, greater than about 20%.
[0061] In one embodiment, the Front-to-Back Delta Chassis
Contraction is less than about 15%, less than about 12.5%, less
than about 10%, less than about 9.5%, less than about 9% when
either the front chassis contraction or the back chassis
contraction is greater than about 18%, greater than about 20%.
[0062] Another object of the present invention is to deliver a
better balance of thickness (caliper)/cushion and contraction in a
waistband than what is currently known in the art. Presently, most
waistbands are either foam based which have good cushion/caliper
for comfort and containment but are limited in the amount of
contraction or the waistbands are a combination of elastic strands
and nonwoven where the elastic strands are pulled at high strain
which delivers high contraction, but very little caliper/cushion in
use. Thus, one embodiment of the present invention is directed to
"consolidation" which provides a waistband having the nonwoven
material and the elastic strand(s) combined under a higher first
strain (installed elongation) and the resulting waistband attached
to the article under a lower applied waistband strain, such that
the folded up nonwoven in the waistband provides a cushion/caliper
in both the relaxed and stretched/in use states. FIG. 9 depicts
cross sectional views of the waistband laminate (3000). FIGS. 9a-b
depict cross sections of the waistband with no extended
consolidation. FIG. 9a depicts a relaxed product cross section at
the waist, parallel to the lateral axis of the diaper chassis (22).
FIG. 9b shows an extended product cross section at the waist,
parallel to the lateral axis of the diaper. FIGS. 9c-d depict cross
sections of the waistband with extended consolidation. FIG. 9c
shows a relaxed product cross section at the waist, parallel to the
lateral axis of the diaper. FIG. 9c shows that the frequency and
amplitude of the waistband is higher than that of the chassis it is
applied to. FIG. 9d shows an extended product cross section at the
waist, parallel to the lateral axis of the diaper. FIG. 9d shows
that even when the chassis is extended, the waistband still has
gathers and caliper.
[0063] In one embodiment, the waistband is comprised of a laminate
comprising a nonwoven material and at least one elastic strand,
wherein the nonwoven material and the elastic strand(s) are
combined under a first strain and the waistband is attached to the
article under an applied waistband strain. In one embodiment, the
first strain, also referred to as the installed strand elongation,
is greater than about 50%, greater than about 75%, greater than
about 100%, greater than about 150%, greater than about 200%,
greater than about 225%, greater than about 250%, greater than
about 300%, greater than about 350%, greater than about 375%. In
one embodiment, the applied waistband strain, also referred to as
the waistband strain is greater than about 25%, greater than about
50%, greater than about 75%, greater than about 100%. In one
embodiment, the difference between the first strain and the applied
waistband strain, also referred to as Consolidation, is greater
than about 0%, greater than about 65%, greater than about 75%,
greater than about 100%, greater than about 150%, greater than
about 200%, greater than about 225%, greater than about 250%,
greater than about 300%.
[0064] In one embodiment, the waistband has a Full Waistband
Consolidation greater than about 95%, greater than about 100%,
greater than about 125%, greater than about 150%, greater than
about 175%, greater than about 200%.
[0065] In one embodiment, the waistband had an Extended Waistband
Consolidation greater than about 35%, greater than about 50%,
greater than about 75%, greater than about 100%, greater than about
125%, greater than about 175%.
[0066] In one embodiment, the waistband is attached near the waist
edge. In one embodiment, the waistband is attached within 20 mm of
the waist edge. In one embodiment, the waistband is attached flush
with the waist edge. In one embodiment, the waistband is present
only at one waist edge. In one embodiment, the waistband is present
at both the first and second waistband edges.
[0067] The nonwoven material and the elastic strand(s) may be
combined with adhesive, mechanical bonds, or any other forms of
attachment known in the art. The waistband may be attached to the
article with adhesive, mechanical bonds, or any other forms of
attachment known in the art.
[0068] In one embodiment, the relaxed caliper of the waistband is
greater than about 1.60 mm, greater than about 2.00 mm, greater
than about 2.25 mm, greater than about 2.50 mm.
[0069] In one embodiment, the extended caliper of the waistband is
greater than about 0.80 mm, greater than about 1.00 mm, greater
than about 1.25 mm.
[0070] Another object of the present invention is to deliver an
integrated leg gasketing system and front/back waistband feature
that provides extra leakage protection around the perimeter of the
article. Thus, one embodiment of the present invention is directed
to "360 Leakage Protection" which provides a common leg gasketing
system and waistband with similar construction having similar
gather counts. Additional embodiments may include leg gasketing
systems and waistbands that overlap or have similar tints,
textures, bond patterns, colors, or other visual cues. FIG. 3
depicts an embodiment having gathers in both the waistband regions
and leg gasketing system.
[0071] In one embodiment, the disposable absorbent article
comprising a waistband and a leg gasketing system, as described
herein, wherein the leg gasketing system has a first gather count
and the waistband has a second gather count such that the ratio of
the first gather count to the second gather count is greater than
about 0.5, greater than about 0.75, less than about 1.25, less than
about 1.50. In one embodiment, the ratio of the first gather count
to the second gather count is about 1.00. In one embodiment, the
ratio of the first gather count to the second gather count is from
about 0.75 to about 1.25. In one embodiment, the ratio of the first
gather count to the second gather count is from about 0.75 to about
1.25, when the leg gasketing system gather count is greater than
about 13. In one embodiment, the ratio of the first gather count to
the second gather count is from about 0.75 to about 1.25, when the
waistband gather count is greater than about 12. In one embodiment,
the ratio of the first gather count to the second gather count is
from about 0.75 to about 1.25, when the absorbent article is a
taped-type product.
[0072] In one embodiment, both of the waistband and leg gasketing
system comprise elastic strands; in one embodiment, the waistband
comprises elastic strands; in one embodiment, both the waistband
and leg gasketing system comprise the same type of stretch material
and/or laminate structure.
[0073] In one embodiment, the waistband has greater than about 10
gathers per 30 mm section, greater than about 12 gathers per 30 mm
section. In one embodiment, the leg gasketing system has greater
than about 10 gathers per 30 mm section, greater than about 12
gathers per 30 mm section.
[0074] In one embodiment, the waistband is present in the first
waist edge and the second waist edge and the leg gasketing system
is present in the first longitudinal edge and the second
longitudinal edge.
[0075] The absorbent article 20 may include a leg gasketing system
70 as described in U.S. Patent Applications Attorney Docket No.
12109P and 12110P, both filed on Apr. 29, 2011. FIGS. 4 and 5
depict schematic cross section views of exemplary leg gasketing
systems. The leg gasketing system 70 may comprise an inner barrier
leg cuff 71 comprising an inner cuff folded edge 72 and an inner
cuff material edge 73. The leg gasketing system 70 may further
comprise an outer cuff 74 comprising an outer cuff folded edge 75
and an outer cuff material edge 76.
[0076] In one embodiment, the leg gasketing system 70 comprises one
web of material. An embodiment having one web of material may
provide a cost advantage over embodiments having more than one web
of material. Further, an embodiment having one web of material may
have fewer leaks, as there are no holes created by bonding more
than one web of material. Also, an embodiment having one web of
material may be more aesthetically pleasing, as few mechanical
bonds are visible.
[0077] In one embodiment, the leg gasketing system 70 has an inner
barrier leg cuff 71 comprised of an inner cuff folded edge 72 and
an inner cuff material edge 73. The leg gasketing system 70 may
further comprise an outer cuff 74 comprising an outer cuff folded
edge 75 and an outer cuff material edge 76. In one embodiment, the
web of material is folded laterally inward to form the outer cuff
folded edge 75 and folded laterally outward to form the inner cuff
folded edge 72. In one embodiment, the leg gasketing system 70
extends from the first waist edge 36 to the second waist edge 38
and is joined to the topsheet 24 and/or backsheet 26 between the
inner cuff folded edge 72 and the outer cuff folded edge 75 in the
crotch region 37. In one embodiment, the outer cuff material edge
76 is disposed laterally inboard the inner cuff material edge
73.
[0078] In one embodiment, the outer leg cuff 74 comprises elastic
members 77 positioned in a lateral array between the outer cuff
folded edge 75 and outer cuff material edge 76; the outer leg cuff
74 optionally comprises at least two elastic members 77, at least
three elastic member 77, at least four elastic members 77, at least
five elastic members 77, at least six elastic members 77. In one
embodiment, the elastic members 77 may be disposed between the
outer cuff folded edge 75 and the inner cuff material edge 73.
[0079] In one embodiment, the inner barrier leg cuff 71 comprises
an array of elastic members 78 in the area of the inner cuff folded
edge 72; the inner barrier leg cuff 71 optionally comprises at
least one elastic member 78, at least two elastic members 78, at
least three elastic members 78, at least four elastic members 78,
at least five elastic members 78. In one embodiment, the elastic
members 78 may be disposed between the inner cuff folded edge 72
and the outer cuff material edge 76. In one embodiment, the leg
gasketing system 70 has an inner barrier leg cuff 71 comprised of
an inner cuff folded edge 72 and an inner cuff material edge 73.
The leg gasketing system 70 may further comprise an outer cuff 74
comprising an outer cuff folded edge 75 and an outer cuff material
edge 76. The leg gasketing system may comprise a first material
comprising the inner barrier leg cuff 71 and a second material
comprising the outer cuff 74. The first and second material may
overlap and be joined together along a longitudinal edge of each
material by any suitable bonding means. In one embodiment, the web
of material is folded laterally inward to form the outer cuff
folded edge 75 and folded laterally outward to form the inner cuff
folded edge 72. In one embodiment, the proximal edges of the outer
cuff 74 are coterminous.
[0080] One advantage of the leg gasketing system 70 of the present
invention is that when a substantially liquid-impervious material
is used in construction of the cuff, the polymeric film layer may
be narrowed or not present at all, resulting in more cost effective
designs. Utilizing adhesive technologies that are more reliably
processed results in more reliable performance and creates
substantially liquid impervious seals. This technology enables
narrowing the film layer to be only slightly wider than the
absorbent core by reducing the need for redundant seals. In one
embodiment of the present invention, the backsheet polymeric film
is less than about 50 mm wider than the absorbent core; optionally
less than about 40 mm wider, less than about 30 mm wider. In one
embodiment, the backsheet polymeric film is at lest about 20 mm
more narrow than the chassis width; optionally at least about 40 mm
more narrow than the chassis width; optionally at least about 60 mm
more narrow than the chassis width; optionally at least about 80 mm
more narrow than the chassis width; optionally at least about 100
mm more narrow than the chassis width; optionally at least about
120 mm more narrow than the chassis width.
[0081] In one embodiment of the present invention, an opacity
strengthening patch 80 may be included. The opacity strengthening
patch 80 is an additional layer of material. The opacity
strengthening patch 80 may be connected to the leg gasketing system
70, the polymeric film layer, or the backsheet 26. The opacity
strengthening patch 80 may be disposed between the backsheet 26 and
leg gasketing system 70 in either the first waist region 36, the
second waist region 38, or both the first waist region 36 and the
second waist region 38 of the article; the opacity strengthening
patch 80 may overlap at least one of the leg gasketing system 70 or
the polymeric film layer. The opacity strengthening patch 80 may be
attached to one or both of the leg gasketing system 70 or the
polymer film layer using any suitable means such as glue,
mechanical bonds, thermal bonds, or the like, so that loads
generated during the application process or during wear can be
transferred from the lateral edge of the article to the leg
gasketing system 70 and/or the polymeric film layer. The opacity
strengthening patch is useful in providing the strength needed to
prevent the article from extending excessively during application
and wearing; it also may provide opacity at the sides and waist to
prevent the skin of the user from showing through the article.
Thus, the patch 80 may be located at any portion of the chassis
where strength and opacity is desirable. Materials suitable to act
as the opacity strengthening patch include materials having a basis
weight of at least about 10 gsm, at least about 15 gsm, at least
about 25 gsm. An opacity strengthening patch useful herein may
exhibit the following tensile properties in the cross direction: at
2% engineering strain for a 1 inch wide sample, 0.4N; at 5%
engineering strain for a 1 inch wide sample, 1.25N; at 10%
engineering strain for a 1 inch wide sample, 2.5N. One opacity
strengthening patch useful herein is available from Pegas, Znojmo,
CZ, as supplier number 803968.
[0082] In one embodiment, the material of the leg gasketing system
70 is made from a substantially liquid impervious material. The
material may be selected from the group consisting of an SMS
nonwoven, SMMS nonwoven material, or a nonwoven component layer
comprising "N-fibers".
[0083] Various nonwoven fabric webs may comprise spunbond,
meltblown, spunbond ("SMS") webs comprising outer layers of
spunbond thermoplastics (e.g., polyolefins) and an interior layer
of meltblown thermoplastics. In one embodiment of the present
invention, the leg gasketing cuff 70 comprises a nonwoven component
layer having fine fibers ("N-fibers") with an average diameter of
less than 1 micron (an "N-fiber layer") may be added to, or
otherwise incorporated with, other nonwoven component layers to
form a nonwoven web of material. In some embodiments, the N-fiber
layer may be used to produce a SNS nonwoven web or SMNS nonwoven
web, for example. N-fibers are further discussed in WO 2005/095700
and U.S. patent application Ser. No. 13/024,844. In one embodiment,
an absorbent article includes an absorbent core 28 that is
substantially cellulose free, as described in U.S. Pat. No.
7,750,203; U.S. Pat. No. 7,744,576, and U.S. Patent Publication No.
2008/0312617A1. Cross-sectional views of examples of suitable
absorbent cores are schematically represented in FIGS. 6-8. In one
embodiment, an absorbent core 28 comprises first and second layers
of material 281, 282 and an absorbent material 283 disposed between
the first and second layers 281, 282. In one embodiment the first
and second layers of material can be a fibrous material chosen from
at least one of a nonwoven fibrous web, a woven fibrous web and a
layer of thermoplastic adhesive material. Although the first and
second layers can be made of a same material, in one embodiment,
the first layer 281 is a nonwoven fibrous web and the second layer
282 is a layer of thermoplastic adhesive material. A nonwoven
fibrous web 281 can include synthetic fibers, such as
mono-constituent fibers of PE, PET and PP, multi-constituent fibers
such as side by side, core/sheath or island in the sea type fibers.
Such synthetic fibers may be formed via a spunbonding process or a
meltblowing process. The nonwoven fibrous web 281 may include a
single layer of fibers but it may also be advantageous to provide
the nonwoven web with multiple layers of fibers such as multiple
layers of spunbond fibers, multiple layers of meltblown fibers or
combinations of individual layer(s) of spunbond and meltblown
fibers. In one embodiment, the nonwoven web 281 can be treated with
an agent (such as a surfactant) to increase the surface energy of
the fibers of the web. Such an agent renders the nonwoven web more
permeable to liquids such as urine. In another embodiment, the
nonwoven web can be treated with an agent (such as a silicone) that
lowers the surface energy of the fibers of the nonwoven web. Such
an agent renders the nonwoven web less permeable to liquids such as
urine.
[0084] The first layer 281 comprises a first surface 2811 and a
second surface 2812 and at least regions 2813 of the first surface
are in direct facial relationship with a significant amount of
absorbent material 283. In one embodiment an absorbent material is
deposited on the first surface 2811 in a pattern to form regions
2813 on the first layer 281, which are in direct facial
relationship with a significant amount of absorbent polymer
material 283 and regions 2814 on the first web that are in facial
relationship with only an insignificant amount of absorbent
material. By "direct facial relationship with a significant amount
of absorbent material" it is meant that some absorbent material is
deposited on top of the regions 2813 at a basis weight of at least
100 g/m.sup.2, at least 250 g/m.sup.2 or even at least 500
g/m.sup.2. The pattern may include regions that all have the same
shape and dimensions (i.e. projected surface area and/or height).
In the alternative the pattern may include regions that have
different shape or dimensions to form a gradient of regions. In one
embodiment, the second layer 282 is a layer of a thermoplastic
adhesive material.
[0085] "Thermoplastic adhesive material" as used herein is
understood to mean a polymer composition from which fibers are
formed and applied to the absorbent material with the intent to
immobilize the absorbent material in both the dry and wet state.
Non-limiting examples of thermoplastic adhesive material may
comprise a single thermoplastic polymer or a blend of thermoplastic
polymers. The thermoplastic adhesive material may also be a hot
melt adhesive comprising at least one thermoplastic polymer in
combination with other thermoplastic diluents such as tackifying
resins, plasticizers and additives such as antioxidants. In certain
embodiments, the thermoplastic polymer has typically a molecular
weight (Mw) of more than 10,000 and a glass transition temperature
(Tg) usually below room temperature or -6.degree.
C.>Tg<16.degree. C. In certain embodiments, typical
concentrations of the polymer in a hot melt are in the range of
about 20 to about 40% by weight.
[0086] Exemplary polymers are (styrenic) block copolymers including
A-B-A triblock structures, A-B diblock structures and (A-B)n radial
block copolymer structures wherein the A blocks are non-elastomeric
polymer blocks, typically comprising polystyrene, and the B blocks
are unsaturated conjugated diene or (partly) hydrogenated versions
of such. The B block is typically isoprene, butadiene,
ethylene/butylene (hydrogenated butadiene), ethylene/propylene
(hydrogenated isoprene), and mixtures thereof. Other suitable
thermoplastic polymers that may be employed are metallocene
polyolefins, which are polymers prepared using single-site or
metallocene catalysts. In exemplary embodiments, the tackifying
resin has typically a Mw below 5,000 and a Tg usually above room
temperature, typical concentrations of the resin in a hot melt are
in the range of about 30 to about 60% by weight, and the
plasticizer has a low Mw of typically less than 1,000 and a Tg
below room temperature, with a typical concentration of about 0 to
about 15%.
[0087] The thermoplastic adhesive material 282 can be disposed
substantially uniformly within the absorbent material 283. In the
alternative, the thermoplastic adhesive material 282 can be
provided as a fibrous layer disposed on top of the absorbent
material 283 and the regions 2814 of the first surface 2811 that
are in facial relationship with only an insignificant amount of
absorbent material.
[0088] In one embodiment, a thermoplastic adhesive material is
applied at an amount of between 1 and 20 g/m.sup.2, between 1 and
15 g/m.sup.2 or even between 2 and 8 g/m.sup.2. The discontinuous
deposition of absorbent material on the first layer 281 imparts an
essentially three-dimensional structure to the fibrous layer of
thermoplastic material 282. In other words, the layer of
thermoplastic adhesive material follows the topography resulting
from the absorbent material 283 deposited on the first nonwoven
fibrous web 281 and the regions 2814 that only include
insignificant amounts of absorbent material. Without intending to
be bound by any theory, it is believed that the thermoplastic
adhesive materials disclosed herein enhance immobilization of the
absorbent material in a dry and wet state.
[0089] In one embodiment, the absorbent core 28 may further
comprise a second layer of a nonwoven fibrous material 284. This
second layer may be provided of the same material as the nonwoven
fibrous layer 281, or in the alternative may be provided from a
different material. It may be advantageous for the first and second
nonwoven fibrous layers 281, 284 to be different in order to
provide these layers with different functionalities.
[0090] The regions 2813 may have any suitable shape in the x-y
dimension of the absorbent core. In one embodiment, the regions
2813 form a pattern of disc that are spread on the first surface of
the first web 281. In one embodiment, the regions 2813 form a
pattern of longitudinal "strips" that extend continuously along the
longitudinal axis of the absorbent core (i.e. along the y
dimension). In an alternative embodiment, these strips may be are
arranged to form an angle of at between 10 and 90 degrees, between
20 and 80 degrees, between 30 and 60 degrees, or even 45 degrees
relative to the longitudinal axis of the absorbent article.
[0091] In one embodiment, the second nonwoven layer 284 has a first
surface 2841 and a second surface 2842 and an absorbent material
283 applied to its first surface 2841 in order to form a pattern of
regions 2843 that are in direct facial relationship with a
significant amount of absorbent material 283 and regions 2844 on
the first surface 2841 that are in facial relationship with only an
insignificant amount of absorbent material as previously discussed.
In one embodiment, a thermoplastic adhesive material 285 may
further be applied on top of the second nonwoven layer 284 as
previously discussed in the context of the first web/absorbent
material/thermoplastic adhesive material composite. The second
nonwoven layer 284 may then be applied on top of the first nonwoven
layer 281. In one embodiment, the pattern of absorbent material
present on the second nonwoven layer 284 may be the same as the
pattern of absorbent material present on the first nonwoven layer
281. In an other embodiment, the patterns of absorbent material
that are present on the first and second nonwoven layers are
different in terms of at least one of the shape of the regions, the
projected surface areas of the regions, the amount of absorbent
material present on the regions and the type of absorbent material
present on the regions.
[0092] The absorbent core 28 may also comprise an auxiliary
adhesive which is not illustrated in the figures. The auxiliary
adhesive may be deposited on at least one of or even both the first
and second nonwoven layers 281, 284 before application of the
absorbent material 283 in order to enhance adhesion of the
absorbent material as well as adhesion of the thermoplastic
adhesive material 282, 285 to the respective nonwoven layers 281,
284. The auxiliary adhesive may also aid in immobilizing the
absorbent material and may comprise the same thermoplastic adhesive
material as described hereinabove or may also comprise other
adhesives including but not limited to sprayable hot melt
adhesives, such as H.B. Fuller Co. (St. Paul, Minn.) Product No.
HL-1620-B. The auxiliary adhesive may be applied to the nonwoven
layers 281, 284 by any suitable means, but according to certain
embodiments, may be applied in about 0.5 to about lmm wide slots
spaced about 0.5 to about 2 mm apart. Non-limiting examples of
suitable absorbent material 283 include absorbent polymer material
such as cross linked polymeric materials that can absorb at least 5
times their weight of an aqueous 0.9% saline solution as measured
using the Centrifuge Retention Capacity test (Edana 441.2-01). In
one embodiment, the absorbent material 283 is absorbent polymer
material which is in particulate form so as to be flowable in the
dry state.
EXAMPLES
Differential Contraction
TABLE-US-00001 [0093] Front Back Waist Front Waist Back Front-to-
Relaxed Stretched Front Relaxed Stretched Back Back Delta Chassis
Chassis Chassis Chassis Chassis Chassis in Chassis Width Width
Contraction Width Width Contraction Contraction (mm) (mm) (%) (mm)
(mm) (%) (%) Products RCFW ECFW FCC RCBW ECBW BCC Delta CC Anerle
294 330 10.91 296 332 10.84 0.1 Diaper (1) Parents 251 286 12.24
247 288 14.24 2.0 Choice Diaper (2) Moony 202 232 12.93 197 238
17.23 4.3 Diaper (3) Huggies 296 340 12.94 299 335 10.75 2.2 Baby
Steps (4) Huggies 251 270 6.91 231 270 14.34 7.4 Supreme (5)
Drypers (6) 300 350 14.29 284 332 14.46 0.2 (1) Anerle Taped Diaper
from Philippines, Size L (9-13 kg), SKU 90324495220, Lot 20121009
WP071157C9236; green foam sandwiched waistband (2) Parents Choice
Taped Diaper (2) from North America, Lot 9344 M02 1759 S-1855;
white foam sandwiched waistband (3) Moony Taped Diaper from Japan,
Lot 910193071; green foam sandwiched waistband (4) Huggies Baby
Steps US, 1991, Size 4, Lot 30251910248; white foam sandwiched
waistband in blue film (5) Huggies Supreme 2001, Size 4, Lot
NM127501F0755; green nonwoven waistband with small denier elastic
strands in white film (6) Drypers, US, Size Large, 9/8/1998; white
foam sandwiched waistband white film
TABLE-US-00002 Front Back Waist Front Waist Back Front-to- Relaxed
Stretched Front Relaxed Stretched Back Back Delta Chassis Chassis
Chassis Chassis Chassis Chassis Chassis Width Width Contraction
Width Width Contraction Contraction (mm) (mm) (%) (mm) (mm) (%) (%)
Examples RCFW ECFW FCC RCBW ECBW BCC Delta CC A 171 212.2 24.1 160
212.4 32.8 8.7 B 175.2 212.6 21.3 165.2 212.6 28.7 7.3 C 179.6
212.6 18.4 166.2 212.6 27.9 9.5 D 179.4 212.4 18.4 164.2 212.8 29.6
11.2 E 191.2 212.4 11.1 163.6 212.4 29.8 18.7 F 184.6 212.2 15.0
170.6 212.6 24.6 9.7 G 199.4 212.2 6.4 163.6 212.6 30.0 23.5 H
192.4 212.6 10.5 165 213 29.1 18.6 I 201.6 212.4 5.4 165 212.4 28.7
23.4 J 208.8 212.8 1.9 164.2 212.8 29.6 27.7 A--Installed
Elongation: 150%; Waistband Strain: 150%; Delta Front/Back
Installed Elongation: 0 B--Installed Elongation: 200%; Waistband
Strain: 200%; Delta Front/Back Installed Elongation: 0 C--Installed
Elongation: 150%; Waistband Strain: 130%; Delta Front/Back
Installed Elongation: 20 D--Installed Elongation: 200%; Waistband
Strain: 180%; Delta Front/Back Installed Elongation: 20
E--Installed Elongation: 150%; Waistband Strain: 110%; Delta
Front/Back Installed Elongation: 40 F--Installed Elongation: 200%;
Waistband Strain: 160%; Delta Front/Back Installed Elongation: 40
G--Installed Elongation: 150%; Waistband Strain: 100%; Delta
Front/Back Installed Elongation: 50 H--Installed Elongation: 200%;
Waistband Strain: 140%; Delta Front/Back Installed Elongation: 60
I--Installed Elongation: 200%; Waistband Strain: 120%; Delta
Front/Back Installed Elongation: 80 J--Installed Elongation: 200%;
Waistband Strain: 100%; Delta Front/Back Installed Elongation:
100
Consolidation
TABLE-US-00003 [0094] Extended Relaxed Total Full Extended Relaxed
Extended Length Length Length Waistband Waistband Caliper Caliper
CEL RWL EWL Consolidation Consolidation Products (mm) (mm) (mm)
(mm) (mm) (%) (%) Huggies Snug & 0.91 0.55 237 172 273 59 -14
Dry (7) Huggies Little 1.08 0.61 223 155 241 56 -14 Movers (8)
Huggies 1.45 0.70 220 131 253 93 33 Overnight (9) K 1.64 0.40 205
125 201 60 -1 L 2.24 0.71 208 132 286 116 53 M 2.40 1.04 203 130
340 162 98 N 2.54 1.01 205 131 386 195 131 O 2.22 1.29 205 126 425
237 176 (7) Huggies Snug & Dry, size 4; Lot No. BI 103108B (8)
Huggies Little Movers, size 3; Lot No. BI 024610B (9) Huggies
Overnight, size 4; Lot No. PA 027104F K--75% Installed Elongation
and 75% Waistband Strain L--150% Installed Elongation and 75%
Waistband Strain M--225% Installed Elongation and 75% Waistband
Strain N--300% Installed Elongation and 75% Waistband Strain
O--375% Installed Elongation and 75% Waistband Strain
360 Leakage Protection
TABLE-US-00004 [0095] Average Leg Ratio of Leg Gasketing Average
Gasketing System System Waistband Gather Count to Gather Gather
Waistband Gather Products Count Count Count P 20.7 22.2 0.9 Q 21.2
21.2 1.0 R 16.7 18.2 0.9 Huggies Baby Steps (4) 23.2 12.5 1.9
Huggies Supreme (5) 17.0 24.0 0.7 Anerle Diaper (1) 20.0 16.0 1.3
Parent Choice (2) 20.0 15.5 1.3 Moony Diaper (3) 12.5 11.2 1.1
P--150% Installed Elongation, 75% Waistband Strain R--150%
Installed Elongation, 75% Waistband Strain Q--150% Installed
Elongation, 75% Waistband Strain
Test Methods
Chassis Contraction Method
[0096] The chassis contraction is measured using a calibrated ruler
capable of measuring to .+-.1 mm, (traceable to National standards
such as NIST), and a force gauge capable of measuring an applied
force of 500 g accurately to .+-.0.5 g (a suitable gauge is the
Chatillon DFS series, available from Ametek, Largo, FL). A spring
loaded clamp, with contact faces 60 mm wide by 10 mm deep, is
attached to the force gauge to hold the test article. All testing
is performed in a room maintained at about 23.+-.2.degree. C. and
about 50.+-.2% relative humidity. All samples were conditioned for
2 hours before testing at about 23.+-.2.degree. C. and about
50.+-.2% relative humidity.
[0097] For this measure the chassis is identified as the portion of
the article with contiguous back sheet and does not include any
attached tabs or attached elastic tabs/ears. Unfold the absorbent
article taking care not to stretch the waist features. Place it on
a horizontal bench surface with the back sheet facing the bench and
the top sheet facing upward. If present, unfold and lie flat any
tabs or ears attached to the back half of the article. Identify the
back waist feature of the article. With the article flat against
the bench, lay the calibrated ruler along the article aligning it
with the lateral midline of the waist feature. Measure the lateral
distance from the right distal edge of the chassis to the left
distal edge of the chassis and record to the nearest 1 mm. This is
the Relaxed Back Chassis Width (RBCW)
[0098] Attach the force gauge to the right distal edge of the
chassis. As attached, the force gauge is oriented to pull from left
to right. The grip faces are parallel to the longitudinal axis of
the article, centered at the lateral midline of the waist feature,
with 3 mm of the chassis within the grip faces.
[0099] Adhere a piece of 2-sided adhesive tape 50 mm in width by
900 mm long to the bench. Hold the article with the back sheet
directed toward the taped surface with the back waist parallel to
the long dimension of the tape. Align the lateral midline of the
waist feature with the lateral midline of the tape strip. Secure
the first 3 mm of the left chassis edge to the adhesive tape. Using
the force gauge, extend the back waist to an applied force of 500
g. Next lower the article and adhere the article's back waist to
the adhesive tape across the lateral width of the chassis. Remove
the force gauge from the chassis. Lay the ruler across the article
aligning it along the lateral midline of the waist feature. Measure
the lateral distance from the right distal edge of the chassis to
the left distal edge of the chassis and record to the nearest 1 mm.
This is the Extended Back Chassis Width (EBCW).
[0100] Repeat this measure in like fashion for the front waist
feature of the article to determine the Relaxed Front Chassis Width
(RFCW) and the Extended Front Chassis Width (EFCW). Calculate the
Chassis Contractions as follows:
% Back Chassis Contraction (% BCC)=(EBCW-RBCW)/EBCW.times.100%
Front Chassis Contraction (% FCC)=(EFCW-RFCW)/EFCW.times.100
Front-to-Back Delta Chassis Contraction=absolute value of (% BCC-%
FCC)
Waist Feature Calipers
[0101] Calipers were performed using an Ono Sokki digital caliper
(GS-503 Linear Gauge Sensor with DG-3610 Digital Gauge, Ono Sokki
Co, Japan) capable of measuring to 0.01 mm. The foot diameter is 1
cm and the applied pressure is 0.5 psi. Readings are taken after a
residence time of 5 sec. Linear measurements are made using a
calibrated ruler capable of measuring to .+-.1 mm (traceable to
National standards such as NIST). A stainless steel plate,
uniformly 1.5 mm thick .+-.0.1 mm, 20 cm wide and 40 cm long is
used for mounting the extended waist. All testing is performed in a
room maintained at about 23.+-.2.degree. C. and about 50.+-.2%
relative humidity. All samples are conditioned for 2 hours before
testing at about 23.+-.2.degree. C. and about 50.+-.2% relative
humidity.
Relaxed Waist Calipers
[0102] Unfold an absorbent article taking care not to stretch the
waist features. Place it on a horizontal bench surface with the
back sheet facing the bench and the top sheet facing upward. If
present, unfold and lie flat any tabs or ears attached to the back
half of the article. Identify the back waist feature of the
article. Using a calibrated ruler measure the lateral width of the
waist feature along its longitudinal midline. This is the Relaxed
Length of the waist feature (RWL) Mark the waist feature along its
midline at 50% of its lateral width. This is waist site 1 (WS1).
Measure and mark two more sites, the first 1.5 cm to the left of
the 50% mark (WS2) and the second 1.5 cm to the right of the 50%
mark (WS3).
[0103] Place the caliper on the anvil and zero the digital
controller. Place the article on the anvil, with the top sheet
facing upward, and use the caliper to measure the thickness at WS1,
WS2, and WS3. Report to the nearest 0.01 mm as the Relaxed Waist
Caliper RWC1, RWC2, and RWC3 respectively.
[0104] Using a cryogenic freeze spray (available as CytoFreeze,
Control Company, Tex.) gently remove the elastic feature from the
article. Place the article on the anvil, with the top sheet facing
upward, and use the caliper to measure the thickness of the article
corresponding to WS1, WS2, and WS3. Report to the nearest 0.01 mm
as Relaxed Back Sheet Caliper RBC1, RBC2, RBC3 respectively.
Calculate the Waist Feature Caliper as:
[0105] Relaxed Waist Feature
Caliper=[(RWC1-RBC1)+(RWC2-RBC2)+(RWC3-RBC3)]/3
[0106] Repeat this procedure for three identical articles and
report as the average to the nearest 0.01 mm.
Extended Waist Calipers
[0107] Unfold an absorbent article taking care not to stretch the
waist features. Assemble a vertical ring stand which supports a
horizontal bar. Attach a spring loaded clamp to the left edge of
the chassis, centered on the waist feature. Attach the clamp to the
horizontal support so that the waist feature hangs vertically.
Attach a second clamp, which has a mass of 300 g.+-.1 g, to the
right edge of the chassis, centered on the midline of the waist
feature. Allow the article to hang for 30 seconds and then using
the calibrated ruler measure the extended length of the waist
feature to the nearest 1 mm. This is the Chassis Extended Length
(CEL). The CEL can be used for all extended waist measures.
[0108] Unfold another absorbent article taking care not to stretch
the waist features. Place it on a horizontal bench surface with the
back sheet facing the bench and the top sheet facing upward. If
present, unfold and lie flat any tabs or ears attached to the back
half of the article. Identify the back waist feature of the
article. Using a calibrated ruler measure the lateral width of the
waist feature along its longitudinal midline. This is the Relaxed
Length of the waist feature (RWL) Mark the waist feature along its
midline at 50% of its lateral width. This is waist site 1 (WS1).
Measure and mark two more sites, the first 1.5 cm to the left of
the 50% mark (WS2) and the second 1.5 cm to the right of the 50%
mark (WS3). Identify the proximal edge of the waist feature, i.e.
the edge closest to the crotch of the article. Mark a lateral line
1.5 cm from the proximal edge toward the crotch, and parallel to
the waist feature. Along a longitudinal axis that passes through
WS1, mark the intersection at the lateral line just drawn (AS1).
Repeat in like fashion for WS2 and WS3 to define sites AS2 and AS3
respectively.
[0109] Place the article, top sheet facing upward, onto the
stainless steel plate. Secure the left distal edge of the chassis
at the waist feature's midline to the steel plate with adhesive
tape. Grasp the right side of the chassis and pull until the waist
feature has been extended equal to the Chassis Extended Length
(CEL). Secure the right side of the chassis to the steel plate with
adhesive tape.
[0110] Place the steel plate with attached article on the anvil of
the caliper. Place the caliper foot on a region of the steel plate
that is not covered by the article and zero the digital control.
Using the caliper, measure the thickness at the six marked sites.
Report to the nearest 0.01 mm as Extended Waist Caliper EWC1, EWC2,
and EWC3. Using a cryogenic freeze spray gently remove the elastic
feature from the article. Place the steel plate with attached
article on the anvil of the caliper and measure the thickness of
the article at the sites corresponding to WS1, WS2 and WS3. Report
to the nearest 0.01 mm as Extended Back Sheet Caliper EBC1, EBC2,
EBC3 respectively. Calculate the Waist Feature Calipers as:
Extended Waist Feature
Caliper=[(EWC1-EBC1)+(EWC2-EBC2)+(EWC3-EBC3)]/3
[0111] Repeat this procedure for three identical articles and
report as the average to the nearest 0.01 mm.
Waist Feature Percent Consolidation
[0112] Linear measurements are made using a calibrated ruler
capable of measuring to .+-.1 mm (traceable to National standards
such as NIST). All testing is performed in a room maintained at
about 23.+-.2.degree. C. and about 50.+-.2% relative humidity. All
samples are conditioned for 2 hours before testing at about
23.+-.2.degree. C. and about 50.+-.2% relative humidity.
[0113] Unfold the absorbent article taking care not to stretch the
waist features. Place it on a horizontal bench surface with the
back sheet facing the bench and the top sheet facing upward. If
present, unfold and lie flat any tabs or ears attached to the back
half of the article. Identify the back waist feature of the
article. Using a calibrated ruler measure the lateral width of the
waist feature along its midline and record to the nearest 1 mm.
This is the Relaxed Length of the waist feature (RWL).
[0114] Using a cryogenic freeze spray (available as CytoFreeze,
Control Company, Tex.) carefully remove the waist feature from the
article. Place the waist feature into a beaker with 100 mL of
dichloromethane and soak for 15 minutes to dissolve the adhesives.
Remove the waist feature from the solvent and remove the elastics.
Lay the waist feature substrate flat in a fume hood to dry.
[0115] Assemble a vertical ring stand which supports a horizontal
bar. Attach a spring loaded clamp, which is at least as wide as the
waist feature, to the left edge of the waist feature. Attach the
clamp to the horizontal support so that the waist feature hangs
vertically. Attach a second clamp, which has a mass of 3 g.+-.1 g
and is at least as wide as the waist feature, to the right edge of
the waist feature. Allow the article to hang for 30 seconds and
then using the calibrated ruler measure the extended length of the
waist feature to the nearest 1 mm. This is the Extended Waist
Feature Length (EWL). Calculate the Full Waistband Consolidation
as:
% Full Waistband Consolidation=(EWL.times.RWL)/RWL.times.100
[0116] Repeat this procedure for three identical articles and
report as the average to the nearest 1 mm.
[0117] Calculate the Extended Waistband Consolidation as:
% Extended Waistband
Consolidation=(EWL-RWL)/RWL.times.100-(1-((CEL-RWL)/CEL)*100)
[0118] Repeat this procedure for three identical articles and
report as the average to the nearest 1 mm.
Frequency of Waistband and Outer Leg Cuff Gathers on Taped Diaper
Products
[0119] In the visual center of the waistband on the diaper both CD
and MD, report the number of gathers per 30 mm on both taped end
(TE) and un-taped end (UTE). Hold in place the measuring template,
as shown in FIG. 10, then count the gather peaks within the 30 mm
window on the template. Make sure not to stretch the gathers.
Perform this on both the taped (TE) inside and outside and then
repeat on the un-taped end (UTE) inside and outside of the product.
Report the number of gathers within the 30 mm.
[0120] In the visual center of the Leg Gasketing System gather on
the diaper both CD and MD, report the number of gathers per 30 mm
on both Baby right and Baby left. Hold in place the measuring
template then count the number of gathers within the 30 mm window
on the template. Make sure not to stretch the gathers. Perform this
on both Baby right and Baby left of the product both CD and MD.
Report the number of gathers within the 30 mm.
[0121] Calculate the Ratio of Leg Gasketing System Gather Count to
Waistband Gather Count as follows:
Ratio=Average Leg Gasketing System Gather Count/Average Waistband
Gather Count
[0122] Repeat this procedure for three identical articles and
report as the average.
CD Length Ratio
[0123] CD Length Ratio is the ratio of chassis extended length
(CEL) to Extended Back Chassis Width (EBCW), as defined here.
[0124] Calculate the CD Length Ratio as follows:
CD Length Ratio=CEL/EBCW
[0125] Repeat this procedure for three identical articles and
report as the average.
[0126] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numeral 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".
[0127] 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 written
document conflicts with any meaning or definition of the term in a
document incorporated by reference, the meaning or definition
assigned to the term in this written document shall govern.
[0128] 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.
* * * * *