U.S. patent application number 13/653762 was filed with the patent office on 2013-02-14 for absorbent articles with garment-like refastenable seams.
This patent application is currently assigned to Kimberly-Clark Worldwide, Inc. The applicant listed for this patent is Kimberly-Clark Worldwide, Inc.. Invention is credited to Lisa Ann Dimitrijevs, Amy Lynn Kading, Christopher Peter Olson, Kathleen Irene Ratliff, Shirlee Ann Weber, Susan Lee West.
Application Number | 20130037200 13/653762 |
Document ID | / |
Family ID | 47388227 |
Filed Date | 2013-02-14 |
United States Patent
Application |
20130037200 |
Kind Code |
A1 |
Dimitrijevs; Lisa Ann ; et
al. |
February 14, 2013 |
Absorbent Articles With Garment-Like Refastenable Seams
Abstract
A disposable absorbent article includes a fastening system that
can be repeatedly fastened, unfastened and refastened. The
refastenable seams formed by the fastening system components
provide a garment-like appearance,
Inventors: |
Dimitrijevs; Lisa Ann;
(Appleton, WI) ; Kading; Amy Lynn; (Freedom,
WI) ; Olson; Christopher Peter; (Neenah, WI) ;
Ratliff; Kathleen Irene; (Neenah, WI) ; Weber;
Shirlee Ann; (Neenah, WI) ; West; Susan Lee;
(Neenah, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kimberly-Clark Worldwide, Inc.; |
Neenah |
WI |
US |
|
|
Assignee: |
Kimberly-Clark Worldwide,
Inc
Neenah
WI
|
Family ID: |
47388227 |
Appl. No.: |
13/653762 |
Filed: |
October 17, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09444080 |
Nov 22, 1999 |
8343127 |
|
|
13653762 |
|
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Current U.S.
Class: |
156/66 |
Current CPC
Class: |
A61F 13/496 20130101;
A61F 2013/5677 20130101 |
Class at
Publication: |
156/66 |
International
Class: |
B32B 37/02 20060101
B32B037/02 |
Claims
1. A method of making an absorbent article, the method comprising:
providing an absorbent chassis defining a longitudinal axis, a
transverse axis, front and back waist edges parallel to the
transverse axis, opposite side edges extending between the front
and back waist edges, a front waist region contiguous with the
front waist edge, a back waist region contiguous with the back
waist edge, and a crotch region which extends between and
interconnects the front and back waist regions, the absorbent
chassis comprising a rectangular composite structure having linear
side edges parallel to the longitudinal axis and opposite linear
end edges parallel to the transverse axis, the composite structure
comprising a bodyside liner, an outer cover bonded to the bodyside
liner, and an absorbent assembly disposed between the bodyside
liner and the outer cover, wherein the absorbent assembly includes
an absorbent batt having opposite side edges generally
longitudinally oriented within the absorbent chassis; bonding a
pair of elastomeric side panels to the rectangular composite
structure in the back waist region, the side panels being
elastomeric in a direction parallel to the transverse axis; bonding
first and second fastening components to the elastomeric side
panels, each of the fastening components having a length dimension,
a width dimension, and a length-to-width ratio of about 2 or
greater; and bonding first and second mating fastening components
to the absorbent chassis in the front waist region along the
opposite side edges abutting the front waist edge, wherein the
mating fastening components have inner side edges disposed
transversely outward from and adjacent to the side edges of the
absorbent batt, and each of the mating fastening components has a
length dimension, a width dimension, and a length-to-width ratio of
about 2 or greater, the fastening components adapted to releasably
engage the mating fastening components.
2. The method of claim 1, wherein the mating fastening components
abut the respective opposite side edges of the absorbent chassis.
Description
[0001] This application claims priority as a divisional of
application Ser. No. 09/444,080, filed on Nov. 22, 1999. The
entirety of application Ser. No. 09/444,080 is incorporated herein
by reference,
BACKGROUND OF THE INVENTION
[0002] The present invention relates to absorbent articles which
are adapted to contain body exudates. More particularly, the
invention pertains to pant-like disposable absorbent articles
having garment-like refastenable seams, and methods of making such
disposable absorbent articles.
[0003] Current disposble absorbent training pants for children
going through the potty training stage have proved to be a
particularly desirable and useful product. Such training pants
generally include an absorbent chassis including a liquid
impervious outer cover, a liquid pervious bodyside liner and an
absorbent structure. The training pants further include stretchable
side panels that are permanently bonded to opposite side edges of
the absorbent chassis. The chassis and side panels thereby form a
unitary waist opening and two leg openings. The fit of the pants
may be further enhanced by gathering means along the waist and leg
openings.
[0004] The components of traditional training pants are permanently
seamed together to provide a pant product. These products are
particularly appealing to caregivers and are useful in the toilet
training process because the pant has a very garment-like look.
Children identify diaper products with babies, and most children do
notlike being identified with or as babies. Cosequently, these
children to not want to wear baby diapers, and instead prefer to
wear training pants that look like adult underwear. Thus, the
switch from a traditional diaper to a more garment-like or
underwear-like training pant can be an important step in the toilet
training process.
[0005] One drawback with current training pants, however, is that
the manner of applying them is limited to being pulled on like a
pant. Applying the product like a pant is advantageous in many
instances, and is particularly suited for active, walking children.
Even for the same child, however, there may be times when it would
be useful to aply the product like a diaper. For instance, it might
be more convenient to apply the product like a diaper when there is
a desire not to remove the child's shoes. Because it is difficult
to know when a particular mode of applying the garment will be
needed, it is beneficial to have a garment that is adaptable to
being used either as a diaper or as a pant. This is preferable to
keeping both types of garments available. A product that can be
applied either like a diaper or a pant permits the interior of the
product to be easily checked without having to pull the product
downward.
[0006] Thus, it would be desirable to have a disposable absorbent
article that provides the garment-like or underwear-like look of a
traditional training pant yet affords the option of being either
like a diaper or like a pant.
SUMMARY OF THE INVENTION
[0007] In response to the above-referenced unfulfilled need in the
art, a new pant-like disposable absorbent article having
garment-like refastenable seams and a method of making such a
disposable absorbent article have been discovered. The absorbent
article includes a fastening system that can be repeatedly
fastened, unfastened and refastened. The refastenable seams formed
by the fastening system components provide a garment-like
appearance.
[0008] In one embodiment, the present invention pertains to an
absorbent article including an absorbent chassis that defines a
longitudinal axis, a transverse axis, a first or front waist edge
and a second or back waist edge which are parallel to the
transverse axis, and opposite side edges that extend between the
front and back waist edges. The absorbent chassis also defines a
first or front waist region contiguous with the front waist edge, a
second or back waist region contiguous with the back waist edge,
and a crotch region which extends between and interconnects the
front and back waist regions. The absorbent chassis includes a
rectangular composite structure having opposite linear side edges
parallel to the longitudinal axis and opposite linear end edges
parallel to the transverse axis. The composite structure includes a
bodyside liner, and outer cover bonded to the bodyside liner, and
an absorbent assembly disposed between the bodyside liner and the
outer cover. A pair of elastomeric side panels is bonded to the
composite structure in the back waist region, with each side panel
being elastomeric in a direction parallel to the transverse axis.
The absorbent article also includes a fastening system for
releasably securing the absorbent article in a pant-like
configuration. The fastening system includes first and second
fastening components adapted to releasably engage first and second
mating fastening components. The fastening components are disposed
on the elastomeric side panels and having a length dimension, a
width dimension, and a length-to-width ratio of about 2 or greater.
The mating fastening components are disposed in the front waist
region and positioned along the opposite side edges abutting the
front waist edge.
[0009] The fastening components and the mating fastening components
form refastenable seams for securing the first and second waist
regions together. The refastenable seams allow the product to be
either pulled on like a pant or applied like a diaper. If the
training pant becomes soiled during use, the fastening components
can be disengaged from the mating fastening components to easily
remove the training pant from the waist of the wearer with reduced
risk of undesirably soiling the clothes or legs of the wearer.
Further, the fastening components can also be easily disengaged
from the mating fastening components to inspect the training pant
for possible soiling. Thus, the training pant is configured to be
pulled on or off over the hips of the wearer such as conventional
training pants and can be readily appplied or removed by
disengaging the fastenting components similar to conventional
diapers. Moreover, the first and second fastening components can be
repositioned if necessary after the training pant has been pulled
on over the legs and hips of the wearer.
[0010] This embodiment of the invention also provides an absorbent
article that is extremely compatible with high-speed manufacturing
processes. The composite structure can be formed as a rectangular
shape and the elastomeric side panels joined to the composite
structure with their waist end edges forming part of the back waist
edge of the absorbent article.
[0011] The design of the absorent chassis and the fastening
components provides the absorbent article with a garment-like
appearance. The refastenable seams in particular can be integrated
within the absorbent chassis so that they are flush with the
overall exterior product shape. The garment-like seams are thus
less likely to disengage inadvertently. The refastenable seams may
also be made less noticeable and as a result may be made harder for
children to open without guidance. Additionally, the fastening
system components can be incorporated into the absorbent article
without interfering with existing outer cover graphics, which have
become an important interactive toilet training feature in current
training pants.
[0012] The garment-like fit of the absorbent article can be
improved by the incorporation of leg elastic members that are
longitudinally aligned along each side edge of the absorbent
chassis. In particular embodiments, the leg elastic members are
also axially aligned with the mating fastening components. This not
only creates an absorbent article that is suited for high-speed
manufacture, but also advantageously positions the mating fastening
components at the front of the wearer's body. Desirably, the front
terminal points of the leg elastic members may be located adjacent
inner end edges of the respective mating fastening components, for
example within about 2 centimeters of the mating fastening
components, particularly within about 1 centimeter of the mating
fastening components, and more particularly abutting or slightly
overlapping the mating fastening components, and the back terminal
points may be located adjacent logitudinally innermost parts of the
side panels, for example within about 2 centimeters of the
longitudinally innermost parts of the side panels, particularly
within about 1 centimeter of the longitudinally innermost parts of
the side panels, and more particularly at the same location or
slightly extending beyond the longitudinally innermost parts of the
side panels.
[0013] Hence, in another embodiment, the present invention pertains
to an absorbent article including an absorbent chassis comprising a
bodyside liner, an out cover bonded to the bodyside liner, and an
absorbent assembly disposed between the bodyside liner and the
outer cover. The absorbent chassis defines a longitudinal axis, a
transverse axis, an overall length dimension, front and back waist
edges parallel to the transverse axis, opposite side edges
extending between the front and back waist edges, a front waist
region contiguous with the front waist edge, a back waist region
contiguous with the back waist edge, and a crotch region which
extends between and interconnects the front and back waist regions.
The side edges in the front waist region and crotch region are
aligned with one another parallel to the longitudinal axis. First
and second side panels extend transversely outward from the
absorbent assembly in the back waist region. The side panels have
opposite waist end and leg end edges and an average length
dimension that is about 20 percent or greater of the overall length
dimension. Leg elastic members are longitudinally aligned along
each side edge. A fastening system of the absorbent article
releasably secures the absorbent article in a pant-like
configuration. The fastening system includes first and second
fastening components that are adapted to releasably engage first
and second mating fastening components. Each of the fastening
components and the mating fastening components have a length
dimension aligned generally parallel to the longitudinal axis, a
width dimension, and a length-to-width ratio of about 5 or greater.
The fastening components are disposed on the side panels, and cover
about 80 to 100 percent of the distance between the opposite edges
of the side panels. The mating fastening components are disposed in
the front waist region along the oposite side edges abutting the
front waist edge. The leg elastic members are axialy aligned with
the mating fastening components.
[0014] The positioning of the mating fastening components can also
be enhanced by positioning inner side edges of the mating fastening
components transversely outward from and adjacent to the side edges
of the primary absorbent structure of the absorbent article. In
doing so, the fastening components and the mating fastening
components tend to form a butt joint that minimizes overlap of the
front and back waist regions and further enchances the garment-like
appearance of the absorbent article. This positioning of the
fastening components also causes the refastenable seams to become
more flush with the primary absorbent structure of the absorbent
article.
[0015] In another embodiment, the present invention pertains to an
absorbent article including a generally inelastic absorbent chassis
comprising a bodyside liner, an outer cover bonded to the bodyside
liner, and an absorbent assembly disposed between the bodyside
liner and the out cover. The absorbent chassis defines a
longitudinal axis, a transverse axis, front and back waist edges
parallel to the transverse axis, opposite side edges extending
between the front and back waist edges, a front waist region
contiguous with the front waist edge, a back waist region
contiguous with the back waist edge, and a crotch region which
extends between and interconnects the front and back waist regions.
First and second elastomeric side panels extend transversely
outward from the absorbent assembly in the back waist region. The
absorbent article also includes a fastening system for releasably
securing the absorbent article in a pant-like configuration. The
fastening system includes first and second fastening components
adapted to releasably engage first and second mating fastening
components. The fastening components are disposed on the
elastomeric side panels and having a length dimension, a width
dimension, and a length-to-width ratio of about 2 or greater. The
mating fastening components are disposed on the generally inelastic
absorbent chassis in the front waist region and positioned along
the opposite side edges abutting the front waist edge.
[0016] The embodiment of the invention provides an absorbent
article with efficient utilization of elastomeric materials to
obtain proper fit on the wearer. The absorbent article can be
formed with a generally inelastic absorbent chassis, which as that
term is used herein, refers to the combined structure of a bodyside
liner, an outer cover and an absorbent assembly where neither the
bodyside liner nor the outer cover is formed with a unitary
elastomeric material. In particular, leg eleastic members and waist
elastic members may be operatively joined to the combined
structure, but the bodyside liner and outercover materials
themselves are not elastomeric. The inelastic absorbent chassis
desirably concentrates the elastic forces over the hips and around
the back side of the wearer. Concentration of elastic forces in
these areas is more efficient for holding the product up on the
wearer than is concentration of elastic forces across the front
waist region. The inelastic absorbent chassis also avoids the
difficulties in mounting a non-stretchable absorbent in an elastic
chassis. Inelastic liners and out covers can be moe suitable for
containing the absorbent structure, in that they help prevent
uncomfortable bunching and migration of absorbent material through
the liner and onto the skin.
[0017] In another embodiment, the present invention pertains to an
absorbent article including a generally inelastic absorbent chassis
and a fastening system for releasably attaching a front waist
region of the absorbent chassis to a back waist region of the
absorbent chassis to define a refastenable pant. The refastenable
pant has a waist opening and a pair of leg openings and includes: a
pair of refastenable seams extending from the waist opening to each
leg opening; a pair of elastomeric side panels extending from the
waist opening to each leg opening; an elastomeric front waistband
disposed in the front waist region and positioned between the pair
of refastenable seams; an elastomeric back waistband disposed in
the back waist region and positioned between the pair of
elastomeric side panels; and a pair of elastomeric leg members
which partially encircle each leg opening, where each elastomeric
leg member extends from adjacent a refastenable seam in the front
waist region to adjacent an elastomeric side panel in the back
waist region.
[0018] This embodiment of th einvention provides an absorbent
article that provides fit and comfort comparable to conventional
training pants, yet provides the added benefits of refastenability.
The elastomeric side panels generally span the hips of the wearer
and provide eleasticity from the waist opening to each leg opening.
The absorbent article fits closely about the body of the wearer due
to the combination of the elastomeric side panels, the elastomeric
front waistband, the elastomeric back waistband, and the
elastomeric leg members, without the need for an elastomeric
absorbent chassis. The absorbent article is securely held in place
with a garment-like seam due to the refastenable seams extending
from the waist opening to each leg opening.
[0019] The refastenable seams are formed when the first and second
fastening components are engaged with the first and second mating
fastening components. The refastenable seams are desirably
relatively thin, narrow and flexible to afford the look and feel of
a cloth garment. Thus, in particular embodiment, the refastenable
seams have a length-to-width ratio of about 2 or greater, such as
about 2 to about 25, particularly about 5 or greater, such as about
5 to about 8. The refastenable seams define a length dimension and
a width dimension that is perpendicular to the length dimension.
For a child of about 9 to about 15 kilograms (20-34 lbs.), for
example, the length dimension is desirably from about 5 to about 13
centimeters, such as about 10 centimeters, and the width dimension
is desirably from about 0.5 to about 3 centimeters, such as about 2
centimeters. Desirably although not necessarily, the length
dimension is aligned generally parallel to the longitudinal axis of
the absorbent article and the width dimension is aligned generally
parallel to the transverse axis of the absorbent article. The term
"generally parallel" as used herein refers to an angle within about
35 degrees or less of the referenced axis, and more particularly
within about 20 degrees or less of the referenced axis.
[0020] The fastening components may comprise any refastenable
fasteners suitable for absobent articles, such as mechanical
fastening elements or adhesive fastening elements. Suitable
mechanical fastening elements can be provided by interlocking
geometric shaped materials, such as hooks, loops bulbs, mushrooms,
arrowheads, balls on stems, male and female mating components,
buckles, snaps or the like. In particular embodiments, the
fastening components and mating fastening components comprise
hook-and-loop-fastening elements. One skilled in the art will
recognize that the shape, density and polymer composition of the
hooks and loops may be selected to obtain the desired level of
securement between the fastening components and the mating
fastening components. A more aggressive hook material may comprise
a material with a greater average hook height, a greater percentage
of directionally-aligned hooks, or a more aggressive hook
shape.
[0021] As disclosed in copending U.S. Patent Application Ser. No.
60/112,709, filed on Dec. 18, 1998 by C. P. Olson at al. and titled
"Absorbent Articles Having Differential Strength Refastenable
Seam," the refastenable seam can include one or more main
refastenable attachment zones and one or more enhanced refastenable
attachment zones. The main and enhanced refastenable attachment
zones may be constructed to provide differential levels of
securement, and particularly augmented levels of securement at
locations which are subject to greater levels of separation
forces.
[0022] As disclosed in copending U.S. Patent Application Ser. No.
60/112,775, filed on Dec. 18, 1998 by C. P. Olson and titled
"Absorbent Articles Having Hinged Fasteners," the refastenable seam
may comprise individual fasening materials with narrow spacings
therebetween. The narrow spacings provide a desireable hinge to
improve fit and securement of the fastening components.
[0023] The disclosed absorbent articles are adapted to be worn
adjacent to the body of a wearer to absorb and contain various
exudates discharged from the body. The absorbent articles are
desirably pre-fastened to provide a pant-like product for the user.
The product can then be pulled on like a conventional training
pant, and subsequently checked or removed with the ease of a
diaper-like product. Moreover, the product may be applied like a
diaper rather than like a pant. Supplemental releasable fastening
means such as frangible point bonds may be employed to maintain the
absorent article in a pant configuration until the user
intentionally disengages the fasteners.
[0024] The fastening system allows for easy inspection of the
interior of the pant-like product. If necessary, the fastening
system also allows the pant to be removed quickly and easily. This
is particularly beneficial when the pant contains messy excrement.
If desired, the caregiver can completely remove the pant-like
product and replace it with a new one without having to remove the
child's shoes and clothing. The present fastening sytem may be used
with a wide variety of absorbent products, including training
pants, diapers, incontinence garments, or other garments using
mechanical or adhesive fasteners.
[0025] The present invention also pertains to a method of making an
absorbent article, in one embodiment, a method of making an
absorbent comprises: providing an absorbent chassis defining a
longitudinal axis, a transverse axis, front and back waist edges
parallel to the transverse axis, opposite side edges extending
between the front and back waist edges, a front waist region
contiguous with the front waist edge, a back waist region
contiguous with the back waist edge, and a crotch region which
exends between and interconnects the front and back waist regions,
the absorbent chassis comprising a rectangular composite structure
having linear side edges parallel to the longitudinal axis and
opposite linear end edges parallel to the transversr axis, the
composite structure comprising a bodyside liner, an outer cover
bonded to the bodyside liner, and an absorbent assembly disposed
between the bodyside liner and the outer cover; bonding a pair of
elastomeric side panels to the rectangular composite structure in
the back waist region, the side panels being elastomeric in a
direction parallel to the transverse axis; bonding first and second
fastening components to the elastomeric side panels, each of the
fastening components having a length dimension, is a width
dimension, and a length-to-width ratio of about 2 or greater; and
bonding first and second mating fastening components to the
absorbent chassis in the front waist region along the opposite side
edges abutting the front waist edge, the fastening components
adapted to releasably engage the mating fasening components.
[0026] A more detailed description of the construction and design
of one form of training pant can be fround in U.S. Pat. No.
4,940,464 issued Jul. 10, 1990 to Van Gompel et al., which is
incorporated herein by reference. The Van Gompel et al. patent
describes various materials of which the training pant ca be made,
and a method of constructing a training pant.
Definitions
[0027] Within the context of this specification, each term or
phrase below will include the folowing meaning or meanings.
[0028] "Bonded" refers to the joining, adhering, connecting,
attaching, or the like, of two elements. Two elements will be
considered to be bonded together when they are bonded directly to
one another or indirectly to one another, such as when each is
directly bonded to intermediate elements.
[0029] "Comprising" is inclusive or open-ended and does not exclude
additional, unrecited elements or method steps.
[0030] "Connected" refers to the joining, adhering, bonding,
attaching, or the like, of two elements. Two elements will be
considered to be connected together when they are connected
directly to one another or indirectly to one another, such as when
each is directly connected to intermediate elements.
[0031] "Disposable" refers to articles which are designed to be
discarded after a limited use rather than being laundered or
otherwise restored for reuse.
[0032] "Disposed," "disposed on," and variations thereof are
intended to mean that one element can be integral with another
element, or that one element can be a separate structure bonded to
or placed with or placed near another element.
[0033] "Elastic," "elasticized" and "elasticity" mean that property
of a material or composite by virtue of which it tends to recover
its original size and shape after removal of a force causing a
deformation.
[0034] "Elastomeric" refers to a material or composite which can be
elongated by at least 25 percent of its relaxed length and which
will recover, upon release of the applied force, at least 10
percent of its elongation. It is generally preferred that the
elastomeric material or composite be capable of being elongated by
at least 100 percent, more preferably by at least 300 percent, of
its relaxed length and recover, upon release of an applied force,
at least 50 percent of its elongation.
[0035] "Fabrics" is used to refer to all of the woven, knitted and
nonwoven fibrous webs.
[0036] "Flexible" refers to materials which are compliant and which
will readily conform to the general shape and contours of the
wearer's body.
[0037] "Force" includes a physical influence exerted by one body on
another which produces acceleration of bodies that are free to move
and deformation of bodies that are not free to move. Force is
expressed in grams per unit area.
[0038] "Graphic" refers to any design, pattern, or the like that is
visible on an absorbent article.
[0039] "Hydrophilic" describes fibers or the surfaces of fibers
which are wetted by the aqueous liquids in contact with the fibers.
The degree of wetting of the materials can, in turn, be described
in terms of the contact angles and the surface tensions of the
liquids and materials involved. Equipment and techniques suitable
for measuring the wettability of particular fiber materials or
blends of fiber materials can be provided by Cahn SFA-222 Surface
Force Analyzer System, or a substantially equivalent system. Whe
measured with this system, fibers having contact angles less than
90 degrees are designated "wettable" or hydrophilic, while fibers
having contact angles greater than 90 degrees are designated
"nonwettable" or hydrophobic.
[0040] "integral" is used to refer to various protions of a single
unitary element rather than separate structures bonded to or placed
with or placed near one another.
[0041] "Inward" and "outward" refer to positions relative to the
center of an absorbent article and particularly transversely and/or
longitudinally closer to or away from the longitudinal and
transverse center of the absorbent article.
[0042] "Layer" when used in the singular can have the dual meaning
of a single element or a plurality of elements.
[0043] "Liquid impermeable", when used in describing a layer or
multi-layer laminate, means that a liquid, such as urine, will not
pass through the layer or laminate, under ordinary use conditions,
in a direction generally perpendicular to the plane of the layer or
laminate at the point of liquid contact. Liquid, or urine, may
spread or be transported parallel to the plane of the liquid
impermeable layer or laminate, bu this is not considered to be
within the meaning of "liquid impermeable" when used herein.
[0044] "Longitudinal" and "transverse" have their customary
meaning, as indicated by the longitudinal and transverse axis
depicted in FIGS. 2 and 3. The longitudinal axis lies in the plane
of the article and is generally parallel to a vertical plane that
bisects a standing wearer into left and right body halves when the
article is worn. The transverse axis lies in the plane of the
article generally perpendicular to the longitudinal axis. The
article as illustrated is longer in the logitudinal direction than
in the transverse direction.
[0045] "Member" when used in the singular can have the dual meaning
of a single element or a plurality of elements.
[0046] "Nonwoven web" means a web of material which is formed
without the aid of a textile weaving or knitting process.
[0047] "Operatively joined," with reference to the attachment of an
elastic member to another element, means that the elastic member
when attached to or connect to the element, or treated with heat or
chemicals, by stretching, or the like, gives the element elastic
properties; and with reference to the attachment of a non-elastic
member to another element, means that the member and element can be
attached in any suitable manner that permits or allows them to
perform the intended or described function of the joinder. The
joining, attaching, connecting or the like can be either directly,
such as joining either member directly to an element, or can be
indirectly by means of another member disposed between the first
member and the first element.
[0048] "Outer cover graphic" refers to a graphic that is directly
visible upon inspection of the exterior surface of a garment, and
for a refastenable garment is in reference to inspection of the
exterior surface of the garment when the fastening system is
engaged as it would be during use.
[0049] "Permanently bonded" refers to the joining, adhering,
connecting, attaching, or the like, of two elements of an absorbent
garment such that the elements tend to be and remain bonded during
normal use conditions of the absorbent garment.
[0050] "Refastenable" refers to the property of two elements being
capable of releasable attachment, separation, and subsequent
releasable reattachment without substantial permanent deformation
or rupture.
[0051] "Releasably attached," "releasably connected," "releasably
engaged" and variations thereof refer to two elemens being
connected or connectable such that the elements tend to remain
connected absent a separation force applied to one or both of the
elements, and the elements being capable of separation without
substantial permanent deformation or rupture. The required
separation force is typically beyond that encountered while wearing
the absorbent garment.
[0052] "Rupture" means the breaking or tearing apart of a material;
in tensile testing, the term refers to the total separation of a
material into two parts either all at once or in stages, or the
development of a hole in some materials.
[0053] "Stretch bonded" refers to an elastic member being bonded to
another member while the elastic member is extended at least about
25 percent of its relaxed length. Desirably, the term "stretch
bonded" refers to the situation wherein the elastic member is
extended at least about 100 percent and more desirably at least 300
percent, of its relaxed length when it is bonded to the other
member.
[0054] "Stretch bonded laminate" refers to a composite material
having at least two layers in which one layer is a gatherable layer
and the other layer is an elastic layer. The layers are joined when
the elastic layer is in an extended condition so that upon relaxing
the layers, the gatherable layer is gathered.
[0055] "Surface" includes any layer, film, woven, nonwoven,
laminae, composite, or the like, whether pervious or impervious to
air, gas, and/or liquids.
[0056] "Tension" includes a uniaxial force tending to cause the
extension of a body or the balancing force within that body
resisting the extension.
[0057] "Thermoplastic" describes a material that softens when
exposed to heat and which substantially returns to a nonsoftened
condition when cooled to room temperature.
[0058] These terms may be defined with additional language in the
remaining portions of the specificaiton.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] The above-mentioned and other features of the present
invention and the manner of attaining them will become more
apparent, and the invention itself will be better understood by
reference to the following description and the accompanying
drawings, wherein similar features in different figures have been
given the same reference numeral.
[0060] FIG. 1 illustrates a front perspective view of one type of
disposble absorbent article incorporating the principles of the
present invention, where the fastening system is shown engaged on
one side of the absorbent article and disengaged on the other side
of the absorbent article.
[0061] FIG. 2 illlustrates a plan view of the disposable absorbent
article shown in FIG. 1 in an unfastened, stretched and laid flat
condition, and showing the surface of the article that faces away
from the wearer, with portions cut away to show the underlying
features.
[0062] FIG. 3 ilustrates a plan view similar to FIG. 2, but showing
the surface of the article that faces the wearer when the article
is worn, and with portions cut away to show the underlying
features.
[0063] FIG. 4 illustrates a plan view of a side panel of an
alternative disposable absorbent article incorporating the
principles of the present invention, in an unfastened, stretched
and laid flat condition and showing the surface of the article that
faces the wearer when the article is worn.
[0064] FIG. 5 illustrates a plan view of an alternative disposable
absorbent article shown in an unfastened, stretched and laid flat
condition, and showing the surface of the article that faces away
from the wearer.
[0065] FIG. 6 illustrates an enlarged sectional view of a portion
of an attachment panel of the absorbent article shown in FIG.
5.
[0066] FIG. 7 illustrates an enlarged plan view of a back side
panel of the type shown in FIG. 5.
[0067] FIG. 8 illustrates an enlarged plan view of a front side
panel of the type shown in FIG. 5.
DETAILED DESCRIPTION OF THE DRAWINGS
[0068] The principles of the present invention can be incorporated
into any suitable disposable absorbent article and its method of
manufature. Examples of such suitable articles include diapers,
training pants, feminine hygiene products, incontinence products,
other personal care or health care garments, or the like. For ease
of explanation, the description hereafter will be in terms of a
child's training pant.
[0069] With reference to FIG. 1, a disposable absorbent article,
such as a training pant 20, is illustrated in a partially fastened
condition. The training pant 20 comprises an absorbent chassis 32
and a fastening system 80. The absorbent chassis 32 defines a front
waist region 22, a back waist region 24, a crotch region 26
interconnecting the front and back waist regions 22, 24, an inner
surface 28 which is configured to contact the wearer, and an outer
surface 30 opposite the inner surface which is configured to
contact the wearer's clothing. With additional reference to FIGS. 2
and 3, the absorbent chassis 32 also defines a pair of transversely
opposed side edges 36 and a pair of longitudinally opposed waist
edges, which are designated front waist edge 38 and back waist edge
39. The front waist region 22 is contiguous with the front waist
edge 38, and the back waist region 24 is contiguous with the back
waist edge 39.
[0070] The illustrated absorbent chassis 32 comprises a rectangular
composite structure 33 and a pair of transversely opposed side
panels 34. The composite structure 33 and side panels 34 may be
integrally formed or comprise two or more separate elements, as
shown in FIG. 1. The illustrated composite structure 33 comprises
and outer cover 40, a bodyside liner 42 which is connected to the
outer cover in a superposed relation, an absorbent assembly 44
(FIGS. 2 and 3) which is located between the outer cover and
bodyside liner, and a pair of containment flaps 46 (FIGS. 1 and 3).
The rectangular composite structure 33 has opposite linear end
edges 45 that form portions of the front and back waist edges 38
and 39, and opposite linear side edges 47 that form portions of the
side edges 36 of the absorbent chassis 32 (FIGS. 2 and 3). For
reference, arrows 48 and 49 depicting the orientation of the
longitudinal axis and the transverse axis, respectively, of the
training pant 20 are illustrated in FIGS. 2 and 3.
[0071] With the training pant 20 in the fastened position as
partially illlustrated in FIG. 1, the front and back waist regions
22 and 24 are joined together to define a three dimensional pant
configuration having a waist opening 50 and a pair of leg openings
52. The front waist region 22 comprises the portion of the training
pant 20 which, when worn, is positioned on the front of the wearer
while the back waist region 24 comprises the portion of the
training pant which, when worn, is positioned on the back of the
wearer. The crotch region 26 of the training pant 20 comprises the
portion of the training pant which, when worn, is positioned
between the legs of the wearer and covers the lower torso of the
wearer. The side panels 34 comprise the portions of the training
pant 20 which, when worn, are positioned on the side hip regions of
the wearer. The back waist region 24 of the absobent chassis 32
includes the transversely opposed side panels 34 and a center panel
35 (FIGS. 2 and 3) positioned between and connecting the side
panels.
[0072] The waist edges 38 and 39 of the absorbent chassis 32 and
the side panels 34 are configured to encircle the waist of the
wearer when worn and provide the waist opening 50 which defines a
waist perimeter dimension. Portions of the transversely opposed
side edges 36 of the absorbent chassis 32 and the side panels 34
generally define th leg openings 52.
[0073] The absorbent chassis 32 is configured to contain and/or
absorb any body exudates discharged from the wearer. For example,
the absorbent chassis 32 desirably although not necessarily
comprises the pair of containment flaps 46 which are configured to
provide a barrier to the transverse flow of body exudates. A flap
elastic member 53 (FIG. 3) is operatively joined with each
containment flap 46 in any suitable manner as is well known in the
art. The elasticized containment flaps 46 define an unattached edge
which assumes an upright, generally perpendicular configuration in
at least the crotch region 26 of the training pant 20 to form a
seal against the wearer's body. The containment flaps 46 can be
located along the transversely opposed side edges of the absorbent
chassis 32, and can extend longitudinally along the entire length
of the absorbent chassis or may only extend partially along the
length of the absorbent chassis. Suitable constructions and
arrangements for the containment flaps 46 are generally well known
to those skilled in the art and are described in U.S. Pat. No.
4,704,116 issued Nov. 3, 1987 to Enloe, which is incorporated
herein by reference.
[0074] To further enhance containment and/or absorption of body
exudates, the training pant 20 desirably includes a front waist
elastic member 54, a rear waist elastic member 56, and leg elastic
members 58, as are known to those skilled in the art (FIG. 3). The
waist elastic members 54 and 56 can be operatively joined to the
outer cover 40 and/or bodyside liner 42 along the opposite waist
edges 38 and 39, and can extend over part or all of the waist
edges.
[0075] The leg elastic membes 58 are desirably operatively joined
to the outer cover 40 and/or bodyside liner 42 along the opposite
side edges 36 and positioned in the crotch region 26 of the
training pant 20. The leg elastic members 58 are desirably
longitudinally aligned along each side edge 47 of the composite
structure 33. Each leg elastic member 58 has a front terminal point
63 and a back terminal point 65, which points represent the
longitudinal ends of the elastic gathering caused by the leg
elastic members.
[0076] The flap elastic members 53, the waist elastics 54 and 56
and the leg elastics 58 can be formed of any suitable elastic
material. As is well known to those skilled in the art, suitable
elastic materials include sheets, strands or ribbons of natural
rubber, synthetic rubber, or thermoplastic elastomeric ploymers.
The elastic members can be stretched and adhered to a substrate,
adhered to a gathered substrate, or adhered to a substrate and then
elasticized or shrunk, for example with the application of heat;
such that elastic constrictive forces are imparted to the
substrate. In one particular embodiment, for example, the leg
elastic members 58 comprise a plurality of dry-spun coalesced
multifilament spandex elastomeric threads sold under the trade name
LYCRA.RTM. and available from E. I. DuPont de Nemours and Company,
Wilmington, Del., U.S.A.
[0077] The outer cover 40 desirably comprises a material that is
substantially liquid impermeable. The outer cover 40 can be a
single layer of liquid impermeable material, but desirably
comprises a multi-layered laminate structure in which at least one
of the layers is liquid impermeable. For instance, the outer cover
40 can include a liquid permeable outer layer and a liquid
impermeable inner layer that are suitably joined together by a
laminate adhesive (not shown). Suitable laminate adhesives, which
can be applied continuously or intermittently as beads, a spray,
parallel swirls, or the like, can be obtained from Findley
Adhesives, Inc., of Wauwatosa, Wis., U.S.A., or from National
Starch and Chemical Company, Bridgewater, N.J., U.S.A. The liquid
permeable outer layer can be any suitable material and desirably
one that provides a generally cloth-like texture. One example of
such a material is a 20 gsm (grams per square meter) spunbond
polypropylene nonwoven web. The outer layer may also be made of
those materials of which liquid permeable bodyside liner 42 is
made. While it is not a necessity for outer layer to be liquid
permeable, it is desired that it provides a relatively cloth-like
texture to the wearer.
[0078] The inner layer of the outer cover 40 can be both liquid and
vapor impermeable, or can be liquid impermeable and vapor
permeable. The inner layer is desirably manufactured from a thin
plastic film, although other flexible liquid impermeable materials
may also be used. The inner layer, or the liquid impermeable outer
cover 40 when a single layer, prevents waste material from wetting
articles, such as bedsheets and clothing, as well as the wearer and
caregiver. A suitable liquid impermeable film for use as liquid
impermeable inner layer, or a signal layer liquid impermeable outer
cover 40, is a 1.0 mil polyethylene film commercially available
from Edison Plastics Company of South Plainfield, N.J., U.S.A. If
the outer cover 40 is a single layer of material, it can be
embossed and/or matte finished to provide a more cloth-like
appearance. As earlier mentioned, the liquid impermeable material
can permit vapors to escape from the interior of the disposable
absorbent article, while still preventing liquids from passing
through the outer cover 40. A suitable "breathable" material is
composed of a microporous polymer film or a nonwoven fabric that
has been coated or otherwise treated to impart a desired level of
liquid impermeability. A suitable microporous film is a PMP-1 film
material commercially available from Mitsui Toatsu Chemicals, Inc.,
Tokyo, Japan, or an XKO-8044 polyolefin film commercially available
from 3M Company, Minneapolis, Minn., U.S.A.
[0079] As shown in FIGS. 1 and 2, the training pant 20 and in
particular the outer cover 40 desirably comprises one or more
appearance-related components. Examples of appearance-related
components include, but are not limited to, graphics; highlighting
or emphasizing leg and waist openings in order to make product
shaping more evident or visible to the user; highlighting or
emphasizing areas of the produt to simulate functional components
such as elastic leg bands, elastic waistbands, simulated "fly
openings" for boys, ruffles for girls; highlighting areas of the
product to change the appearance of the size of the product;
registering wetness indicators, temperature indicators, and the
like in the product; registering a back label, or a front label, in
the product; and registering written instructions at a desired
location in the product.
[0080] The illustrated training pant 20, which is designed for use
by young girls, includes a registered outer cover graphic 60. In
this design, the outer cover graphic 60 includes a rainbow, sun,
clouds, wagon and balloon. Again, any suitable design can be
utilized for a training pant intended for use by young girls, so as
to be aesthetically and/or functionally pleasing to them and the
caregive. The appearance-related components are desirably
positioned on the training pant 20 at selected locations, which can
be carried out using the methods disclosed in U.S. Pat. No.
5,766,389 issued Jun. 16, 1998 to Brandon et al., which is
incorporated herein by reference.
[0081] The liquid permeable bodyside liner 42 is illustrated as
overlying the outer cover 40 and absorbent assembly 44, and may but
need not have the same dimensions as the outer cover 40. The
bodyside liner 42 is desirably compliant, soft feeling, and
non-irritating to the child's skin. Further, the bodyside liner 42
can be less hydrophilic than the absorbent assembly 44, to present
a relatively dry surface to the wearer and permit liquid to readily
penetrate through its thickness.
[0082] The bodyside liner 42 can be manufactured from a wide
selection of web materials, such as synthetic fibers (for example,
polyester or polypropylene fibers), natural fibers (for example,
wood or cotton fibers), a combination of natural and synthetic
fibers, porous foams, reticulated foams, apertured plastic films,
or the like. Various woven and nonwoven fabrics can be used for the
bodyside liner 42. For example, the bodyside liner 42 can be
composed of a meltblown or spunbonded web of polyolefin fibers. The
bodyside liner 42 can also be a bonded-carded web composed of
natural and/or synthetic fibers. The bodyside liner 42 can be
composed of a substantially hydrophobic material, and the
hydrophobic material can, optionally, be treated with a surfactant
or otherwise processed to impart a desired level of wettability and
hydrophilicity. For example, the material can be surface treated
with about 0.28 weight percent of a surfactant commercially
available from the Rohm and Haas Co. under the trade designation
Triton X-102. The surfactant can be applied by any conventional
means, such as spraying, printing, brush coating or the like. The
surfactant can be applied to the entire bodyside liner 42 or can be
selectively applied to particular sections of the bodyside liner,
such as the medial section along the longitudinal centerline.
[0083] A suitable liquid permeable bodyside liner 42 is a nonwoven
bicomponent web having a basis weight of about 27 gsm. The nonwoven
bicomponent can be a spunbond bicomponent web, or a bonded carded
bicomponent web. Suitable bicomponent staple fibers include a
polyethylene/polypropylene bicomponent fiber available from CHISSO
Corporation, Osaka, Japan, In this particular bicomponent fiber,
the polypropylene forms the core and the polyethylene forms the
sheath of the fiber. Other fiber orientations are possible, such as
multi-lobe, side-by-side, end-to-end, or the like. While the outer
cover 40 and bodyside liner 42 can comprise elastomeric materials,
it is particularly desirable in some embodiments described herein
for the outer cover and bodyside liner to comprise materials that
are generally not elastomeric.
[0084] The absorbent assembly 44 (FIG. 3) is positioned between the
outer cover 40 and the bodyside liner 42, which components can be
joined together by any suitable means such as adhesives as is well
known in the art. The absorbent assembly 44 can be any structure
which is generally compressible, conformable, non-irritating to the
child's skin, and capable of absorbing and retaining liquids and
certain body wastes. The absorbent assembly 44 can be manufactured
in a wide variety of sizes and shapes, and from a wide variety of
liquid absorbent materials commonly used in the art. For example,
the absorbent assembly 44 can suitably comprise a matirx of
hydrophilic fibers, such as a web of cellulosic fluff, mixed with
particles of a high-absorbency material commonly known as
superabsorbent material. In a particular embodiment, the absorbent
assembly 44 comnprises a matrix of cellulosic fluff, such as wood
pulp fluff, and superabsorbent hydrogel-forming particles. The wood
pulp fluff can be exchanged with synthetic, polymeric, meltblown
fibers or with a combination of meltblown fibers and natural
fibers. The superabsorbent particles may be substantially
homogeneously mixed with the hydrophilic fibers or may be
nonuniformly mixed. The fluff and superabsorbent particles can also
be selectively placed into desired zones of the absorbent assembly
44 to better contain and absorb body exudates. The concentration of
the superabsorbent particles can also vary through the thickness of
the absorbent assembly 44. Alternatively, the absorbent assembly 44
can comprise a laminate of fibrous webs and superabsorbent material
or other suitable means of maintaining a superabsorbent material in
a localized area.
[0085] Suitable superabsorbent materials can be selected from
natural, synthetic, and modified natural polymers and materials.
The superabsorbent materials can be inorganic materials, such as
silica gels, or organic compounds, such as crosslinked polymers.
Suitable superabsorbent materials are available from various
commercial vendors, such Dow Chemical Company located in Midland,
Mich., U.S.A. and Stockhausen GmbH & Go. KG, D-47805 Krefeld,
Federal Republic of Germany. Typically, a superabsorbent material
is capable of absorbing at least about 15 times its weight in
water, and desirably is capable of absorbing more than about 25
time its weight in water.
[0086] In one embodiment, the absorbent assembly 44 is generaly
rectangular in shape, and comprises a blend of wood pulp fluff and
superabsorbent material. One preferred type of fluff is identified
with the trade designation CR1654, available from Kimberly-Clark
Corporation, Neenah, Wis., U.S.A., and is a bleached, highly
absorbent sulfate wood pulp containing primarily soft wood fibers.
As a general rule, the superabsorbent material is present in the
absorbent assembly 44 in an amount of from about 5 to about 90
weight percent based on total weight of the absorbent assembly 44,
The absorbent assembly 44 suitably has a density within the range
of 0.10 to about 0.35 grams per cubic centimeter. The absorbent
assembly 44 may or may not be wrapped for encompassed by a suitable
tissue wrap that maintains the integrity and/or shape of absorbent
assembly 44.
[0087] The absorbent chassis 32 can also incorporate other
materials that are designed primarily to receive, temporarily
store, and/or transport liquid along the mutually facing surface
with absorbent assembly 44, thereby maximizing the absorbent
capacity of absorbent assembly 44. One suitable mateial is referred
to as a surge layer (not shown) and comprises a material having a
basis weight of about 50 grams per square meter, and comprising a
through-air-bonded-carded web of a homogenous blend of 60 percent 3
denier bicomponent fiber comprising a polyester core/polyethylene
sheath, commercially available from BASF Corporation, and 40
percent 6 denier polyester fiber, commercially available from
Hoechst Celanese Corporation located in Portsmouth, Va., U.S.A.
[0088] For purposes of the present invention, the absorbent
assembly 44 is considered to have an absorbent batt 75 that
represents the primary absorbent structure of the absorbent
assembly 44. The absorbent batt 75 includes opposite side edges 76
that are generally longitudinally oriented within the absorben
chassis 32 (FIGS. 2 and 3).
[0089] As noted previously, the illustrated training pant 20 has a
side panel 34 disposed on each side of the absorbent chassis 32.
The pair of transversely opposed side panels 34 are permanently
bonded to the composite structure 33 of th absorbent chassis 32 in
at least one of the waist regions 22 and 24 and releasably attached
to the absorbent chassis in the opposite waist region. For example,
as shown best in FIGS. 2 and 3, the side panels 34 are permanently
bonded to and extend transversely beyond the side edges 47 of the
composite structure 33 in the back waist region 24 along an
attachment line 66.
[0090] The illustrated side panels 34 define a distal edge 68 that
is spaced from the attachment line 66, a leg end edge 70, and a
waist end edge 72. The leg end edge 70 and waist end edge 72 extend
from the side edges 47 of the composite structure 33 to the distal
edges 68. The leg end edges 70 of the side panels 34 form part of
the side edges 36 of the absorbent chassis 32 and are desirably
although not necessarily angled relative to the transverse axis 49
to provide greater coverage toward the back of the pant as compared
to the front of the pant. The waist end edges 72 are desirably
parallel to the transverse axis 49 and form part of the back waist
edge 39 of the absorbent chassis 32. Further, the waist end edges
72 are desirably substantially aligned with the linear end edges 45
of the composite structure 33, and particularly longitudinallly
offset by about 1 centimeter or less.
[0091] In particular embodiments for improved fit and appearance,
the side panels 34 desirably have an aveage length dimension
measured parallel to the longitudinal axis 48 that is about 20
percent or greater, and particularly about 25 percent or greater,
of the overall length dimension of the absorbent article, also
measued parallel to the longitudinal axis 48. For example, in
training pants having an overall length dimension of about 54
centimeters, the side panels 34 desirably have an average length
dimension of about 10 centimeters or greater, such as abuot 15
centimeters. As illustrated the side panels 34 extend from the
waist opening 50 to one of the leg openings 52 and have a
continually decreasing length dimension moving from the attachment
line 66 to the distal edge 68.
[0092] The side panels 34 are permanently bonded to the composite
structure 33 along the attachment line 66 using attachment means
known to those skilled in the art such as adhesive, thermal or
ultrasonic bonding. In such a configuration, each of the side
panels 34 can be releasably attached to the absorbent chassis 32 in
the front waist region 22 of the training pant 20 as will be
discussed heeinafter in more detial. Alternatively, the side panels
34 may be permanently bonded to the side edges 47 in the front
waist region 22 and releasably attached to the side edges 36 in the
back waist region 24 if it is desired that the fasteners be located
towards the back of the wearer. Such a configuration may be
desirable to pevent a wearer from unfastening the article
prematurely.
[0093] Each of the side panels 34 can include one or more
individual, distinct pieces of material. In particular embodiments,
for example, each side panel 34 can include front and back side
panel portions that are joined at a seam (see FIG. 4). Still
alternatively, each individual side panel 34 can include a single
piece of material which is folded over upon itself along an
intermediate fold line (not shown).
[0094] The side panels 34 desirably comprise an elastic material
capable of stretching in a direction parallel to the transverse
axis 49 of the training pant 20. In particular embodiments, each
side panel 34 may comprise an interior portion 78 desposed between
the distal edge 68 and the center panel 35 of the back waist region
24. In the illustrated embodiment, the interior portion 78 is
disposed between the distal edge 68 and the side edges 47 of the
rectangular composite structure 33. The elastic material of the
side panels 34 can be disposed in the interior portions 78 to
render the side panels elastomeric in a direction parallel to the
transverse axis 49. Most desirably, each side panel 34 is
elastomeric from the waist end edge 72 to the leg and edge 70. More
specifically, individual samples of side panel material, taken
between the waist end edge 72 and the leg end edge 70 parallel to
the transverse axis 49 and having a length from the attachment line
66 to the distal edge 68 and a width of 2 centimeters, are all
elastomeric.
[0095] Suitable elastic materials, as well as one described process
of incorporating elastic side panels into a training pant, are
described in the following U.S. patents; U.S. Pat. No. 4,940,464
issued Jul. 10, 1990 to Van Gompel et al.; U.S. Pat. No. 5,224,405
issued Jul. 6, 1993 to Pohjola; U.S. Pat. No. 5,104,116 issued Apr.
14, 1992 to Pohjola; and U.S. Pat. No. 5,046,272 issued Sep. 10,
1991 to Vogt et al.; all of which are incorporated herein by
reference. In particular embodiments, the elastic material
comprises a stretch-thermal laminate (STL), a neck-bonded laminate
(NBL), a reversibly necked laminate, or a stretch-bonded laminate
(SBL) material. Methods of making such materials are well known to
those skilled in the art and described in U.S. Pat. No. 4,663,220
issued May 5, 1987 to Wisneski et al.; U.S. Pat. No. 5,226,992
issued Jul. 13, 1993 to Mormon; and European Patent Application No.
EP 0 217 032 published on Apr. 8, 1987 in the names of Taylor et
al.; all of which are incorporated herein by reference.
Alternatively, the side panel material may comprise other woven or
nonwoven materials, such as those described above as being suitable
for the outer cover 40 or bodyside liner 42.
[0096] The training pant 20 according to the present invention also
includes a fastening system 80 for securing the training pant about
the waist of the wearer (FIGS. 2 and 3). The illustrated fastening
system 80 includes first and second fastening componens 82 and 83
that are adapted to refastenably connect to first and second mating
fastening components 84 and 85. In one embodiment, one surfce of
each of the first and second fastening components 82 and 83
comprises a plurality of engaging elements that project from that
surface. The engaging elements of these fastening components 82 and
83 are adapted to repeatedly engage and disengage the engaging
elements of the mating fastening components 84 and 85.
[0097] In one particular embodiment, the first and second fastening
components 82 and 83 each comprise hook type fasteners and the
first and second mating fastening components 84 and 85 each
comprise complimentary loop type fasteners. In another particular
embodiment, the first and second fastening components 82 and 83
each comprise loop type fasteners and the first and second mating
fastening components 84 and 85 each comprise complimentary hook
type fasteners. Loop type fasteners typically comprise a fabric or
material having a base or backing structure and a plurality of loop
members extending upwardly from at least one surface of the backing
structure. The loop material can be formed of any suitable
material, such as acrylic, nylon, or polyester, and can be formed
by methods such as warp knitting, stitch bonding or needle
punching. Suitable loop materials are available from Guilford
Mills, Inc., Greensboro, N.C., U.S.A. under the trade designation
No. 36549.
[0098] Hook type fasteners typically comprise a fabric or material
having a base or backing structure and a plurality of hook members
extending upwardly from at least one surface of the backing
structure. In contrast to the loop type fasteners which desirably
comprise a flexible fabric, the hook material advantageously
comprises a resilient material to minimize unintentional
disengagement of the fastener components as a result of the hook
material becoming deformed and catching on clothing or other items.
The term "resilient" as used herein refers to an interlocking
material having a predetermined shape and the property of the
interlocking material to resume the predetermined shape after being
engaged and disengaged from a mating, complementary interlocking
material. Suitable hook material can be molded or extruded of
nylon, polypropylene or another suitable material. Suitable
single-sided hook materials for the fastening components 82 and 83
or the mating fastening components 84 and 85 are available from
Velcro Industries B.V., Amsterdam, Netherlands or affiliates
thereof, and are identified as Velcro HTH-829 with a unidirectional
hook pattern and having a thickness of about 0.089 millimeters (3.5
mils) and HTH-851 with a uni-directional hook pattern and having a
thickness of about 0.051 millimeters (2 mils).
[0099] With reference to FIG. 3, the first and second fastening
components 82 and 83 are desirably located on the inner surface 28
of the training pant 20 in the back waist region 24. The first and
second fastening components 82 and 83 are desirably positioned
along the distal edge 68 of the side panels 34. The first and
secnod fastening components 82 and 83 can be adhered to the side
panels 34 by any means known to those skilled in the art such as
adhesive bonds, sonic bonds or thermal bonds.
[0100] With reference to FIG. 2, the first and second mating
fastening components 84 and 85 can be located on the out surface 30
of the training pant 20 in the front waist region 22. The first and
second mating fastening components 84 and 85 are sized to receive
the first and second fastening components 82 and 83 and are
desirably positioned along the side edges 36 of the absorbent
chassis 32, and in particular along the linear side edges 47 of the
rectangular composite structure 33, abutting the front waist edge
38. In particular embodiments the mating fastening components 84
and 85 have their inner side edges 86 disposed transversely outward
from the closely adjacent to the side edges 76 of the absorbent
batt 75. Moreover, the leg elastic members 58 are desirably axially
aligned with the mating fastening components 84 and 85. The front
terminal points 63 of the leg elastic members 58 are desirably
located adjacent inner end edges 87 of the respective mating
fastening components 84 and 85, and the back terminal points 65 of
the leg elastic members are desirably located adjacent the
longitudinally innermost parts of the side panels 34.
[0101] The first and second mating fastening components 84 and 85
can be adhered to the outer cover 40 by any means known to those
skilled in the art such as adhesive bonds, sonic bonds or thermal
bonds. In an alternative embodiment, the training pant 20 includes
only a single mating fastening component disposed in the front
waist region 22 for refastenably connecting to the first and second
fastening components 82 and 83 (not shown). In a further
alternative embodiment, the outer cover 40 and/or bodyside liner 42
functions as a mating fastening component in that it comprises a
material that is releasably engageable with the first and second
fastening components 82 and 83. In other alternative embodiments,
the fastening components are located on the outer surface and the
mating fastening components are located on the inner surface. The
first and second mating fastening components 84 and 85 are
desirably rectangular, although they may alternatively be square,
round, oval, curved or otherwise nonrectangularly shaped.
[0102] When the fastening components and the mating fastening
components 82-85 are releasably engaged, the side edges 36 of the
absorbent chassis 32 in the crotch region 26 define the leg
openings 52, and the waist edges 38 and 39 of the absorbent chassis
32, including the waist end edges 72 of the side panels 34, define
the waist opening 50. Due to the composite structure 33 being
rectangular and the side panels 34 being attached in the back waist
region 24, the side edges 36 of the absorbent chassis 32 in the
front waist regiona 22 and the crotch region 26 are aligned with
one another and are parallel to the longitudinal axis 48, that is
they form common linear edges.
[0103] When connected, the fastening components and the mating
fastening components 82-85 form a refastenable seam 88 (FIG. 1). In
particular embodiments, each of the fastening components and the
mating fastening components 82-85 define a length dimension that is
aligned generally parallel with the longitudinal axis 48 of the
training pant 20 and a width dimension that is aligned generally
parallel with the transverse axis 49 of the training pant 20. For a
child of about 9 to about 15 kilograms (20-35 lbs.), for example,
the length dimension of the fastening components and mating
fastening components is desirably from about 5 to about 13
centimeters, such as about 10 centimeters, and the width dimension
is desirably from about 0.5 to about 3 centimeters, such as about 2
centimeters. The fastening components and the mating fastening
components desirably have a length-to-width ratio of about 2 or
greater, such as about 2 to about 25, and particularly about 5 or
greater, such as about 5 to about 8. Alternatively, the fastening
components and refastenable seams may be curved or otherwise
non-linear.
[0104] The refastenable seams 88 desirably extend substantialy the
entire distance between the waist opening 50 and the leg openings
52 when the fasteners 82-85 are engaged. More specifically, the
refastenable seams 88 can cover about 80 to 100 percent, and
particularly about 90 to about 98 percent, of the distance between
the waist opening 50 and each leg opening 52, which distance is
measured parallel to the logitudinal axis 48. To construct the
seams 88 to extend substantially the entire distance between the
waist and leg openings 50 and 52, the fastening components 82 and
83 that are disposed on the side panels 34 can be formed to cover
about 80 to 100 percent, and more particularly about 90 to about 98
percent, of the distance between the waist end edge 70 and the leg
end edge 72 of the side panels 34.
[0105] The absorbent chassis 32 and the fastening system 80
together define a refastenable pant having a waist opening 50 and a
pair of leg openings 52. When the fastening system is engaged, it
can be appreciated that the refastenable pant includes a pair of
refastenable seams 88 extending from the waist opening 50 to each
leg opening 52, a pair of elastomeric side panels 34 extending from
the waist opening 50 to each leg opening 52, an elastomeric front
waistband 54 disposed in the front waist region 22 and positioned
between the pair of refastenable seams 88, an elastomeric back
waistband 56 disposed in the back waist region 24 and positioned
between the pair of elastomeric side panels, and a pair of
elastomeric leg members 58 which partially encircle each leg
opening 52. Each elastomeric leg member 58 extends from adjacent a
refastenable seam 88 in the front waist region 22 to adjacent an
elastomeric side panel 34 in the back waist region 24.
[0106] A single side panel 34 of an alternative disposable
absorbent article is shown in FIG. 4. The side panel 34 is bonded
to a composite structure 33 at an attachment line 66. The side
panel 34 includes a distal edge 68 transversely spaced from the
attachment line 66 and a leg end edge 70 and a waist end edge 72
that extend from the composite structure to the distal edge 68. The
side panel 34 illustrated in FIG. 4 includes a separate first
member 90, second member 92, and third member 94 that are arranged
in series from the attachment line 66 to the distal edge 68. The
fastening component 83 is disposed on the third member 94 adjacent
the distal edge 68.
[0107] The first member 90 and the second member 92 are desirably
attached to one another at a manually tearable seam 96 that extends
from the leg end edge 70 to the waist end edge 72. The tearable
seam 96 is desirably formed of suitable means such as ultrasonic
bonds that permit the side panel 34 to be torn easily at or along
the tearable seam by the caregiver. The tearable seam 96 is
desirably but not necessarily an outwardly directed fin seam. The
second member 92 and the third member 94 are desirably attached to
one another at a permanent seam 98 that extends from the leg end
edge 70 to the waist end edge 72. The permanent seam 98 may be
formed by adhesives, sonic or thermal bonds, or some combination
thereof and is designed to resist tearing. In particular
embodiments, the first and second member 90 and 92 comprise
elastomeric materials and the third membe 94 comprises a
non-elastomeric material. Alternatively, the side panel 34 may
comprise two members, one or both of which may be elastomeric, that
are bonded together at either a tearable seam or a permanent seam
(not shown). A training pant 20 incorporating the side panel 34
illlustrated in FIG. 4 comprises a pair of refastenable seams 88
and a pair of manually tearable seams 96.
[0108] An alternative training pant 300 is illustrated in a
stretched and laid flat condition in FIG. 5. The training pant 300
includes first and second mating fastening components 84 and 85
disposed in the front waist region 22 on the outer surface 30. The
training pant 300 also includes a panel member 302 disposed in the
back waist region 24. The panel member 302 desirably forms first
and second side panels 304 and 306 that exend transversely outward
from the composite structure 33 and the absorbent assembly 44 (FIG.
3) in the back waist region 24. First and second fastening
components 82 and 84 of the training pant 300 are bonded to the
inner surface 28 of the side panels 304 and 306.
[0109] The panel member 302 can comprise an integral portion of a
component of the composite structure 33, such as the bodyside liner
42 or a layer of the outer cover 40; or comprise a separate element
bonded to the composite structure; or comprise a plurality of
layers, whether integral portions, separate elements, or a
combination thereof. The panel member 302 and thus the side panels
304 and 305 can comprise either an elastic material or an inelastic
material. With additional reference to FIG. 6, the panel member 302
in the illustrated embodiment comprises a plurality of elastomeric
segments 310 disposed between an outer facing layer 312 and an
inner facing layer 314.
[0110] The elastomeric segments 310 can be positioned and arranged
so that both side panels 304 and 305 have elastic properties in a
direction parallel to the transverse axis 49 of the training pant
300. The elastomeric segments 310 can comprise elastomeric films,
webs, strands, fibers, or the like, and can comprise elastic
materials similar to those described in relation to other elastic
components of the training pants 20 and 300. The facing layers 312
and 314 can comprise materials of the type described in relation to
the bodyside liner 42, the side panels 34, or the like.
[0111] An enlarged plan view of a back side panel 34 of the type
shown in FIG. 1 is illustrated in FIG. 7. Only one side panel 34 is
shown in FIG. 7, although it should be understood that other side
panels can employ a similar construction. The side panel 34 can be
bonded to and extend transversely beyond the linear side edge 47 of
the composite structure 33 along attachment line 66. The side panel
34 defines a distal edge 68 that is spaced from the attachment line
66, a leg end edge 70 disposed toward the longitudinal center of
the training pant 20, and a waist end edge 72 disposed toward a
longitudinal end of the training pant 20. Alternatively, the side
panels 34 can comprise an integral portion of a component of the
composite structure 33, such as the bodyside liner or the outer
cover 40.
[0112] In particular embodiments, the fastening component 83 is
spaced inward from the distal edge 68 and the end edges 70 and 72
in order to protect the wearer from irritation that might be caused
by contact with the fastening component 83. Specifically, the
fastening component 83 can be spaced transversely inward from the
distal edge 68 in the region of reference numeral 100. Also, the
fastening component 83 can be spaced longitudinally inward from the
leg end edge 70 in the region of reference numeral 102, and spaced
longitudinally inward from the waist end edge 72 in the region of
reference numeral 104.
[0113] The degree of spacing balances the fact that a smaller
distance is harder for children and parents to remove but provides
a more garment-like appearance, while a larger distance is easier
for children and parents to remove but provides a loose and floppy
appearance that is not garment-like. Thus, the fastening component
83 is desirably spaced transversely inward from the distal edge 68
by about 1 to about 15 millimeters, particularly about 1 to about 5
millimeters, such as about 2 milimeters. The fastening component 83
is desirably spaced longitudinally inward from the leg end edge 70
and from the waist end edge 72 by about 2 millimeters or more,
particularly about 5 millimeters or more, such as from about 5 to
about 15 millimeters.
[0114] FIG. 8 illustrates an enlarged plan view of a front waist
region 22 including a mating fastening component 85. As with the
embodiment illustrated in FIG. 7, the fastening component 85 can be
spaced transversely inward from the side edge 36 in the region of
reference numeral 100 and longitudinally spaced inward from the end
edge 45 in the region of reference numeral 104. The preferred
distances from the edges are the same as those specified above in
relation to the embodiment of FIG. 7.
[0115] The training pants 20 and 300 may further include releasable
side bonds (not shown) for improved reliability of maintaining the
pant in a prefastened condition particularly when it is being
pulled on or off over the hips of the wearer. Such releasable side
bonds are desirably configured to be readily broken such that the
caregiver can easily remove the training pant 20 after it has been
soiled. The releasable side bonds desirably comprise ultrasonic
point bonds. Absorbent articles including such releasable side
bonds are further described in U.S. patent application Ser. No.
09/100,574 titled "Disposable Absorbent Articles Having Passive
Side Bonds And Adjustable Fastening Systems" filed Jun. 19, 1998 by
Elsberg, which is incorporated herein by reference.
[0116] The methods of the different aspects of the present
invention are directed at reliably and consistently providing the
refastenable training pants 20 and 300 as described herein and
representatively illustrated in the Figures. The various components
of the training pant 20 are integrally assembled together empoying
various types of suitable attachment means, such as adhesive, sonic
and thermal bonds or combinations thereof.
[0117] It will be apreciated that details of the foregoing
embodiment, given for purposes of illustration, are not to be
construed as limiting the scope of this invention. Although only a
few exemplary embodiments of this invention have been described in
detail above, those skilled in the art will readily appreciate that
many modifications are possible in the exemplary embodiments
without meterially departing from the novel teachings and
advantages of this invention. Accordingly, all such modifications
are intended to be included within the scope of this invention,
which is defined in the following claims and all equivalents
thereto. Further, it is recognized that many embodiments may be
conceived that do not achieve all of the advantages of some
embodiments, particularly of the preferred embodiments, yet the
absence of a particular advantage shall not be construed to
necessarily mean that such an embodiment is outside the scope of
the present invention.
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