U.S. patent application number 13/967844 was filed with the patent office on 2013-12-19 for printed absborbent article components for a uniform appearance.
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 David Flegar Bishop, Kimberly Marie Downs, Julia Hartono, Patsy Ann Krautkramer, Tami Lynn Kurtz, Marcille Faye Ruman, Daniel Robert Schlinz, Katherine Carol Shaw.
Application Number | 20130338622 13/967844 |
Document ID | / |
Family ID | 43876637 |
Filed Date | 2013-12-19 |
United States Patent
Application |
20130338622 |
Kind Code |
A1 |
Bishop; David Flegar ; et
al. |
December 19, 2013 |
Printed Absborbent Article Components For A Uniform Appearance
Abstract
A method is presented for manufacturing a disposable absorbent
article having multiple components including selecting a first
material appropriate for use as an outer cover; producing a chassis
including the outer cover, the outer cover including an outer cover
central region having an outer cover central region appearance;
selecting a second material appropriate for use as an elastic
panel, wherein the second material is different from the first
material; and producing a first elastic panel having a first
elastic panel central region. The method also includes printing the
first elastic panel central region with a first elastic panel
printed graphic; and attaching the first elastic panel to the
chassis, wherein the selecting and printing are performed such that
the first elastic panel central region gives the appearance of
being substantially similar to the outer cover central region
appearance.
Inventors: |
Bishop; David Flegar;
(Appleton, WI) ; Krautkramer; Patsy Ann; (Omro,
WI) ; Hartono; Julia; (Greenville, WI) ; Shaw;
Katherine Carol; (Menasha, WI) ; Ruman; Marcille
Faye; (Oshkosh, WI) ; Schlinz; Daniel Robert;
(Greenville, WI) ; Downs; Kimberly Marie;
(Oshkosh, WI) ; Kurtz; Tami Lynn; (Oshkosh,
WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kimberly-Clark Worldwide, Inc. |
Neenah |
WI |
US |
|
|
Assignee: |
Kimberly-Clark Worldwide,
Inc.
Neenah
WI
|
Family ID: |
43876637 |
Appl. No.: |
13/967844 |
Filed: |
August 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12580882 |
Oct 16, 2009 |
8529725 |
|
|
13967844 |
|
|
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|
Current U.S.
Class: |
604/385.24 |
Current CPC
Class: |
A61F 13/49017 20130101;
A61F 13/51478 20130101; A61F 13/51496 20130101; A61F 2013/15243
20130101; A61F 13/15577 20130101; A61F 13/15585 20130101; A61F
13/84 20130101 |
Class at
Publication: |
604/385.24 |
International
Class: |
A61F 13/49 20060101
A61F013/49 |
Claims
1. A disposable absorbent article having a uniform garment-like
appearance, the article comprising: a chassis including an outer
cover, a liner generally parallel to the outer cover, an absorbent
core disposed therebetween, and an outer cover central region
including an outer cover printed graphic; a first elastic panel
attached at a seam to the chassis, the first elastic panel
including a first elastic panel central region having a first
elastic panel central region appearance; wherein the outer cover
includes a first material, wherein the first elastic panel includes
a second material, wherein neither the outer cover central region
nor the first elastic panel central region includes a printed
waistband, and wherein the outer cover central region has the
appearance of being substantially similar to the first elastic
panel central region appearance.
2. The article of claim 1, wherein the first elastic panel central
region appearance includes a first elastic panel texture
appearance, and wherein the outer cover printed graphic is printed
to appear substantially similar to the first elastic panel texture
appearance.
3. The article of claim 1, wherein the first elastic panel central
region appearance includes a first elastic panel printed graphic,
wherein the first elastic panel printed graphic is substantially
similar to the outer cover printed graphic.
4. The article of claim 1, wherein the first elastic panel central
region and the outer cover central region do not include a
waistband or a leg band.
5. The article of claim 1, further comprising: a second elastic
panel attached at a seam to the chassis, the second elastic panel
including a second elastic panel central region having a second
elastic panel central region appearance, wherein the outer cover
central region has the appearance of being substantially similar to
the second elastic panel central region appearance.
6. A disposable absorbent article having a uniform garment-like
appearance, the article comprising: a chassis including an outer
cover, a liner generally parallel to the outer cover, and an
absorbent core disposed therebetween; a first elastic panel
attached at a seam to the chassis; a second elastic panel attached
at a seam to the chassis, wherein the first elastic panel is
attached at a seam to the second elastic panel; a waist opening and
two leg openings; and a lateral circumference taken between the
waist opening and the leg openings, wherein the outer cover
includes a first material, wherein each elastic panel includes a
second material, wherein the first material is different from the
second material, and wherein the article includes a printed graphic
along the entire circumference and on the outer cover.
7. The article of claim 6, wherein the second material has a
greater elasticity than the first material.
Description
RELATED APPLICATION DATA
[0001] This application claims priority as a Divisional of
application Ser. No. 12/580,882, filed on Oct. 16, 2009. The
entirety of application Ser. No. 12/580,882 is incorporated herein
by reference.
BACKGROUND
[0002] Absorbent products are often created from multiple materials
and components that typically differ in look and feel. Real cloth
underwear, however, is generally created from a single chassis
material and waist and leg bands. As a result, the real cloth
underwear has a consistent look and feel. With respect to
disposable absorbent products made from multiple nonwoven
components, consumers generally prefer products that more closely
emulate the appearance of real cloth underwear. This desire leads
to a need to reduce the actual differences in the appearance of a
disposable absorbent across its different materials and components
and to create perceptions of a similar look and feel across
different materials.
[0003] Previous attempts in this area have focused on matching a
solid color printed nonwoven with a pigmented nonwoven material, or
by manufacturing what is typically referred to as a one-piece
chassis.
SUMMARY
[0004] These problems can be addressed by using a method for
manufacturing a disposable absorbent article having multiple
components including selecting a first material appropriate for use
as an outer cover; producing a chassis including the outer cover,
the outer cover including an outer cover central region having an
outer cover central region appearance; selecting a second material
appropriate for use as an elastic panel, wherein the second
material is different from the first material; and producing a
first elastic panel having a first elastic panel central region.
The method also includes printing the first elastic panel central
region with a first elastic panel printed graphic; and attaching
the first elastic panel to the chassis, wherein the selecting and
printing are performed such that the first elastic panel central
region gives the appearance of being substantially similar to the
outer cover central region appearance.
[0005] In addition, a method for manufacturing a disposable
absorbent article having a uniform garment-like appearance includes
producing an assembly of at least a chassis having an outer cover
and an elastic panel attached to the chassis, the assembly having a
physical structure; and masking the physical structure of the
assembly by printing the same graphic continuously on the outer
cover and the elastic panel.
[0006] Further, a disposable absorbent article having a uniform
garment-like appearance includes a chassis including an outer
cover, a liner generally parallel to the outer cover, an absorbent
core disposed therebetween, and an outer cover central region
including an outer cover printed graphic; and a first elastic panel
attached at a seam to the chassis, the first elastic panel
including a first elastic panel central region having a first
elastic panel central region appearance; wherein the outer cover
includes a first material, wherein the first elastic panel includes
a second material, wherein neither the outer cover central region
nor the first elastic panel central region includes a printed
waistband, and wherein the outer cover central region has the
appearance of being substantially similar to the first elastic
panel central region appearance.
[0007] Additionally, a disposable absorbent article having a
uniform garment-like appearance includes a chassis including an
outer cover, a liner generally parallel to the outer cover, and an
absorbent core disposed therebetween; a first elastic panel
attached at a seam to the chassis; and a second elastic panel
attached at a seam to the chassis, wherein the first elastic panel
is attached at a seam to the second elastic panel. The article also
includes a waist opening and two leg openings; and a lateral
circumference taken between the waist opening and the leg openings,
wherein the outer cover includes a first material, wherein each
elastic panel includes a second material, wherein the first
material is different from the second material, and wherein the
article includes a printed graphic along the entire circumference
and on the outer cover.
[0008] Other features and aspects of the present disclosure are
described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A full and enabling disclosure of the present disclosure,
including the best mode thereof, directed to one of ordinary skill
in the art, is set forth more particularly in the remainder of the
specification, which makes reference to the appended figures in
which:
[0010] FIG. 1 is a side elevation of a child's pants with a
fastening system of the pants shown connected on one side of the
pants and disconnected on the other side of the pants;
[0011] FIG. 2 is a bottom plan view of the pants of FIG. 1 in an
unfastened, stretched and laid flat condition to show the surface
of the pants which faces away from the wearer;
[0012] FIG. 3 is a top plan view of the pants in its unfastened,
stretched and laid flat condition to show the surface of the pants
which faces the wearer when the pants are worn, with portions of
the pants being cut away to reveal underlying features;
[0013] FIG. 4 representatively illustrates a plan view of one
aspect of an absorbent garment in a longitudinally-stretched and
laid-flat condition, prior to the joining of the front and back
waist regions, and showing the surface of the article that faces
the wearer when the article is worn, and with portions cut away to
show underlying features; and
[0014] FIG. 5 representatively illustrates the garment of FIG. 4 in
a closed condition.
[0015] Repeat use of reference characters in the present
specification and drawings is intended to represent same or
analogous features or elements of the disclosure.
DETAILED DESCRIPTION
[0016] As used herein, the terms "machine direction" or "MD"
generally refers to the direction in which a material is produced.
The term "cross-machine direction" or "CD" refers to the direction
perpendicular to the machine direction.
[0017] As used herein the terms "extensible" or "extensibility"
generally refers to a material that stretches or extends in the
direction of an applied force by at least about 25%, in some
aspects about 50%, and in some aspects, at least about 75% of its
relaxed length or width. An extensible material does not
necessarily have recovery properties. For example, an elastomeric
material is an extensible material having recovery properties. A
meltblown web can be extensible, but not have recovery properties,
and thus, be an extensible, non-elastic material.
[0018] As used herein, the term "elastomeric" and "elastic" refers
to a material that, upon application of a stretching force, is
stretchable in at least one direction (such as the CD direction),
and which upon release of the stretching force, contracts/returns
to approximately its original dimension. For example, a stretched
material can have a stretched length that is at least 50% greater
than its relaxed unstretched length, and which will recover to
within at least 50% of its stretched length upon release of the
stretching force. A hypothetical example would be a one (1) inch
sample of a material that is stretchable to at least 1.50 inches
and which, upon release of the stretching force, will recover to a
length of not more than 1.25 inches. Desirably, the material
contracts or recovers at least 50%, and even more desirably, at
least 80% of the stretched length.
[0019] As used herein, the term "thermal point bonding" generally
refers to a process performed, for example, by passing a material
between a patterned roll (e.g., calender roll) and another roll
(e.g., anvil roll), which may or may not be patterned. One or both
of the rolls are typically heated.
[0020] As used herein, the term "breathability" generally refers to
the water vapor transmission rate (WVTR) of an area of a material.
Breathability is measured in grams of water per square meter per
day (g/m.sup.2/24 hours). The WVTR of a material can be measured in
accordance with ASTM Standard E96-80. Alternatively, for materials
having WVTR greater than about 3000 g/m.sup.2/24 hours testing
systems such as, for example, the PERMATRAN-W 100K water vapor
permeation analysis system, commercially available from Modern
Controls, Inc. (MOCON) of Minneapolis, Minn., can be used.
[0021] Reference now will be made in detail to various aspects of
the disclosure, one or more examples of which are set forth below.
Each example is provided by way of explanation, not limitation of
the disclosure. In fact, it will be apparent to those skilled in
the art that various modifications and variations can be made in
the present disclosure without departing from the scope or spirit
of the disclosure. For instance, features illustrated or described
as part of one aspect, can be used on another aspect to yield a
still further aspect. Thus, it is intended that the present
disclosure cover such modifications and variations.
[0022] The methods and apparatus of the present disclosure can be
used to make a variety of disposable absorbent articles such as
disposable absorbent garments including diapers, training pants,
feminine hygiene products, incontinence products, medical garments,
other personal care or health care garments, swim pants, and the
like. For ease of explanation, the methods and apparatus of the
present disclosure are first described in connection with making
child's pants, generally indicated as 20 in FIG. 1. In particular,
the methods and apparatus will be described in terms of those for
making pre-fastened disposable pants as described in U.S. patent
application Ser. No. 09/444,083 titled "Absorbent Articles With
Refastenable Side Seams" and filed Nov. 22, 1999 (corresponding to
PCT application WO 00/37009 published Jun. 29, 2000) by A. L.
Fletcher et al., the disclosure of which is incorporated herein by
reference. Pants 20 can also be constructed using the methods and
apparatus disclosed in U.S. Pat. No. 4,940,464 issued Jul. 10, 1990
to Van Compel et al.; and U.S. Pat. No. 5,766,389 issued Jun. 16,
1998 to Brandon et al.; the disclosures of which are also
incorporated herein by reference.
[0023] The methods and apparatus of the present disclosure are
thereafter further described in connection with making an adult
pant, generally indicated at 220 in FIGS. 4 and 5.
[0024] It should be understood that as used herein, the term
"component" includes not only discrete objects, but also objects
yet to be formed into discrete objects (e.g., objects yet to be
severed into discrete objects from a continuous sheet or web of
material), particles (e.g., superabsorbent particles or polymers),
adhesives, lotions, ointments, and other substances, as well as
portions or characteristics of any such components including, for
example, fold lines, bond lines (e.g., ultrasonic bond lines),
bonded or adhered regions, and registration marks applied to or
about components for subsequent detection during a manufacturing or
inspection process.
[0025] With reference now to the drawings, and in particular to
FIG. 1, a pair of pants 20 is illustrated in a partially fastened
condition and include an absorbent chassis 32 having a front waist
region 22, a back waist region 24, a crotch region 26
interconnecting the front and back waist regions, an inner surface
28 which is configured to contact the wearer, and an outer surface
30 opposite the inner surface and configured to contact the
wearer's clothing. With additional reference to FIGS. 2 and 3, the
absorbent chassis 32 also has a pair of laterally opposite side
edges 36 and a pair of longitudinally opposite waist edges,
respectively 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.
[0026] The illustrated absorbent chassis 32 includes a composite
structure 33 (FIGS. 2 and 3), which when laid flat can be
rectangular or any other desired shape, and has a pair of laterally
opposite front side panels 34 and a pair of laterally opposite back
side panels 134 extending outward therefrom. Each side panel 34,
134 includes a side panel central region 76 positioned generally on
each side panel 34, 134, and does not include a waistband or leg
bands (FIG. 2). The side panel central region 76 has a side panel
central region appearance, which is the physical appearance of the
side panel central region 76.
[0027] The composite structure 33 and side panels 34, 134 can
include two or more separate elements, as shown in FIG. 1, or be
integrally formed. Integrally formed side panels 34, 134 and
composite structure 33 would include at least some common
materials, such as the bodyside liner, flap composite, outer cover,
other materials and/or combinations thereof, and could define a
one-piece elastic, stretchable, or non-stretchable pants. The
illustrated composite structure 33 includes an outer cover 40, a
bodyside liner 42 (FIGS. 1 and 3) connected to the outer cover in a
superposed relation, an absorbent assembly 44 (FIG. 3) disposed
between the outer cover and the bodyside liner, and a pair of
containment flaps 46 (FIG. 3). The illustrated composite structure
33 has opposite ends 45 (FIGS. 2 and 3) that form portions of the
front and back waist edges 38 and 39, and opposite side edges 47
which form portions of the side edges 36 of the absorbent chassis
32 (FIGS. 2 and 3). The outer cover 40 includes an outer cover
central region 75 positioned generally in the front and/or back
waist regions 22, 24, and does not include a waistband or leg bands
(FIG. 2). The outer cover central region 75 has an outer cover
central region appearance, which is the physical appearance of the
outer cover central region 75.
[0028] For reference, arrows 48 and 49 (FIGS. 2 and 3) depict the
orientation of the longitudinal axis and the transverse or lateral
axis, respectively, of the pants 20.
[0029] With the pants 20 in the fastened position as partially
illustrated in FIG. 1, the front and back side panels 34, 134 are
connected together by a fastening system 80 to define a
three-dimensional pants configuration having an interior space 51,
a waist opening 50 for receiving the wearer into the interior space
of the pants, a pair of leg openings 52 and engagement seams 88
along which the side panels 34, 134 are connected. The interior
space 51 of the pants 20 is thus bounded by the absorbent chassis
32, the engagement seams 88 and the portions of the side panels 34,
134 extending on opposite sides of the engagement seams 88 (e.g.,
between the engagement seams 88 and the absorbent chassis 32). As
used herein, the "interior space" 51 is intended to refer to the
space between any two portions of a three-dimensional article which
generally oppose each other. It is understood that a transverse
cross-section of the article need not be closed, e.g., continuous,
to define the interior space 51. For example, a two-dimensional
article can be generally folded over on itself so that two portions
of the article oppose each other to define an interior space of the
article therebetween. Thus, the interior space 51 of the pants 20
shown in FIG. 1 can be defined by the side panels 34, 134
themselves or, if the side panels 34,134 are fully straightened
therebetween, the interior space is defined by a combination of the
side panels 34, 134 and the front and back waist regions 22, 24 of
the absorbent chassis 32.
[0030] The front waist region 22 includes the portion of the pants
20 which, when worn, is positioned on the front of the wearer while
the back waist region 24 includes the portion of the pants which,
when worn, is positioned on the back of the wearer. The crotch
region 26 of the pants 20 includes the portion of the pants 20
which, when worn, is positioned between the legs of the wearer and
covers the lower torso of the wearer. The front and back side
panels 34 and 134 include the portions of the pants 20 which, when
worn, are positioned on the hips of the wearer. The waist edges 38
and 39 of the absorbent chassis 32 are configured to encircle the
waist of the wearer when worn and together define the waist opening
50 (FIG. 1). Portions of the side edges 36 in the crotch region 26
generally define the leg openings 52.
[0031] The absorbent chassis 32 is configured to contain and/or
absorb any exudates discharged from the wearer. For example, the
absorbent chassis 32 desirably although not necessarily includes
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) can be 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 configuration in at least the crotch region 26
of the pants 20 to form a seal against the wearer's body. The
containment flaps 46 can be located along the side edges 36 of the
absorbent chassis 32, and can extend longitudinally along the
entire length of the absorbent chassis 32, or can only extend
partially along the length of the absorbent chassis 32. 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.
[0032] To further enhance containment and/or absorption of body
exudates, the pants 20 desirably although not necessarily include a
front waist elastic member 54, a back 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 the bodyside liner 42 along the
opposite waist edges 38 and 39, and can extend over part or all of
the waist edges. The leg elastic members 58 can be operatively
joined to the outer cover 40 and/or the bodyside liner 42 along the
opposite side edges 36 and positioned in the crotch region 26 of
the pants 20. The leg elastic members 58 can be 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 represent the longitudinal ends of the
elastic gathering caused by the leg elastic members. The front
terminal points 63 can be located adjacent the longitudinally
innermost parts of the front side panels 34, and the back terminal
points 65 can be located adjacent the longitudinally innermost
parts of the back side panels 134.
[0033] As shown in FIGS. 1 and 2, the pants 20 and in particular
the outer cover 40 desirably includes 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 product 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.
[0034] The illustrated pair of pants 20 is designed for use by
young girls and includes a registered outer cover graphic 60 (FIGS.
1 and 2). In this design, the registered graphic 60 includes a
primary pictorial image 61, simulated waist ruffles 62, and
simulated leg ruffles 64. The primary pictorial image 61 includes
an object graphic such as a rainbow, sun, clouds, animal
characters, wagon and balloons. Any suitable design can be utilized
for pants intended for use by young girls, so as to be
aesthetically and/or functionally pleasing to them and the
caregiver. The appearance-related components are desirably
positioned on the pants 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., the entire disclosure of
which is incorporated herein by reference. The primary pictorial
image 61 is desirably positioned in the front waist region 22 along
the longitudinal center line of the pants 20.
[0035] The printed graphics on the pants 20 can share a color
palette, can be of the same color, can be of complementary colors,
or can follow any suitable color scheme. Different areas of the
pants 20 can also be printed with similar or identical graphical
elements such as stars, circles, butterflies, etc. Different areas
of the pants 20 can also be printed with similar or identical
graphics that share a graphic theme. For example, the pants 20 can
be printed with flowers that might or might not be identical in
size, type, color, etc., but that all share the flower theme. In
another aspect, the article can be reverse printed such that
graphical elements, for example, appear as an absence of
printing.
[0036] As noted previously, the illustrated pants 20 have front and
back side panels 34 and 134 disposed on each side of the absorbent
chassis 32. The front side panels 34 can be permanently bonded
along seams 66 to the composite structure 33 of the absorbent
chassis 32 in the respective front and back waist regions 22 and
24. More particularly, as seen best in FIGS. 2 and 3, the front
side panels 34 can be permanently bonded to and extend transversely
outward beyond the side edges 47 of the composite structure 33 in
the front waist region 22, and the back side panels 134 can be
permanently bonded to and extend transversely outward beyond the
side edges of the composite structure in the back waist region 24.
The side panels 34 and 134 can be bonded to the composite structure
33 using attachment means known to those skilled in the art such as
adhesive, thermal or ultrasonic bonding. Alternatively, the side
panels 34 and 134 can be formed as an integral portion of a
component of the composite structure 33. For example, the side
panels can include a generally wider portion of the outer cover 40,
the bodyside liner 42, and/or another component of the absorbent
chassis 32. The front and back side panels 34 and 134 can be
permanently bonded together or be releasably connected with one
another such as by the fastening system 80 of the illustrated
aspect.
[0037] As best illustrated in FIGS. 2 and 3, the front and back
side panels 34, 134 each have an outer edge 68 spaced laterally
from the seam 66, a leg end edge 70 disposed toward the
longitudinal center of the pants 20, and a waist end edge 72
disposed toward a longitudinal end of the pants. The leg end edge
70 and waist end edge 72 extend from the side edges 47 of the
composite structure 33 to the outer edges 68. The leg end edges 70
of the side panels 34 and 134 form part of the side edges 36 of the
absorbent chassis 32. In the back waist region 24, the leg end
edges 70 are desirably although not necessarily curved and/or
angled relative to the transverse axis 49 to provide greater
coverage toward the back of the pants 20 as compared to the front
of the pants. The waist end edges 72 are desirably parallel to the
transverse axis 49. The waist end edges 72 of the front side panels
34 form part of the front waist edge 38 of the absorbent chassis
32, and the waist end edges 72 of the back side panels 134 form
part of the back waist edge 39 of the absorbent chassis 32.
[0038] In particular aspects for improved fit and appearance, the
side panels 34, 134 desirably have an average length measured
parallel to the longitudinal axis 48 which is about 15 percent or
greater, and particularly about 25 percent or greater, of the
overall length of the pants, also measured parallel to the
longitudinal axis 48. For example, in pants 20 having an overall
length of about 54 centimeters, the side panels 34, 134 desirably
have an average length of about 10 centimeters or greater, such as
about 15 centimeters. While each of the side panels 34, 134 extends
from the waist opening 50 to one of the leg openings 52, the
illustrated back side panels 134 have a continually decreasing
length dimension moving from the seam 66 to the outer edge 68, as
is best shown in FIGS. 2 and 3.
[0039] Each of the side panels 34, 134 can include one or more
individual, distinct pieces of material. In particular aspects, for
example, each side panel 34, 134 can include first and second side
panel portions that are joined at a seam, or can include a single
piece of material which is folded over upon itself (not shown).
[0040] The side panels 34, 134 desirably although not necessarily
include an elastic material capable of stretching in a direction
generally parallel to the transverse axis 49 of the pants 20.
Suitable elastic materials, as well as one process of incorporating
elastic side panels into pants, are described in the following U.S.
Pat. Nos. 4,940,464 issued Jul. 10, 1990 to Van Compel et al.;
5,224,405 issued Jul. 6, 1993 to Pohjola; 5,104,116 issued Apr. 14,
1992 to Pohjola; and 5,046,272 issued Sep. 10, 1991 to Vogt et al.;
all of which are incorporated herein by reference. An alternative
elastic material is described below. In particular aspects, the
elastic material includes 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 Morman; 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 can
include other woven or nonwoven materials, such as those described
above as being suitable for the outer cover 40 or bodyside liner
42; mechanically pre-strained composites; or stretchable but
inelastic materials.
[0041] The methods and apparatus of the present disclosure are
further described in connection with an adult pant, generally
indicated at 220 in FIGS. 4 and 5. Referring to FIG. 4, which
illustrates exemplary aspects of the present disclosure, a
pant-like disposable absorbent garment includes a front panel 222,
the front panel 222 defining a front waist edge 223, first and
second front leg edges 221, opposing first and second front side
edges 224 and 225 that extend from the front waist edge 223 to the
first and second front leg edges 221, and a front panel width 234
that extends from the first front side edge 224 to the second front
side edge 225 (as measured at the front waist edge when the product
is in a laid-flat, open, and fully extended configuration).
[0042] The garment further includes a back panel 226, the back
panel 226 defining a back waist edge 227, first and second back leg
edges 245, opposing first and second back side edges 228 and 229
that extend from the back waist edge 227 to the first and second
back leg edges 245, and a back panel width 244 that extends from
the first back side edge 228 to the second back side edge 229 (as
measured at the back waist edge when the product is in a laid-flat,
open and fully extended configuration). The front panel 222 and the
back panel 226 each include an elastic panel central region 276
positioned generally on each front and back panel 222, 226, and
does not include a waistband or leg bands (FIG. 4). The elastic
panel central region 276 has an elastic panel central region
appearance, which is the physical appearance of the elastic panel
central region 276.
[0043] In one aspect, the garment further includes a crotch panel
230 positioned longitudinally between the front panel 222 and the
back panel 226, wherein the front panel 222, the back panel 226,
and the crotch panel 230 are continuous and integral with each
other, as representatively illustrated in FIGS. 4 and 5. One
version of such an aspect includes an hourglass-shaped panel having
an elastomeric film laminate. In particular aspects, the laminate
includes two nonwoven layers superposed on opposing top and bottom
surfaces of an elastomeric polymeric film such that the polymeric
film is sandwiched between the two nonwoven facings, wherein both
the polymeric film and both nonwoven layers extend substantially
through the entire area of each laminate. Another version of such
an aspect includes providing an hourglass panel including a
nonwoven substrate that is imparted with elastic properties by
adhesively attaching elastic strands thereto. The strands and
adhesive are, in particular aspects, sandwiched to the hourglass
panel with a second nonwoven layer or layers.
[0044] The garment further includes an absorbent insert 235. The
insert includes an absorbent member 236. One example of a suitable
insert 235 includes a liquid-permeable bodyside liner, a
garment-side liquid-impermeable backsheet 237, and an absorbent
member 236 included of wood pulp fluff and superabsorbent polymer.
Each absorbent insert 235 is attached to an hourglass-shaped panel.
The absorbent insert is attached to and extends between the front
panel 222 and the back panel 226 (FIG. 4). The backsheet 237
includes an outer cover central region 275 positioned generally on
the backsheet 237, and does not include a waistband or leg bands
(FIG. 4). The outer cover central region 275 has an outer cover
central region appearance, which is the physical appearance of the
outer cover central region 275.
[0045] As illustrated in FIG. 4, the garment defines a longitudinal
direction 232 that extends between the front waist edge 223 and the
back waist edge 227, and a transverse direction 233 that is
perpendicular to the longitudinal direction 232 and that extends
between the first front side edge 224 and the second front side
edge (and between the first back side edge 228 and the second back
side edge 229).
[0046] In particular aspects shown in FIG. 5, side seams 268 of the
garment 220 are permanently bonded, non-refastenable side seams.
For example, the joining of the first and second front side edges
to the first and second back side edges creates a pair of
permanently bonded, non-refastenable side seams. In other aspects,
the side seams 268 are releasable and refastenable. For example,
the joining of the first and second front side edges to the first
and second back side edges creates a pair of releasable and
refastenable seams. The closed article as shown in FIG. 6 includes
a waist opening 250 and a pair of leg openings 252.
[0047] In particular aspects of the present disclosure, the front
panel defines a front crotch edge longitudinally opposite the front
waist edge, and the back panel defines a back crotch edge
longitudinally opposite the back waist edge, and the front crotch
edge is longitudinally spaced apart from the back crotch edge such
that the front panel and the back panel are separate from and
non-integral with each other.
[0048] It is apparent that the disposable absorbent articles
described herein share similar features, even though such features
are conventionally labeled differently for different types of
products. The present disclosure is intended to apply to any
product described herein. For example, subject matter using the
term "side panel" is intended to be equally applicable to the body
panel of an adult care product and to the more generic terms
elastic panel and stretchable panel. Subject matter using the term
"chassis" is intended to be equally applicable to the absorbent
insert of an adult care product. Subject matter using the term
"outer cover" is intended to be equally applicable to the backsheet
of an adult care product. Leg openings, waist openings, waist
edges, waistbands, and leg bands are similar for all products.
Other similarities and equivalencies will be apparent to those
skilled in the art.
[0049] In one aspect of the present disclosure, the elastic panels
can be constructed from an elastic laminate that is a composite
that includes an elastic film laminated to a meltblown facing. By
replacing VFL elastic panels with a new elastic laminate material
described herein on baby, child, and youth pants and replacing the
stranded chassis with the new material described herein on adult
pants, one-piece garment-like look can be achieved while
maintaining the high stretch properties required to fit the
user.
[0050] The smoothness or texture quality of a retracted elastic
laminate can be quantified through relatively simple physical
measurements. For a laminate having a cross section defined by the
y-z plane, where the material is elastically functional along the y
axis, and the x-y plane defines the printable surface of the
laminate, the corrugations formed by the retracted facing in the
y-z plane have descriptive values similar to those of a wave.
Whereas a wave has a frequency, wavelength, and amplitude, the
corrugations of the facings have a corrugation density, a
corrugation spacing, and a corrugation height. It is both the
magnitude and variability of these values that determine the
resulting smoothness or texture of the material.
[0051] The regularity of the corrugation height determines the
uniformity and thus smoothness of the retracted surface. For a
laminate having a cross section in the y-z plane, and a printable
surface in the x-y plane, the regularity of corrugation height
measured on the z axis determines the consistency of laminate look
and feel. A perfectly-consistent corrugation height wave to wave
yields the same contact length at the crest of each wave. For the
elastic laminate described herein, the corrugation height standard
deviation varies from 120 to 190 micrometers versus a standard
deviation range of 240-410 micrometers for VFL, as much as a 200%
advantage. The magnitude of corrugation density determines the
surface area available on the elastic laminate. The greater the
area available the smoother the material will look and feel. With
retracted laminates, look and feel is primarily accomplished at the
crest of the corrugation wave. The higher the corrugation density,
the more facings area at the laminate surface that is available.
The elastic laminates described herein possess 1.4-2.0 corrugations
per linear mm compared to 0.7-1.10 corrugations per linear mm for
VFL and 0.7 corrugations per linear mm for LYCRA-brand synthetic
fiber laminate, which yields as much as a 200% advantage in smooth
surface area. A corrugation density of greater than 1.2
corrugations per liner mm is preferable to satisfactorily match the
appearance of a non-elastic printed surface such as SFL. It should
be noted that corrugation density and corrugation spacing are
simply different representations of the same physical data.
[0052] Further, for an elastic laminate of the present disclosure,
adjacent cross sections have corrugation spacing standard
deviations of 165 micrometers and 187 micrometers for average
corrugation spacings of 670 micrometers and 714 micrometers
respectively, while VFL has corrugation spacing standard deviations
of 230 micrometers and 410 micrometers for average corrugation
spacings of 1215 micrometers and 1560 micrometers respectively. The
laminate of the present disclosure has a variation in variability
from plane to plane of less than 15% while VFL has a variation in
variability from plane to plane is greater than 75%.
[0053] Elastic laminate of the present disclosure also possesses a
corrugation height range of 385-521 micrometers compared to
826-1552 micrometers for VFL and 1680 micrometers for LYCRA-brand
synthetic fiber laminate, resulting in as much as a 300% advantage.
A corrugation height of less than 700 micrometers is preferred to
satisfactorily maintain quality across the performance range of an
elastic laminate fit for use in an elastic panel application.
[0054] It should be noted that the magnitude of the wave values for
the elastic laminate of the present disclosure on average are
approximately half that of VFL or LYCRA-brand synthetic fiber
laminate. This is not a coincidence. The fundamental construction
of an elastic laminate of the present disclosure is completely
unique. VFL and LYCRA-brand synthetic fiber laminate are
constructed using a spray-on or sure-wrap glue that results in a
significant amount of SB to SB bonding in the spaces between
strands. Conversely, the elastic laminate of the present disclosure
has zero SB to SB bonding of any type. As a result, when VFL or
LYCRA-brand synthetic fiber laminate retract, the bonded facings
between strands reacts as a single mat of material, creating one
large-scale continuous corrugation between the strand and random
small scale corrugations at the strand surface. This results in
large absolute wave values in the cross section between the strands
and large wave value variations in the planes between the strands
versus through the strands. Conversely, facings of the elastic
laminate of the present disclosure form corrugations that are
mirrored about the y axis, and hence have by definition wave values
(and subsequent standard deviations) of at least half that of a VFL
of comparable range. In addition, because the mechanical bonding of
the elastic laminate of the present disclosure is exact when
compared to the random disposition of bond points resulting from
glue lamination, the variation of the wave values tends to be even
less than would be expected as a result of the reduction in
absolute magnitudes alone.
[0055] Lamination of the elastic laminate is accomplished via a
patterned bonding technique (e.g., thermal point bonding,
ultrasonic bonding, etc.) in which the materials are supplied to a
nip defined by at least one patterned roll. Through selective
control of certain parameters of the lamination process, such as
film content, bonding pattern, degree of film tension, bonding
conditions, etc., the durability of the meltblown facing can be
improved. During lamination, for example, apertures and discrete
bond sites can be concurrently formed in the elastic film. The
discrete bond sites can be located proximate (adjacent or near to)
a perimeter defined by corresponding apertures formed by
displacement of the film. The location of the bond sites adjacent
to or near the apertures can enhance the durability of the
meltblown facing by strengthening the area surrounding the
apertures. Furthermore, the polymer content of the elastic film and
the temperature/pressure of lamination can be selected so that the
film possesses a sufficient tack for adhering to the facing at
regions other than those fused together by the bonding elements of
the patterned roll. Such secondary bonding further stabilizes the
meltblown facing and renders it suitable for printing.
[0056] Other aspects of the lamination technique of the present
disclosure can also help provide a surface of the meltblown facing
that is suitable for printing. For example, the film is under
tension in the machine direction during lamination. Subsequent to
lamination, however, the film is retracted so that the facing
retracts toward its original machine direction length, thereby
gathering and forming pleats. When formed according to the present
disclosure, it has been discovered that these pleats have a
relatively small amplitude (height), as well as a substantially
uniform frequency across the surface of the facing. Such a small
height and increased regularity improves the ability to transfer an
ink to the "peaks" of the pleats, thereby improving the print
quality and uniformity.
[0057] The elastic film of the present disclosure is formed from
one or more elastomeric polymers that are melt-processible, i.e.,
thermoplastic. Any of a variety of thermoplastic elastomeric
polymers can generally be employed in the present disclosure, such
as elastomeric polyesters, elastomeric polyurethanes, elastomeric
polyamides, elastomeric copolymers, elastomeric polyolefins, and so
forth. In one particular aspect, elastomeric semi-crystalline
polyolefins are employed due to their unique combination of
mechanical and elastomeric properties. That is, the mechanical
properties of such semi-crystalline polyolefins allows for the
formation of films that readily aperture during thermal bonding,
but yet retain their elasticity.
[0058] Besides polymers, the elastic film of the present disclosure
can also contain other components as is known in the art. In one
aspect, for example, the elastic film contains a filler. Fillers
are particulates or other forms of material that can be added to
the film polymer extrusion blend and that will not chemically
interfere with the extruded film, but which can be uniformly
dispersed throughout the film. Fillers can serve a variety of
purposes, including enhancing film opacity and/or breathability
(i.e., vapor-permeable and substantially liquid-impermeable). For
instance, filled films can be made breathable by stretching, which
causes the polymer to break away from the filler and create
microporous passageways. Breathable microporous elastic films are
described, for example, in U.S. Pat. Nos. 5,997,981; 6,015,764; and
6,111,163 to McCormack, et al.; 5,932,497 to Morman, et al.;
6,461,457 to Taylor, et al., which are incorporated herein in their
entirety by reference thereto for all purposes.
[0059] Other additives can also be incorporated into the film, such
as melt stabilizers, processing stabilizers, heat stabilizers,
light stabilizers, antioxidants, heat aging stabilizers, whitening
agents, antiblocking agents, bonding agents, tackifiers, viscosity
modifiers, etc.
[0060] The elastic film of the present disclosure can be mono- or
multi-layered. Multilayer films can be prepared by co-extrusion of
the layers, extrusion coating, or by any conventional layering
process. Such multilayer films normally contain at least one base
layer and at least one skin layer, but can contain any number of
layers desired. The thickness of the skin layer(s) is generally
selected so as not to substantially impair the elastomeric
properties of the film. The properties of the resulting film can
generally vary as desired.
[0061] Generally speaking, the facing used in the composite
contains a meltblown web to improve the receptiveness of the facing
to an ink. Namely, meltblown webs generally have small pores that
allow the ink to exhibit better surface retention upon printing.
The small pore size can also provide other benefits, such as
inhibiting the passage of liquids and particles, while allowing
gases (e.g., air and water vapor) to pass therethrough.
[0062] The meltblown web is typically formed from a polymer having
a softening temperature that is higher than the temperature
imparted during bonding. In this manner, the polymer does typically
not soften to such an extent that the fibers of the meltblown web
become completely melt flowable and unable to form bonds. If
desired, biodegradable polymers, such as those described above, can
also be employed. Synthetic or natural cellulosic polymers can also
be used. It should be noted that the polymer(s) can also contain
other additives, such as processing aids or treatment compositions
to impart desired properties to the fibers, residual amounts of
solvents, pigments or colorants, and so forth.
[0063] Monocomponent and/or multicomponent fibers can be used to
form the meltblown web. Monocomponent fibers are generally formed
from a polymer or blend of polymers extruded from a single
extruder. Multicomponent fibers are generally formed from two or
more polymers (e.g., bicomponent fibers) extruded from separate
extruders. The polymers can be arranged in substantially constantly
positioned distinct zones across the cross-section of the fibers.
The components can be arranged in any desired configuration, such
as sheath-core, side-by-side, pie, island-in-the-sea, three island,
bull's eye, or various other arrangements known in the art.
[0064] The desired denier of the fibers can vary depending on the
desired application.
[0065] Although not required, the meltblown web can optionally be
bonded using any conventional technique, such as with an adhesive
or autogenously (e.g., fusion and/or self-adhesion of the fibers
without an applied external adhesive). Suitable autogenous bonding
techniques can include ultrasonic bonding, thermal bonding,
through-air bonding, calender bonding, and so forth. As is well
known to those skilled in the art, the temperature and pressure
required can vary depending upon many factors including but not
limited to, pattern bond area, polymer properties, fiber properties
and nonwoven properties. The meltblown web can also be necked in
one or more directions prior to lamination to the film of the
present disclosure.
[0066] If desired, the meltblown facing can have a multi-layer
structure. Suitable multi-layered facings can include, for
instance, spunbond/meltblown/spunbond (SMS) laminates and
spunbond/meltblown (SM) laminates.
[0067] The meltblown facing can also contain an additional fibrous
component such that it is considered a composite. For example, a
meltblown web can be entangled with another fibrous component using
any of a variety of entanglement techniques known in the art (e.g.,
hydraulic, air, mechanical, etc.). In one particular aspect, the
facing can be a "coform web" made by a process in which at least
one meltblown die head is arranged near a chute through which other
materials are added to the web while it is forming.
[0068] Regardless of its particular construction, one particular
benefit of the present disclosure is that the meltblown facing can
have a relatively low basis weight and yet remain durable and still
present a suitable surface for printing. Such a low basis weight
can provide a variety of benefits, including reduced costs and
improved flexibility.
[0069] In addition to an elastic film and meltblown facing, the
composite of the present disclosure can also include other facings
as is known in the art. For example, the composite can include an
additional nonwoven facing, such as a meltblown web, spunbond web,
bonded carded web, wet-laid web, airlaid web, coform web,
hydraulically entangled web, etc. The additional facing(s) can be
multi-layered and/or a composite material, such as described
above.
[0070] Lamination is accomplished via a patterned bonding technique
(e.g., thermal point bonding, ultrasonic bonding, etc.) in which
the materials are supplied to a nip defined by at least one
patterned roll. Thermal point bonding, for instance, typically
employs a nip formed between two rolls, at least one of which is
patterned. Ultrasonic bonding, on the other hand, typically employs
a nip formed between a sonic horn and a patterned roll. Regardless
of the technique chosen, the patterned roll contains a plurality of
raised bonding elements to bond the film to the meltblown
facing.
[0071] As indicated above, the durability and stability of the
meltblown facing is enhanced by the concurrent formation of
apertures and discrete bond sites during lamination. Such apertures
can also provide a desired level of texture, softness, hand feel,
and/or aesthetic appeal to the composite without having a
significant adverse effect on its elastic properties. Aperture and
bond formation are accomplished in the present disclosure by
selectively controlling certain parameters of the lamination
process, such as film content, bonding pattern, degree of film
tension, bonding conditions, etc. The size of the bonding elements,
for example, can be specifically tailored to facilitate the
formation of apertures in the film and enhance bonding between the
film and the meltblown facing.
[0072] Besides the size of the bonding elements, the overall
bonding pattern can also be selectively controlled to achieve the
desired aperture formation. In this manner, the bonding elements
will present a relatively large surface to the film in a direction
substantially perpendicular to that which the film moves. This
increases the area over which shear stress is imparted to the film
and, in turn, facilitates aperture formation.
[0073] The pattern of the bonding elements is generally selected so
that the nonwoven composite has a total bond area of less than
about 50% (as determined by conventional optical microscopic
methods), and in some aspects, less than about 30%.
[0074] The selection of an appropriate bonding temperature (e.g.,
the temperature of a heated roll) will help melt and soften the
low-softening point elastomeric polymer(s) of the film at regions
adjacent to the bonding elements. The softened elastomeric
polymer(s) can then flow and become displaced during bonding, such
as by pressure exerted by the bonding elements. The displaced
portions of the film surrounding the apertures can also fuse to the
meltblown facing, thereby forming an integral nonwoven composite.
Furthermore, because the elastomeric polymer(s) can physically
entrap or adhere to the fibers at the bond sites, adequate bond
formation can be achieved without requiring substantial softening
of the polymer(s) used to form the meltblown facing. Thus, the
meltblown facing remains substantially unbonded to the film or
other materials at those regions located directly adjacent to (e.g.
above or below) the apertures. Further, the meltblown facing is
also generally unapertured, although it can of course develop some
small cuts or tears during processing.
[0075] To achieve such concurrent aperture and bond formation
without substantially softening the polymer(s) of the meltblown
facing, the bonding temperature and pressure can be selectively
controlled. Likewise, the pressure exerted by rolls ("nip
pressure") during thermal bonding can be varied. Of course, the
residence time of the materials can influence the particular
bonding parameters employed.
[0076] Another factor that influences concurrent aperture and bond
formation is the degree of tension in the film during lamination.
An increase in film tension, for example, typically correlates to
an increase in aperture size. Of course, a film tension that is too
high can adversely affect the integrity of the film.
[0077] The film can be "pre-stretched" (prior to lamination) by
rolls rotating at different speeds of rotation so that the sheet is
stretched to the desired stretch ratio in the machine direction.
This uniaxially stretched film can also be oriented in the
cross-machine direction to form a "biaxially stretched" film. The
orientation temperature profile during the "pre-stretching"
operation is generally below the melting point of one or more
polymers in the film, but high enough to enable the composition to
be drawn or stretched. When "pre-stretched" in the manner described
above, the degree of stretch during lamination can be increased,
maintained, or slightly reduced (retracted) to desired degree of
tension.
[0078] Upon lamination, the elastic film is bonded to the meltblown
facing and apertured. The size and/or pattern of the resulting
apertures generally correspond to the size and/or pattern of the
bonding elements. That is, the apertures can have a length, width,
aspect ratio, and orientation as described above. Similarly, the
longitudinal axis of one or more of the apertures (longest
dimension along a center line of the aperture) can be skewed
relative to the machine direction of the elastic film.
[0079] Upon formation, the elastic film can retract toward its
original machine direction length and become shorter in the machine
direction, thereby forming "pleats" in the meltblown facing. The
resulting elastic composite thus becomes extensible in the machine
direction to the extent that the pleats in the facing can be pulled
back out flat, thereby allowing the elastic film to elongate.
[0080] Generally speaking, the resulting "pleats" in the meltblown
facing have a relatively small amplitude (height) and wavelength
("peak-to-peak" distance), thereby rending the surface more
suitable for printing. It is believed that pleats having a small
height and wavelength (high density) can improve print quality by
providing a larger effective surface area for transfer of the
ink.
[0081] Further detail with respect to elastic laminates of the
present disclosure can be found in U.S. Pat. No. 7,803,244 entitled
"Nonwoven Composite Containing An Apertured Elastic Film," and in
U.S. patent application Ser. No. 12/580,847, entitled "Matching
Absorbent Article Components For A Uniform Appearance," which are
incorporated herein by reference to the extent they do not conflict
herewith.
[0082] Materials and processes suitable for forming such absorbent
articles are well known to those skilled in the art. Absorbent
articles can include, for example, a substantially
liquid-impermeable layer (e.g., outer cover), a liquid-permeable
layer (e.g., bodyside liner, surge layer, etc.), and an absorbent
core. In one particular aspect of the present disclosure, the
printed nonwoven composite can be used to form a substantially
liquid-impermeable layer (e.g., outer cover) of the absorbent
article. In another aspect, the printed nonwoven composite of the
present disclosure can be used to form a liquid-permeable layer
(e.g., bodyside liner, surge layer) of the absorbent article.
[0083] Returning to FIGS. 1-3, pants 20 can have the side panels
34, 134 affixed to each other for securing the pants 20 about the
waist of the wearer. The side panels 34, 134 can be affixed by
bonding, mechanical fasteners, or any other suitable method, and
can be affixed permanently, in a tearable manner, or in a
refastenable manner. The illustrated pants 20 includes the
fastening system 80 for refastenably securing the pants about the
waist of the wearer. The illustrated fastening system 80 includes
first fastening components 82 adapted for refastenable engagement
to corresponding second fastening components 84. In one aspect, one
surface of each of the first fastening components 82, 84 includes a
plurality of engaging elements which project from that surface. The
engaging elements of the first fastening components 82 are adapted
to repeatedly engage and disengage engaging elements of the second
fastening components 84.
[0084] The fastening components 82, 84 can include separate
elements bonded to the side panels 34, 134, or they can be
integrally formed with the side panels. Thus, unless otherwise
specified, the term "fastening component" includes separate
components which function as fasteners, and regions of materials
such as the side panels 34, 134 which function as fasteners.
Moreover, a single material can define multiple fastening
components to the extent that different regions of the material
function as separate fasteners. The fastening components 82, 84 can
be located on the side panels 134, 34, between the side panels such
as on the absorbent chassis 32, or a combination of the two.
[0085] Components, alignment, and articles can be inspected using
an infrared inspection system such as that described in U.S. Pat.
No. 6,885,451 to Vogt, et al., and in U.S. patent application Ser.
No. 12/580,765, entitled "Disposable Absorbent Articles
Incorporating Black-Free Colorant" each of which is incorporated
herein by reference to the extent it does not conflict
herewith.
[0086] Examples of suitable materials from and processes by which
components can be constructed and printed can be found in U.S.
patent application Ser. No. 12/023,447, entitled "Printable Elastic
Composite," which is incorporated herein by reference to the extent
it does not conflict herewith.
[0087] Absorbent products are often created from multiple materials
and components that typically differ in look and feel. Real cloth
underwear, however, is generally created from a single chassis
material and waist and leg bands. As a result, the real cloth
underwear has a consistent look and feel. With respect to
disposable absorbent products made from multiple nonwoven
components, consumers generally prefer products that more closely
emulate the appearance of real cloth underwear. This desire leads
to a need to reduce the actual differences in the appearance of a
disposable absorbent across its different materials and components
and to create perceptions of a similar look and feel across
different materials.
[0088] Attempts to produce disposable absorbent products with the
look and feel of a real garment have fallen short of delivering on
the desired integrated look. To manage costs, elastic panels with
one set of material properties are often combined with a central
chassis having different material properties. For example, in a
closed pant, the elastic panels have a gathered texture, whereas
the chassis, because it does not need to stretch, conventionally
has a smoother texture. Printing these two different materials with
the same desired design results in a significant difference in how
the appearance of the printed graphic due to differences in how the
ink interacts with the different materials and with the stretch of
an elastic panel.
[0089] One solution to this problem is to print one or more
components to match other components in the disposable absorbent
article.
[0090] Any printing technique can be employed to apply an ink to
the surface of the meltblown facing, such as gravure printing,
flexographic printing, screen printing, ink-jet printing, laser
printing, thermal ribbon printing, piston printing, etc. In one
particular aspect, ink-jet printing techniques are employed to
apply an ink to the meltblown facing. Ink-jet printing is a
non-contact printing technique that involves forcing an ink through
a tiny nozzle (or a series of nozzles) to form droplets that are
directed toward the support. Two techniques are generally utilized,
i.e., "DOD" (Drop-On-Demand) or "continuous" ink-jet printing. In
continuous systems, ink is emitted in a continuous stream under
pressure through at least one orifice or nozzle. The stream is
perturbed by a pressurization actuator to break the stream into
droplets at a fixed distance from the orifice. DOD systems, on the
other hand, use a pressurization actuator at each orifice to break
the ink into droplets. The pressurization actuator in each system
can be a piezoelectric crystal, an acoustic device, a thermal
device, etc. The selection of the type of ink jet system varies on
the type of material to be printed from the print head. For
example, conductive materials are sometimes required for continuous
systems because the droplets are deflected electrostatically.
[0091] The particular type or style of ink pattern is not a
limiting factor of the disclosure, and can include, for example,
any arrangement of stripes, bands, dots, or other geometric shape.
The pattern can include indicia (e.g., trademarks, text, and
logos), floral designs, abstract designs, any configuration of
artwork, etc. The pattern can be targeted for a specific class of
consumers. For example, in the case of diapers or training pants,
the pattern can be in the form of cartoon characters, and so forth.
It should be appreciated that the "pattern" can take on virtually
any desired appearance. The printing scheme can leave little or no
white space, or the printing scheme can leave some or much white
space.
[0092] The ink generally includes one or more colorants (e.g.,
pigments, dyes, etc.) that impart a certain color to the facing,
such as black, white, yellow, cyan, magenta, red, green, blue, etc.
For example, the colorant can be an inorganic and/or organic
pigment. Some examples of commercially-available organic pigments
that can be used in the present disclosure include those that are
available from Clariant Corp. of Charlotte, N.C., under the trade
designations GRAPHTOL.RTM. or CARTAREN.RTM.. Other pigments, such
as lake compounds (blue lake, red lake, yellow lake, etc.), can
also be employed. Inorganic and/or organic dyes can also be
utilized as a colorant. Exemplary organic dye classes include
triarylmethyl dyes, monoazo dyes, thiazine dyes, oxazine dyes,
naphthalimide dyes, azine dyes, cyanine dyes, indigo dyes, coumarin
dyes, benzimidazole dyes, paraquinoidal dyes, fluorescein dyes,
diazonium salt dyes, azoic diazo dyes, phenylenediamine dyes, diazo
dyes, anthraquinone dyes, trisazo dyes, xanthene dyes, proflavine
dyes, sulfonaphthalein dyes, phthalocyanine dyes, carotenoid dyes,
carminic acid dyes, azure dyes, acridine dyes, and so forth. One
particularly suitable class of dyes includes anthraquinone
compounds, which can be classified for identification by their
Color Index (CI) number. For instance, some suitable anthraquinones
that can be used in the present disclosure, as classified by their
"CI" number, include Acid Black 48, Acid Blue 25 (D&C Green No.
5), Acid Blue 40, Acid Blue 41, Acid Blue 45, Acid Blue 129, Acid
Green 25, Acid Green 27, Acid Green 41, Mordant Red 11(Alizarin),
Mordant Black 13 (Alizarin Blue Black B), Mordant Red 3 (Alizarin
Red S), Mordant Violet 5 (Alizarin Violet 3R), Natural Red 4
(Carminic Acid), Disperse Blue 1, Disperse Blue 3, Disperse Blue
14, Natural Red 16 (Purpurin), Natural Red 8, Reactive Blue 2, and
so forth.
[0093] Prior to application, the colorant is typically dissolved or
dispersed in a solvent to form the ink. Any solvent capable of
dispersing or dissolving the components is suitable. The
concentration of solvent in the ink formulation is generally high
enough to allow easy application, handling, etc.
[0094] The ink can also include various other components as is well
known in the art, such as colorant stabilizers, photoinitiators,
binders, solvents, surfactants, humectants, biocides or biostats,
electrolytic salts, pH adjusters, etc. Other additives can also be
included to improve ink performance, such as a chelating agent to
sequester metal ions that could become involved in chemical
reactions over time, a corrosion inhibitor to help protect metal
components of the printer or ink delivery system, a biocide or
biostat to control unwanted bacterial, fungal, or yeast growth in
the ink, and a surfactant to adjust the ink surface tension.
[0095] In one aspect of the present disclosure, two or more
components are printed with a single graphic or pattern to mask the
inherent appearance of the materials from which those components
are constructed, and/or to mask the physical structure of those
components or of the article itself.
[0096] The resulting appearance can be created by printing an
object graphic, a random graphic, a background pattern, a simulated
texture, or some combination of these. The printing spans multiple
components and can minimize the area of white and/or unprinted
space on the outer surface of the article. The printing can be used
to break up areas of white space or to otherwise optimize the use
of white space on the article.
[0097] Numerous aspects of the present disclosure can be used to
accomplish a uniform look. For example, the masking pattern can
serve as a primary or background graphic and the overall graphics
can include such elements as a waistband, leg bands, object
graphics, and random graphics. Although nonwoven materials and
components made therefrom typically have a white background, the
printing described herein can be done on pigmented substrates such
as a pink outer cover and pink elastic panels, or on a combination
of pigmented and un-pigmented substrates such as a white outer
cover with pink elastic panels. The key is that printing is done on
at least one material to accomplish a uniform look across multiple
materials.
[0098] In another aspect of the present disclosure, when printing
on material components that do not stretch, that differ in stretch,
or that might or might not be fully stretched in use, it is
desirable to print a graphic that is not greatly distorted during
use as the different materials stretch to differing extents. In
addition, materials with variable or non-uniform stretch
characteristics in different regions can be printed such that the
different regions have a similar appearance. More practically, the
materials should provide a similar look when pulled from the
package and when worn by a user. One way to accomplish this is to
optimize the printed graphic to include identical or substantially
similar elements in various sizes. For example, the printed graphic
can include stars of at least two sizes such that the smaller stars
when stretched resemble the larger stars. This ensures that some of
the elements look the same between the outer cover and the elastic
panel both when pulled from the package and when worn by the user.
In another example, a non-uniform sinusoidal wave, such as one with
tall and short heights, and/or with wide and narrow widths, can be
used to better mimic the look of both the stretch material in
different states and the non-stretch material.
[0099] In another aspect of the present disclosure, and as apparent
to those skilled in the art, material characteristics of a
substrate to be printed should be considered when selecting a
substrate, a printing method, an ink, and an intended result.
[0100] In typical disposable absorbent article, areas of white or
unprinted space on the chassis and the elastic panels tend to
emphasize the physical structure of the article by, for example,
highlighting seams, inherent textures, and other material features.
With the use of printing to mask such texture and physical
structures, the areas of white or unprinted space on the chassis
and the elastic panels can be used to indicate a uniform look
across the article.
[0101] In one example of this aspect, both the outer cover and
elastic panels of a pant be printed with the same graphic such that
the materials from which those components are constructed look
different from their original states but now match each other. Once
these components are assembled into a pant, the pant takes on a
one-piece garment look because the stretch and non-stretch
materials look substantially the same. In one example, the
components can be printed with thermal knit or ribbed knit
pattern.
[0102] In another aspect of the present disclosure, one component
can be printed to match the inherent appearance of the material
from which another component is constructed.
[0103] Although the descriptions herein are largely directed toward
printing an elastic panel to mask or mimic the appearance of an
outer cover, the same disclosure can be applied to printing an
outer cover to mask or mimic the appearance of an elastic panel, or
to print any component of the article to mask or mimic the
appearance of another component in the article.
[0104] A uniform look across multiple components can be achieved by
mimicking the inherent appearance of one component's non-printed
material via printing a replicated inherent appearance on another
component. It is not simply replicating a color between different
nonwoven materials. The printed component is printed in such a way
as to appear to exhibit the inherent appearance of the non-printed
component.
[0105] When printing on material components that do not stretch,
that differ in stretch, or that might or might not be fully
stretched in use, it is desirable to print a graphic that is not
greatly distorted during use as the different materials stretch to
differing extents. In various solutions, the printing is done to
replicate either the inherent appearance of the article in its
unstretched state, such as just out of a package, or the average
stretched state of the article as it is worn by a user.
[0106] Additionally, the printed texture graphic can serve as a
primary or background graphic and the overall graphics can include
such elements as a waistband, leg bands, object graphics, and
random graphics. The materials being matched can be pigmented or
non-pigmented.
[0107] In an alternative aspect of the present disclosure, the
printed texture graphic can mimic the texture or appearance of one
portion of another component, rather than the specific material
from which that component is constructed. For example, the printed
texture graphic can be printed on an elastic panel to emulate the
gathers in the elastic waistband of the chassis 32 such that an
appearance of a uniform elastic waistband is presented.
[0108] Further detail with respect to methods for measuring visual
and tactile properties, and products exhibiting such properties,
can be found in U.S. Patent Application Publication Nos.
US2006/0161129 and US2006/0161130 and in U.S. Pat. No. 6,174,303,
which are incorporated herein by reference to the extent they do
not conflict herewith.
[0109] It has been shown that surface printing of differing
materials such as a stretch elastic panel and a non-stretch outer
cover can successfully look the same if care is taken to create a
surface texture on the non-stretch material that looks similar to
that of the stretch material when in a relaxed state. The desired
texture is arrived at through experimentation with facing basis
weight and bond pattern as described in more detail below.
[0110] Alternatively, the printed texture graphic on stretch
material can be designed such that the stretch material has the
appearance of being smoother than it is in a perception of
smoothness versus actual smoothness. In one example, a grey heather
pattern is printed onto the stretch material of the elastic panel
to allow the elastic panel to appear smoother in texture.
[0111] In another aspect of the present disclosure, it is
undesirable to have the printed texture pattern emulate the
inherent appearance of another component if such inherent
appearance has an aesthetic cue (e.g., unattractive or rough) that
would undermine the desired uniform look of the article. In this
aspect, it is often better to use printing to mask the inherent
appearances of the various components. In one example, a grey
heather pattern is printed onto the stretch material of the elastic
panel and an open grey heather pattern is printed onto the
non-stretch material of the outer cover to mask the appearance of
each component.
[0112] It should be noted that the present disclosure encompasses a
combination of different printing types as well as a combination of
internal and external printing. One or more printing types can be
used in a single article, where the printing types include, but are
not limited to, digital, flexographic, gravure, contact,
non-contact, online, and offline printing. In addition, printing
can be surface printing on the outermost layer of a given
component, or printing can be on an internal surface or on an
internal layer of a given component such that the printing is
visible at the surface of that component. For example, an article
can be manufactured with external printing on one component and
printing sandwiched between materials such as a film and a surface
facing on a different component.
[0113] In further examples, stretch material such as that which
might be employed in an elastic panel can be externally printed,
while a non-stretch portion of an outer cover can be internally
printed, or vice versa. An article can have both external and
internal printing on the garment-facing surface of the article, or
alternatively or additionally on the body-facing surface of the
article. Barrier material and/or non-barrier material can be
printed. Breathable and/or non-breathable material can be printed.
Materials with different printing types can be attached directly to
each other and can be either the same material (e.g., elastic panel
to elastic panel junction) or different materials (e.g., body
panels to insert). The materials can vary by thickness, texture,
topography, and any other suitable characteristic.
[0114] In still further examples, printed random graphics can be
combined with registered graphics. Graphics can be integrated on
the externally- and internally-printed materials. Printing can be
done on pigmented or otherwise-colored material and/or on
unpigmented or "white" material.
[0115] In one particular aspect of the present disclosure, the
elastic panels of a disposable absorbent article are printed on the
exterior facing surface of their elastic panel material, while the
outer cover of the disposable absorbent article is printed on the
film of the outer cover and covered with a nonwoven facing layer.
In effect, the article of this aspect is both externally (elastic
panels) and internally (outer cover) printed. More specifically, in
this aspect the elastic panels are flexographically printed
offline. The film of the outer cover is also flexographically
printed offline and covered with a nonwoven facing. Both materials
are then introduced into the article manufacturing process such
that the printing on the elastic panels is aligned with the
printing on the outer cover.
[0116] In a different particular aspect of the present disclosure,
a disposable absorbent article has a flexographically-printed outer
cover (internal printing) and a digitally-printed waistband
(external printing) on the elastic panels.
[0117] The various aspects of the present disclosure can be applied
in either machine-direction or cross-direction processes. In one
example, an article with a three-piece chassis can include printing
on the body panels and the insert. Such an article can be printed
digitally on the outer surface of the body panel, such as a back
label indicator, and printed internally on the insert. Variations
of this example can include any combination of internal, external,
digital, flexographic, or any other suitable printing method.
[0118] While this disclosure generally describes printing stretch
materials with external printing and non-stretch materials with
internal printing, the opposite can also be used with stretch
materials having internal printing and non-stretch materials having
external printing. In addition, both materials can be stretch, both
can be non-stretch, both can be internally printed, or both can be
externally printed. Additional detail related to printing on
various materials and components can be found in U.S. Patent
Application Publication No. US 2005/0217791, and in U.S. Pat. Nos.
5,562,037; 5,566,616; 5,501,149; 5,597,642; 5,612,118; and
6,231,715, each of which is incorporated herein by reference to the
extent it does not conflict herewith.
[0119] In practice, a disposable absorbent article of the present
disclosure can have multiple printed components. Materials
appropriate for use in manufacturing the outer cover and the
elastic panels can be selected as described above. The material
used in the manufacture of the outer cover is typically different
from the material used in the manufacture of the elastic panels,
although this is not a requirement in manufacturing the article.
The outer cover in the manufactured article has an outer cover
central region positioned generally in the front and/or back waist
regions. The outer cover central region does not include a
waistband or leg bands. The outer cover central region has an outer
cover central region appearance, which is the physical appearance
of the outer cover central region. It should be noted that the
central regions described herein are arbitrary areas taken to
include a swatch or a sample of the printing, texture, or general
appearance of an area. Such regions are generally located centrally
in the longitudinal direction between the leg openings and the
waist opening, and do not include printed waistbands or printed leg
bands. Central regions are intended to allow one to compare the
appearance of areas of an article. Although illustrated in FIGS. 2,
4, and 5 as being generally ovoid, the central regions can be of
any suitable shape.
[0120] The elastic panel is printed either before or after
attachment to the chassis as described above. The elastic panel can
be printed to match the outer cover central region appearance
whether or not the outer cover central region is printed. The
elastic panel can be printed to match the printing in the outer
cover central region, or the elastic panel can be printed to match
the outer cover texture of the material from which the outer cover
is constructed. In either case, the elastic panel central region is
printed to appear identical or substantially similar to the outer
cover central region appearance. Second, third, and fourth elastic
panels can be manufactured in much the same manner.
[0121] Further, the article can be manufactured such that the outer
cover central region and the first elastic panel central region
have no lateral gap therebetween, or can be disposed such that a
lateral gap in printing is present between the regions. In other
words, the outer cover central region and the elastic panel central
region can be a continuous region of printing or other appearance,
or there can be a lateral gap between the outer cover central
region and the elastic panel central region. In a specific example,
the lateral gap between the outer cover central region and the
first elastic panel central region should be less than 15 mm,
preferably less than 10 mm, more preferably less than 5 mm, and
most preferably 0 mm. It should be noted that some printed
graphics, such as those with vertical stripes, can include an
inherent lateral gap as part of their patterns. Such inherent
lateral gaps are not included herein in the definition of a lateral
gap.
[0122] In another aspect of the present disclosure, a lateral
circumference taken between the waist opening and the top of the
leg openings can be seen to cross at least two elastic panels. Each
component along the circumference can be printed such that at least
a portion of each component is identical or substantially similar
in appearance to the other components. In addition, the outer
cover, if not on the circumference, can also be printed to be
identical or substantially similar in appearance to the other
components.
[0123] In still another aspect of the present disclosure, the pants
20 can also include a printed waistband and/or printed leg bands as
described in U.S. patent application Ser. No. 12/580,529 entitled
"Alignment Of Leg And Waistbands On Disposable Absorbent Article,"
which is incorporated herein by reference to the extent that it
does not conflict herewith.
[0124] While the disclosure has been described in detail with
respect to the specific aspects thereof, it will be appreciated
that those skilled in the art, upon attaining an understanding of
the foregoing, can readily conceive of alterations to, variations
of, and equivalents to these aspects. Accordingly, the scope of the
present disclosure should be assessed as that of the appended
claims and any equivalents thereto.
* * * * *