METHOD FOR MAKING ABSORBENT ITEMS HAVING AN ADJUSTABLE CINTÜRÓNField of the InventionThe present invention relates to disposable absorbent articles which are adapted to contain exudates from the body. More particularly, the present invention relates to absorbent articles having adjustable belts and methods for making them.
Background of the InventionIt is desired that absorbent articles such as diapers, training underpants and incontinence garments provide a comfortable and closed fit around the wearer and contain exudates from the body. Furthermore, it is desirable that such absorbent articles, after they have been soiled, can be removed from the user in a convenient and clean manner without undesirably contaminating the caregiver or the surrounding areas such as the wearer's clothing. In certain circumstances, it is also desirable that the absorbent articles be capable of being pulled up or down onto the user's hips to allow the user or caregiver to easily pull the item upward and easily remove the item if it is not removed. has messed up For example, such absorbent articles can assist in training for the children's toilet or toilet.
Conventional diapers have typically included a front waist portion, a back waist portion which are releasably connected around the user's hips during use by conventional fasteners such as adhesive tape fasteners or hook-type fasteners. and curl. For example, conventional fasteners have included a pair of fasteners, such as adhesive tape appendages, located on the outermost corners of the diaper in the posterior belt region of the diaper and a complementary fastener, such as a curb panel, located on the outer surface of the outer diaper cover on the diaper front waist portion. In such a configuration, the diaper has been placed between the legs of the wearer and the appendages of tape have been releasably attached to the wrapping panel to secure the back waist portion to the front waist portion of the diaper to secure the diaper around the diaper. waist of the user. Such conventional diapers are easy to fasten around the user and to remove them from the user after use without undesirably messing with the caregiver.
However, such conventional diapers are not provided in a presumed configuration and are therefore not configured to be pulled up or lowered onto the wearer's hips when the fasteners are attached. In addition, such conventional diapers generally have a set of fasteners which must be disengaged and re-clamped to further conform the waist portions of the diaper to the wearer. Such disengagement and resumption can be difficult to achieve when the user is active.
Various attempts have been made to provide absorbent articles which notch at the user's waist to effectively contain exudates from the body, which are capable of being raised or lowered onto the wearer's hips and provide ease of cleaning and removal after they have been removed. dirty. For example, some conventional absorbent articles, such as conventional training underpants, have included integral side panels which connect the front waist portion to the back waist portion of the absorbent article. The side panels have been made stretchable so that the waist opening of the absorbent article can be expanded to allow the absorbent article to be raised or lowered onto the wearer's hips if desired. Such side panels have also been designed so that they can be torn to remove the user's training underpants after the latter has become soiled.
However, many such attempts have not been completely satisfactory. For example, absorbent articles such as the training underpants have not always been able to achieve a conformal and closed fit on the wearer while still being able to expand enough to rise and fall on the wearer's hips. Frequently such training underpants fit into the wearer's waist loosely which may undesirably result in run-off. As a result of this, many such articles have not always contained the exudates of the body as effectively as conventional diaper-type articles which can be adjusted to achieve a more conformant notch on the wearer. In addition, the removal of soiled absorbent articles which have integral side panels, such as conventional training underpants, have not always been completely satisfactory. For example, the side panels have been difficult to tear when attempting to remove the article from the user's waist instead of pulling the article down on the user's hips.
Therefore, despite attempts to develop improved absorbent articles, there is still a need for absorbent articles which can provide the benefits of both conventional training underpants and conventional diapers. That is, there is still a need for absorbent articles which conform to the user to effectively contain exudates from the body, which are able to be raised and lowered on the user's hips and buttocks without opening, and which are more secure easily around the user and removed from it in a convenient and clean way. In addition, there is a need for improved methods to reliably and consistently make such absorbent articles.
Synthesis of the InventionIn response to the difficulties and problems discussed above, new methods for making disposable absorbent articles having an adjustable belt have been discovered. In one aspect, the present invention relates to a method for making disposable absorbent articles which include an outer cover, an absorbent frame and an adjustable belt. The method includes providing two continuous laterally spaced and separated strips of fastener material and joining the belt segments between the strips of the fastener material at spaced apart locations longitudinally in a continuous ladder type configuration. Two tapes are also provided that are spaced apart laterally and continuously inward and to one side of each of the straps of fastener material. The fastener tapes and belt loop material tapes are selectively cut into discrete adjustable belts each of which defines one of the belt segments, a pair of laterally spaced and spaced fasteners attached to the opposite end portions of the belt. belt segment, a pair of belt loop parts spaced apart laterally.
The longitudinal ends of the belt loop portions of each of the adjustable belts are attached to a waist region of each of the absorbent articles to slidably contain the adjustable belts between the longitudinal ends of the belt loop portions or of the belt loops. waistband. The fasteners on the adjustable belts are configured to engage releasably on the opposite waist region of the absorbent article to conform the waist regions to the wearer's body after the absorbent article has been placed on the wearer. The belt loop portions may include a fastening material on the face facing the body to provide another pair of fasteners.
In another aspect, the present invention relates to a method for making a disposable absorbent article which defines an absorbent, a front waist region, a posterior waist region, a crotch region which extends between and connects the regions of waist, a pair of opposite side edges and a pair of opposite waist edges.
The method includes the steps of: a) supplying an outer cover for the absorbent article which defines a face-to-body surface and a face-to-face surface; b) providing an adjustable belt which includes a pair of fasteners on the opposite end portions of the belt; c) providing two parts of belt or waistband curls inwards and to one side of each of the fasteners on the adjustable belt; and d) attaching the longitudinal ends of the belt loop portions to the face facing surface of the outer shell in one of the waist regions of the absorbent article to slidably contain the adjustable belt between the belt loops and the outer shell. The fasteners on the adjustable belt are configured to releasably engage the face facing surface of the outer cover in the opposite waist region of the absorbent article.
In still another aspect, the present invention relates to a method for making a disposable absorbent article presumed which defines a front waist region, a posterior waist region, a crotch region which extends between and connects waist regions , a pair of opposite side edges and a pair of opposite waist edges. The method includes providing a continuously moving fabric of the outer cover material, intermittently joining the adjustable belts and the absorbent frame to the outer cover material at the spaced apart locations, cutting the fabric into discrete absorbent articles, folding the absorbent articles, and releasably engages the fasteners at a waist region to the opposite waist region to provide the presumed article. Adjustable belts are provided by intermittently cutting a continuous web of adjustable belts into discreet adjustable belts each of which define a belt segment, a pair of laterally spaced apart side fasteners attached to the opposite end portions of the belt segment , and a pair of spaced and laterally separated belt loops which further define a pair of primary fasteners on a body facing surface thereof. The adjustable belts are intermittently attached to the fabric of the outer cover material at spaced apart locations by holding the longitudinal ends of the belt loops to the outer cover material so that the adjustable belt is slidably contained between the longitudinal ends of the loops. of belt and outer cover material. The article is provided in a configuration presumed by releasably engaging the primary fasteners on the belt loop portions with an opposite waist region of the absorbent article. The secondary fasteners on the adjustable belt are configured to releasably engage the opposite waist region to conform the waist regions to the wearer's body after the presumed absorbent article is pulled on the wearer's hips.
In a particular embodiment, the adjustable belts are provided by providing two tape spaced apart laterally and continuous of secondary fastening material; joining the belt segments between and the straps of fastener material at the longitudinally spaced apart locations in a continuous ladder type configuration to provide a continuous web of the adjustable belts; and selectively cutting the continuous web of adjustable belts to provide each adjustable belt. Two continuous belts of secondary fastener material can be provided by a continuous fabric of the secondary fastener material which is cut along a longitudinal extension in a serpentine path to provide the two belts of secondary fastener material each defining a serpentine cutting edge and an opposite edge and crossing the tapes one over the other to place the serpentine cutting edge of each of the tapes laterally outward from the opposite edge of the respective tape before joining the belt segments thereto.
In another aspect, the present invention relates to disposable absorbent articles made according to various aspects of the method of the invention.
The present invention advantageously provides disposable absorbent articles which include an adjustable waistband for improved fit and operation and a method for making the same. In particular, the present invention provides methods for attaching adjustable belts to disposable absorbent articles in a consistent and reliable manner. The absorbent article of the present invention is capable of being reliably raised or lowered over the wearer's hips to assist in training for the toilet or toilet of the wearer in a manner similar to conventional training underpants. After having climbed onto the wearer's hips, the adjustable belt of the absorbent article can be used to further shape the waist of the article to the wearer's body by providing improved notch and drainage control. In addition, similarly to conventional diapers, the absorbent article of the present invention can be advantageously applied to the user and removed from it after it has been soiled with relative ease and cleanliness. Aspects of the method of the present invention further result in exact match and removal of the belt assemblies to facilitate sliding cutting and high-speed application of the adjustable belts to the individual diapers. Therefore, the methods can provide a uniform and consistent hold of each belt to the diaper. The methods can further provide a reduced waist through the use of the serpentine cut and the crossing over the serpentine cut fabrics to provide secondary fasteners shaped over the adjustable belts.
Brief Description of the DrawingsThe present invention will be more fully understood and the additional advantages will become apparent when reference is made to the following detailed description of the invention and the accompanying drawings in which similar numbers represent similar elements. The drawings are merely representative and are not intended to limit the scope of the appended claims.
Figure 1 representatively shows a schematic view of an example of a method for making a disposable absorbent article having an adjustable belt according to the present invention.
Figure 2 representatively shows a side view of an example of a disposable absorbent article made according to the present invention.
Figure 3 representatively shows a side view of the disposable absorbent article of Figure 2 e where the adjustable belt has been extended to conform the waist regions of the article to the wearer's waist.
Figure 4 representatively shows a plan view of the disposable absorbent article of Figure 2 in a condition not held, stretched and placed flat with the surface of the article contacting the caring user; YFigure 5 representatively shows a plan view of the disposable absorbent article of Figure 2 in a non-stretched, stretched and laid condition with the surface of the article contacting the wearer's clothing of which he or she observes.
Detailed description of the inventionThe present invention relates to disposable absorbent articles which are configured to closely conform to the wearer's body to effectively contain body exudates and methods for making them. The absorbent articles can be provided in a presumed configuration so that these can be raised or lowered onto the wearer's hips and buttocks and are configured to be easily secured and removed directly from the wearer's waist. As such, the absorbent articles of the present invention can function in a manner similar to conventional training underpants when in a presumed condition or in a manner similar to conventional diapers when they are in a non-restrained configuration. Disposable absorbent articles are adapted to be worn on one side of a user's body to absorb and contain the various exudates discharged from the body. How it is used here, the term "disposable" refers to articles which are intended to be disposed of after limited use and which are not intended to be washed or re-restored for re-use.
The disposable absorbent articles of the present invention and methods for making them will be described in terms of a disposable diaper article which is adapted for use by infants around the lower torso. In particular, the absorbent articles will be described in terms of a disposable absorbent diaper having an adjustable belt. It is understood that the articles and methods of the present invention are equally adaptable to other types of absorbent articles such as adult incontinent products, training briefs, women's hygiene products, other personal care products or garments. for health care, and the like.
Figure 1 representatively illustrates a schematic view of an example of a method for making a disposable diaper according to the present invention. Figures 2 and 3 representatively illustrate an example of a disposable diaper, as indicated generally in item 20, which can be made according to the methods of the present invention. Figures 4 and 5 representatively illustrate the diaper of Figure 2 in an unclamped, stretched and laid flat configuration. As illustrated in Figures 2-5, diaper 20 defines a front waist region 22, a rear waist region 24, and a crotch region 26 which extends and connects the front and rear waist regions 22 and 24 The diaper 20 further defines a pair of laterally opposite side edges 30, a pair of longitudinally opposite waist edges 32, and an inner surface 34 which is configured to make contact with the wearer, an outer surface 36 opposite the surface interior 34, a longitudinal direction 38 and a lateral direction 40.
The front waist region 22 comprises the part of the diaper 20 which, when worn, is placed on the front of the wearer while the back waist region 24 comprises the part of the diaper 20 which, when worn, is placed over the back of the user. The crotch region 26 of the diaper 20 comprises the part of the diaper 20 which, when worn, is placed between the user's legs and covers the lower torso of the wearer. The laterally opposite side edges 30 of the diaper 20 generally define the leg openings which may be curvilinear. The waist edges 32 of the diaper 20 are configured to surround the wearer's belt when worn and provide a belt opening when fastened which defines a waist circumference dimension.
The illustrated diaper 20 includes an outer cover 42, an absorbent frame 44 and a fastening system 60. The absorbent frame 44 includes a lower sheet 46, a side-to-body liner 48 which is connected to the lower sheet 46 in a relationship overlap, and an absorbent core 50 which is located between the side-to-body liner 48 and the lower sheet 46. The fastening system 60 includes a pair of primary fasteners 62, and an adjustable belt 64, a pair of secondary fasteners. 66 attached to the laterally opposite end portions of the adjustable belt 64 and a pair of belt loop parts 70. In the illustrated embodiment, the adjustable belt 64 is slidably contained between the belt loop or waistband 70 parts and the outer shell 42 of the diaper 20.
The absorbent frame 44 is configured to contain and / or absorb any exudates from the body discharged from the user. While the outer cover 42, the primary fasteners 62, the adjustable belt 64 and the secondary fasteners 66 are configured to hold the diaper 20 around the wearer's waist, they hide the absorbent frame 44 from the view, and provide an appearance of type of pledge The diaper 20 can further include the leg elastics 52, the containment fins 54 and the waist elastics 56 as is known to those skilled in the art. It should be recognized that the individual components of the diaper 20 may be optional depending on the intended use of the diaper 20.
A suitable arrangement for the different components of the diaper of the present invention is described in the patent application of the United States of America series number 08 / 907,585 entitled "A MULTIFUNCTIONAL BRAZIER FOR DISPOSABLE ABSORBENT ARTICLES" and presented on August 8, 1997 to name of J. Suprise, and the patent application of the United States of North America entitled "ABSORBENT ARTICLES HAVING BELT CURLS AND AN ADJUSTABLE BELT" presented concurrently with it in the name of T. Blenke and others and having the number of attorney's case 14.006 whose descriptions of them are incorporated herein by reference.
The methods of the various aspects of the present invention are directed to consistently provide reliable disposable absorbent articles having an adjustable belt 64, such as that which is representatively illustrated in Figures 2-5. A schematic view of an example of a method according to the present invention is illustrated in Figure 1. In general, the illustrated method provides a continuous fabric of adjustable belts 98 ch, one of which includes an adjustable belt 64 and a pair of belts. secondary fasteners 66 attached to the laterally opposite end portions of the adjustable belt 64. The fabric of adjustable belts 98 is cut into discrete adjustable belts which are attached to a fabric of outer cover material 110 at spaced apart locations using the parts of belt loops 70 so that the adjustable belt 64 is slidably contained between the outer cover 42 and the belt loop parts 70.
The multiple absorbent frame 44 as illustrated in Figures 2-5 may be attached to the fabric of the outer cover material 110 at spaced apart locations to provide a continuous web of interconnected diapers (not shown). In such a configuration, the front waist region 22 of the front diaper 20 can be connected to the rear waist region 24 of the tail diaper 20 to form the continuous weave of interconnected diapers. Alternatively, the rear waist region 24 of the front diaper can be connected to the front waist region 22 of the tail diaper or the diapers can be arranged in a front-to-back / back-to-back relationship.
Additional components, such as the leg elastics 52, the containment fins 54 and the waist elastics 56 can also be connected to the continuously moving fabric of the outer cover material or to the individual absorbent frame connected thereto to provide the fabric of diapers interconnected. The different components of the diaper 20 can be connected together by means known to those skilled in the art such as, for example, adhesive, thermal or ultrasonic bonding. Desirably, most of the components are connected using an ultrasonic joint for improved manufacturing efficiency and a reduced raw material cost.
The continuous weave of the adjustable belt assemblies 98 can be provided by means known to those skilled in the art. For example, as illustrated in Figure 1, a continuous web of the secondary fastener material 80 is unwound and passed through the die cutter 82 which selectively cuts the fabric of the secondary fastener material 80 along the longitudinal extension. in the direction of the machine in two separate and laterally spaced tapes of the material of the secondary fastener 84. As used herein, the phrase "machine direction" refers to the direction in which the respective fabric of material moves continuously while the phrase "cross machine direction" refers to the direction perpendicular to the direction in which the respective material web is moving. The terms "longitudinal" and "lateral" also generally refer to the direction of the machine and the direction transverse to the machine respectively. For example, as illustrated in Figures 4 and 5, the longitudinal direction 38 and the lateral direction 40 of the diaper 20 correspond to the direction of the machine and the direction transverse to the machine, respectively, when the diapers are made a ratio of front to back or from waist to waist.
It is desirable to provide a non-linear edge of the secondary adjusters, the die cutter 82 can cut the fabric of the secondary fastener material 80 along a serpentine path whereby each tape 84 is provided with a cutting edge 86 and a opposite edge 88. In such a configuration, the discrete tapes of the secondary fastener material 84 are then crossed over one another to place the cutting edge 86 of each tape 84 laterally outward from the opposite edge 88. As used herein, the term "outside" "refers to a distance in the direction transverse to the machine or laterally outward of the longitudinal centerline of the respective movable fabric.
In the illustrated method, a continuous web of adjustable belt material 90 is also unwound and passed through the cutter 92 which cuts the fabric of adjustable belt material 90 in the transverse direction to the machine in individual adjustable belt segments 94. Opposite end portions of discrete adjustable belt segments 94 are attached by means of linker 96 to spaced apart tape of fastener material 84 to provide a continuous fabric of adjustable belt assembly 94. Adjustable belt segments 94 are joined to the straps of the fastener material 84 in spaced and longitudinally spaced locations. Therefore, as illustrated in Figure 1, the adjustable belt assembly fabric 98 can be provided in a ladder type configuration.
Desirably, the adjustable belt material 90 is a latent elastic material. In such a configuration, the methods of the present invention include activating the latent elastic material by means known to those skilled in the art. For example, the material can be heated so that the adjustable belts 94 contract elastically in a pretensioned configuration in the diaper 20. In an alternate embodiment, the fabric of the adjustable belt assemblies 98 or each of the adjustable belt segments 94 may extend at least about 25 percent and more desirably at least about 50 percent in the transverse direction before joining the diaper 20 or the tapes of the fastened material 84 so that the adjustable belts 94 are in a configuration pretended in the diaper 20.
In the illustrated embodiment, belts of belting curls 104 are provided by passing a fabric of belt loop material 100 through die cutter 102 which selectively cuts the fabric of two belts. The belts of the belt loop material 10 can then be laterally spaced apart from one another as illustrated. The ribbons of the belt loop material 104 are then fused with the fabric of the adjustable belts 98 so that the belt loop material 104 is inwardly from one side of the straps of the secondary fastener material 84 over the belt fabric. Adjustable Desirably, the belt loop material 104 includes the fastener material on a body facing surface thereof. For example, the body facing surface of the belt loop material may include the hook material of a hook-and-loop type fastener such that the belt loop material provides the pair of primary clips 62 on the diaper. 20 representatively illustrated in Figures 2-5.
As representatively illustrated in Fig. 1, the fabric of adjustable belts 98 and belts of the belt loop material 104 are then cut into discreet adjustable belts by the cutter 106. The discrete adjustable belts are then attached at spaced apart locations to the continuous fabric of the outer covering material 110 or a fabric of absorbent articles interconnected using the joiner 108. In the illustrated embodiment, the joiner 108 joins the longitudinal ends of the belt loops to the outer cover material 110 so that the adjustable belt 64 is contained slidably between the parts of belt loops and the outer cover material or the absorbent article.
Alternatively, the secondary fastener material 84 and the belt loop material 104 can be provided by the same fabric of material for improved matching and control of the belt assemblies. For example, a fabric of the hook-type material can be provided which is selectively cut into four separate tapes, two of which provide the tapes of the secondary fastening material 84 and two of which provide the tapes of the belt-loop material. In such configuration, the tape of the secondary fastener material and the tape of the belt loop material104 for each end of the adjustable belts may not be completely cut off from each other in the cutting process. Instead, the two tapes can remain selectively attached to one another along a perforation line to provide two strips of material. The perforation lines can then be broken in use to facilitate the adjustment of the secondary fasteners for an improved diaper notch around the wearer's waist. Such an arrangement can result in additional improved control since the belt loop parts and the secondary clips can selectively join together.
The proper bonding equipment which can be used to provide the bonding of the different components of the diaper is well known to those skilled in the art. Desirably the binders 96 and 108 are ultrasonic binders for improved efficiency and cost effectiveness. For example, as illustrated in Figure 1, the joiner 96 may include one or more rotating ultrasonic horns and an anvil roller between which the individual ends of the adjustable belts and the straps of fastener material 84 are passed to provide the fabric ladder type of adjustable belts 98. Revolving ultrasonic horns are described in United States Patent No. 5,110,403 issued to Ehlert, the description of which is incorporated herein by reference. Such rotating ultrasonic horns generally have a diameter of from about 5 to about 20 centimeters and a width of from about 2 to about 15 centimeters. Alternatively, the ultrasonic horn may be a stationary ultrasonic horn as is known to those skilled in the art. Other suitable ultrasonic horns and ultrasonic binders are commercially available from Branson Sonic Power Company, a business having offices in Danbury, Connecticut. The binders 98 and 108 may otherwise be a thermal bond or adhesive as is well known.
The binders 96 and 108 can be configured to provide the joining of the different components in a variety of patterns and shapes or sizes. For example, the joints can be provided as dot patterns, circles, squares, triangles and the like which can be arranged in a linear or non-linear configuration. Such patterns may be located on the connecting horn or the anvil roller.
Suitable cutters for providing matrix cutters 82 and 102 and cutters 92 and 106 for selectively cutting fabrics of the method of the present invention are generally known to those skilled in the art. For example, the die cutter 82 may include the combination of a cutter roll and an anvil roll through which the fabric 80 is moved. The anvil roll may include a hardened steel rotating roll while the cutter roll may include one or more flexible hardened steel blades attached to another rotating roller. The pinch force between the blade on the cutter roll and the anvil roller creates the cut. The cutting roller can have one or more blades depending on the desired distance between cuts. The cutters 92 and 10 can further be configured to provide a spacing between the individual cutting pieces after they are cut. Such spacing can be provided by transferring the cutting pieces out of the cutter at a speed greater than the speed at which the fabric is provided to the cutter.
The continuous web of interconnected diapers provided by the methods mentioned above can further be passed through another matrix cutter which selectively cuts the fabric into individual and discrete diapers. The discrete diapers can then be folded into a conventional blade bend around a lateral fold line in the crotch region of the diaper so that the waist regions of each diaper are placed in a facing relationship. If it is desired that the diapers be provided in a presumed configuration, the primary fasteners on the belt loops can also be folded over and engage releasably with the outer surface of the opposite waist region of each diaper. Such presumed diapers, as illustrated in Figure 2, can then be pulled on or lowered in a manner similar to conventional training underpants articles.
The methods of the present invention, as representatively illustrated in Figure 1, can reliably and consistently provide absorbent articles that have an adjustable belt such as the diaper illustrated in Figure 2. In particular, the ladder type arrangement of the belts and the belt loops of the methods of the present invention provide an exact match and an exact alignment to facilitate the cutting and high speed application of the adjustable belts to the individual diapers. Thus, the methods can provide a consistent and consistent fastening of each belt to the diaper. The methods can also result in reduced waste through the use of the serpentine cut and the crossing over the serpentine fabrics to provide secondary fasteners formed on the adjustable belts.
The different components of the absorbent articles made by the methods described above may include a variety of materials. For example, as representatively illustrated in Figures 2-5, the outer cover 42 of the diaper 20 may suitably be composed of a material which is either liquid permeable or liquid impervious. Since the absorbent frame 44 of the different aspects of the present invention is designed to contain the exudate of the body discharged from the user, it is not generally necessary that the outer cover 42 be impermeable to liquid. For example, the outer cover 42 may include various woven or non-woven materials such as a spunbonded material, or meltblown material, a cotton material, a rayon material or combinations thereof such as a bonded laminate material. with spinning-blown with fusion-linked with spinning (SMS). The outer cover 42 may otherwise be at least partially impervious to the liquid to further prevent any runoff of body exudates. For example, a typical outer cover 42 can be made of a thin plastic film or other flexible liquid impervious material, woven or non-woven fibrous layers, "breathable" microporous materials, elastic materials and combinations thereof. .
The absorbent frame 44 of the diaper 20 is suitably connected to the outer cover 42 to provide the disposable diaper 20. The absorbent frame 44 can be connected to the outer cover 42 in ways well known to those skilled in the art. For example, the absorbent frame 44 may be attached to the outer cover 42 using adhesive, thermal or ultrasonic bonding techniques known to those skilled in the art. Alternatively, the absorbent frame 44 can be connected to the outer cover 42 using conventional fasteners such as buttons, hook-type and curl-type fasteners, adhesive tape fasteners, and the like. The other components of the diaper 2 can be suitably connected together using similar means.
Desirably, the absorbent frame 44 is connected to the outer cover 42 only or at the adjacent waist edges 32 of the outer cover 42 thereby creating a front bonded portion, a later bonded portion and an unclamped portion which extends between and connect the joined parts. The unattached part of the absorbent frame 44 remains essentially unattached to the outer cover 42 and is generally configured to fit between the user's legs and at least partially cover the lower torso of the user when in use. As a result of this, the unattached part is generally the part of the absorbent frame 44 which is configured to initially receive the exudates from the user's body. Therefore, the absorbent frame 44 is connected to the outer cover 42 in a manner such as to secure the frame 44 in place while not adversely restricting the movement of the outer cover 42 in use. Alternatively, the absorbent frame 44 may be attached to the outer cover 42 along the entire longitudinal extent of the absorbent frame 44 or any part thereof or along only the outer periphery of the absorbent frame 44.
As representatively illustrated in Figure 4, the absorbent frame 44 according to the present invention can include a lower sheet 46, a side-to-body liner 48 which is connected to the lower sheet 46 in an overlap relationship, and a absorbent core 50 which is located between the side-to-body liner 48 and the lower sheet 46. In the alternate configurations wherein the outer cover 42 is at least partially resistant to the flow of liquids therethrough, the sheet bottom 46 can optionally be omitted from absorbent frame 44.
The absorbent frame 44 is generally conformable and is capable of absorbing and retaining exudates from the body. Absorbent frame 44 can have any of a number of shapes and sizes. For example, as representatively illustrated in Figure 4, the absorbent frame 44 can be rectangular, I-shaped or T-shaped. The size and absorbent capacity of the absorbent frame 44 must be compatible with the size of the intended user and of the fluid load imparted by the intended use of the diaper 20. Typically, it is desired that the absorbent frame 44 has an absorbent capacity of at least about 300 grams of urine. It is generally preferred that the absorbent frame 44 be narrower in the crotch region 26 than in the waist regions 22 and 24. It has been found that the absorbent frame 44 of the present invention is particularly useful when the width dimension in the region crotch 26 is from about 2.5 to about 10.2 centimeters, desirably no more than about 7.6 centimeters and more desirably no more than about 5.1 centimeters. The narrow crotch width dimension of the absorbent frame 44 allows the absorbent frame 44 to better fit between the user's legs.
The body side liner 48 of the absorbent frame 44, as depicted representatively in Figure 4, suitably presents a body facing surface which is intended to be worn on one side of the wearer's body and is docile, soft feeling and Non-irritating to the user's skin. In addition, the body side liner 48 may be less hydrophilic than the absorbent core 50, to present a relatively dry surface to the wearer, and may be sufficiently porous to be permeable to the liquid, allowing the liquid to easily penetrate through its thickness . A suitable body side liner 48 can be manufactured from a wide selection of woven materials, such as woven and non-woven fabrics, porous foams, cross-linked foams, perforated plastic films, natural fibers (e.g. cotton or wood), synthetic fibers (for example, polyether or polypropylene fibers) or a combination of natural and synthetic fibers. The body side liner 48 is suitably employed to help isolate the wearer's skin from fluids maintained in the absorbent core 50 of the absorbent frame 4.
The lower sheet 46 of the absorbent frame 44 com is illustrated representatively in Figure 4, it can suitably be composed of a material which is already permeable to liquid or impervious to liquid. It is generally preferred that the bottom sheet 46 be formed of a material which is essentially fluid-impermeable. A typical lower leaf can be made of a thin plastic film or other material impervious to the flexible liquid. The lower blade 46 can also be constructed of a material which is similar to the described material as being suitable for the outer shell 42.
The body side liner 48 and bottom sheet 46 are generally adhered to one another to form a pocket in which the absorbent core 50 is located to provide the absorbent frame 4. The body side liner 48 and the bottom sheet 46 can adhere directly to each other around the outer periphery of the absorbent frame 44 by any means known to those skilled in the art such as adhesive joints, sonic joints, or the thermal connections. For example, a continuous and uniform layer of adhesive, a patterned adhesive layer, a meltblown or meltblown adhesive pattern or an array of lines, swirls or spots of adhesive can be used to attach the body side liner 48 to bottom sheet 46. You should note that both the side-to-body liner 48 and the bottom sheet 46 n require full extension to the outer periphery of absorbent frame 44. For example, bottom sheet 46 can extend to the outer periphery of the absorbent frame 4 while the side-to-body liner 48 may be attached to the lower sheet 46 inward of the outer periphery of absorbent frame 44, or more toward the longitudinal centerline of the diaper 20. In alternate configurations, especially e where it is omitted the lower sheet 46, the side liner to the body 48 can suitably adhere directly to the absorbent core 50 or to the outer cover 42.
The absorbent core 50, as representatively illustrated in Figure 4, is positioned between the side-to-body liner 48 and the lower sheet 46 to form the absorbent frame 44. The absorbent core 50 is desirably conformable and capable of absorbing and retaining the exudates of the body. The absorbent core 50 may have any number of shapes or sizes. For example, the absorbent core may be rectangular, I-shaped or T-shaped. It is generally preferred that the absorbent core 50 be narrower in the crotch region 26. The size of the absorbent core 50 must be compatible with the size of the intended user and the desired absorbent capacity of the absorbent frame 44.
The absorbent core 50 of the absorbent frame 4 may suitably comprise various types of hydrophilic and wettable fibrous materials. Examples of suitable materials include naturally occurring organic fibers composed of intrinsically wettable material, such as cellulosic fibers; synthetic fibers composed of cellulose or cellulose derivatives, such as raydn fibers; inorganic fibers composed of an inherently wettable material, such as glass fibers; synthetic fibers made of inherently wettable thermoplastic polymers, such as the particular polyester and polyamide fibers; and synthetic fibers composed of non-wettable thermoplastic polymer, such as polypropylene fibers, which have been hydrophilized through appropriate means known to those skilled in the art. The absorbent core 50 can also comprise selected blends of the various types of fibers mentioned above.
In a particular aspect of the invention, the absorbent core 50 may include a matrix of hydrophilic fibers, such as a fabric of cellulosic fibers, mixed with particles of a high-absorbency material such as is commonly known as the super-absorbent material. How it is used here, the term "high absorbency material" refers to materials that are capable of absorbing at least ten times their own weight in the liquid. In a particular embodiment, the absorbent core 50 comprises a mixture of super absorbent hydrogel-forming particles and wood pulp fluff. The wood pulp fluff can be interchanged with meltblown, polymeric and synthetic fibers or with a combination of meltblown fibers and natural fibers. The high-absorbency material can be mixed in an essentially homogeneous form with the hydrophilic fibers or can be mixed not uniformly The high absorbenci material can also be arranged in a generally discrete layer within the hydrophilic fiber matrix. Alternatively, the absorbent core 50 may comprise a fibrous tissue laminate and high absorbency material or other suitable means for maintaining the high absorbency material in a localized area.
As representatively illustrated in Figure 4, the absorbent frame 44 of the disposable diaper 20 may include a pair of containment fins 54 which are configured to provide a barrier to the lateral flow of exudates from the body. The containment fins 54 may be located along the laterally opposite side edges of the absorbent frame 44. Each containment fin 54 typically defines an unbonded edge which is configured to maintain a perpendicular and vertical configuration in at least the region crotch 26 of the diaper 20 to form a seal against the wearer's body. The containment fins 54 may extend longitudinally along the entire length of the absorbent frame 44 or may only extend partially along the length of the absorbent frame 44. When the containment fins 54 are shorter in length than the absorbent frame 44, the containment fins 54 can be selectively positioned anywhere along the side edges of the absorbent frame 44. In a particular aspect of the invention, the containment fins 54 extend along the entire length of the absorbent frame. 44 to better contain body exudates.
Such containment fins 54 are generally well known to those skilled in the art. For example, suitable constructions and arrangements for containment fins 54 are described in U.S. Patent No. 4,704,116 issued November 3, 1987, to K. Enloe whose description of which is incorporated herein by reference. reference.
The disposable diaper 20 of the various aspects of the present invention can further include elastics at the waist edges 32 and at the side edges 30 of the diaper 20 to further prevent runoff of body exudates and hold the absorbent frame 44. For example , as representatively illustrated in Figure 4, the diaper 20 of the present invention can include a pair of leg elastic members 52 which are connected to the laterally opposite edges 30 in the crotch region 26 of the diaper 20 and a a pair of elastic waist members 56 which are connected to the longitudinally opposite waist edges 32 of the diaper 20. The leg elastics 52 and the waist elastics 56 are generally adapted to fit around the legs and waist of a wearer Use to maintain a positive contact relationship with the user to effectively reduce or eliminate draining of the exudates of the body from the diaper 20.
Suitable materials for use as leg elastics 52 and waist elastics 56 are well known to those skilled in the art. Examples of such materials are the sheets or threads or tapes of a polymeric and elastomeric material which are adhered to the outer cover 42 in a stretched position, or which are attached to the outer cover 42 while the outer cover is folded, so that the elastic constriction forces are imparted to the outer cover 42. The leg elastics can also include such materials as polyurethane, synthetic and natural rubber.
The absorbent article of the various aspects of the present invention further includes a fastening system 60 for securing the absorbent article around the wearer's waist. The fastening system includes fasteners located on one of the waist regions 22 and 24 of the diaper 20 which are configured to releasably engage the opposite waist region of the diaper 20 to hold the diaper around the wearer's waist. The use of the fasteners which are releasably releasable or engageable allows the ease of securing and removing the diaper 20 from the wearer's waist.
As it was representatively illustrated in the Figures2-5, the fastening system 60 of the present invention includes a pair of primary fasteners 62 which are located on the lateral edges 30 of the diaper 20 in the rear waist region 24 of the diaper 20. In such a configuration, the primary fasteners they are configured to surround the user's hips and engage the outer surface 36 of the front waist region 22 of the diaper 20 to hold the diaper 20 on the wearer. Alternatively, the primary fasteners 62 can be located on the front waist region 22 and can be configured to releasably engage the outer surface 36 of the rear waist region 24 of the diaper 20.
Desirably, the primary fasteners 62 are releasably engaged directly with the exterior surface of the outer cover 42 of the diaper 20 to provide improved fastening ease.
Alternatively, as representatively illustrated in Figures 2-5, the disposable diaper 20 of the present invention may further include a junction panel 68 located on the outer cover 42 in one of the waist regions 22 and 2 of the diaper 20. In In such a configuration, the primary fasteners 6 are releasably engageable with the attachment panel 68 to hold the diaper 20 around the wearer's waist. When the primary fasteners 62 are releasably engaged, the side edges 30 of the diaper 20 define the leg openings which are configured to surround the legs of the wearer and the waist edges 32 define a waist opening which is configured to encircle the waist. waist of the user. As illustrated in Figure 5, the jointing panel 68 can include two separate panels located along the opposite side edges in one of the waist regions 22 and 24 of the diaper 20. Alternatively, the jointing panel 68 can include a single piece of material which extends essentially through the respective waist edge 32 of the diaper 20.
In a particular embodiment, the primary fasteners 62 are configured to be releasably engaged with the outer surface of the opposite waist region 22 and 24 of the diaper 20 before the diaper 20 is placed over the wearer to provide a presumed diaper. In such a configuration, the presumed diaper 20 can be raised or lowered over the user's legs and hips. If the diaper 20 s becomes dirty during use, the primary fasteners 62 can be disengaged to easily remove the diaper 20 from the wearer's belt with a reduced risk of unwanted soiling of the legs or the wearer's clothing. Thus, in such a configuration, the diaper 20 of the different aspects of the present invention can be configured to be pulled down on the wearer's hips such as conventional training pants and can be removed by unhooking the fasteners to remove the diaper 20 at a similar way to conventional diaper articles.
The fastening system 60 on the disposable diaper 20 of the present invention further includes an adjustable belt having a pair of secondary fasteners thereon to provide improved securing of the diaper 20 around the wearer's waist when after the primary fasteners 62 have been hooked releasably. The adjustable belt and secondary fasteners of the present invention are configured to further conform the waist regions 22 and 24 of the diaper 20 to the wearer's waist. For example, as representatively illustrated in Figures 2-5, the diaper 20 may include the adjustable belt 64 which includes a pair of secondary fasteners 66 located on the opposite end portions of the adjustable belt 64. Secondary fasteners 66 are located in one of the waist regions 22 and 24 of the diaper 20 are configured to surround the wearer's hips and engage the outer surface 36 in the opposite waist region 22 and 24 of the diaper 20. For example, the adjustable belt 64 and the secondary clips 66 can be located along the waist edge 32 of the diaper 20 in the rear waist region 24 of the diaper 20. In such a configuration, the adjustable belt 64 and the secondary clips 66 are configured to encircling the user's hips and engaging the outer surface 36 of the front waist region 22 of the diaper 20 to hold the diaper 20 on the wearer. Alternatively, the adjustable belt 64 and the secondary clips 66 can be located on the front waist region 22 and can be configured to releasably engage the outer surface 36 of the rear waist region 24 of the diaper 20.
Desirably, the secondary fasteners 66 are releasably engageable directly with the outer surface of the outer cover 42 of the diaper 20 to provide improved fastening ease. Alternatively, as described above and representatively illustrated in Figure 5, the diaper 20 of the present invention may further include a junction panel 68 located on the outer cover 42 in one of the waist regions 22 and 24 of the diaper 20. In such a configuration, the secondary fasteners 66 can also be releasably engaged with the attachment panel 68 to hold the diaper 20 around the wearer's waist.
The use of such an adjustable belt 64 with the secondary fasteners 66 has been found to be particularly desirable when the primary fasteners 62 are releasably engaged with the respective waist region of the diaper 20 to provide a presumed diaper which can be pulled over the legs and the hips of the user. In such a configuration, the waist opening of the diaper 20 when the primary fasteners 62 are engageable should be sufficient to allow the presumed diaper to pull on the wearer's hips. However, the circumference of the user's waist is typically less than the circumference around the wearer's hips. Therefore, the waist opening of the presumed diaper may not conform to the wearer's waist which may result in unwanted draining. In such a configuration, the adjustable belt 64 and the secondary clips 66 of the diaper 20 of the present invention are configured to conform to the waist regions of the diaper 20 to the wearer after the presumed diaper is raised over the wearer. Therefore, the caregiver does not require that the primary fasteners 62 be repositioned to conform the waist regions 22 and 24 to the wearer's waist. As a result of this, when the diaper 20 is to be removed from the user, the caregiver can simply unhook the secondary fasteners 66 if necessary and pull the diaper presujetado down on the user's hips and legs without having to reposition the primary fasteners 62.
In such configurations, the adjustable belt 64 and the secondary fasteners 66 are intended to hold the diaper 20 in a conformal and closed notch around the wearer's waist to reduce runoff of body exudates when in use. The primary fasteners 62 are intended to maintain the front and rear waist regions 22 and 24 of the diaper 20 connected in such a manner that the diaper 20 can be raised or lowered onto the wearer's hips after the secondary fasteners 66 have disengaged. Secondary fasteners 66 can also be selectively disengaged to facilitate inspection of diaper 20 to determine if it has been soiled. The primary fasteners 62 can also provide a "child resistant function" by keeping the diaper 20 at least partially secured around the user's waist if the user disengages the secondary fasteners 66.
Suitable fasteners are well known to those skilled in the art and may include adhesive tape appendage fasteners, hook and loop fasteners, mushroom fasteners, boteroles, pins, belts and the like and combinations thereof . For example, as representatively illustrated in Figures 2-5, primary fasteners 62 and secondary fasteners 66 can be hook-type fasteners and outer cover 42 or fastening panel 68 can be configured to function as a fastener type of complementary curls. Desirably, the fasteners 62 and 66 are hook type fasteners which engage releasably with the outer cover 42. Such an arrangement provides the ability to vary the size of the waist opening in very small increments over a wide range for notching the waist. of the user. The fasteners can have any shape and size and provide the desired fastening of the diaper 20 around the wearer's waist. It is further desirable that the outer surface of the secondary fasteners 66 provide a visual cue to the caregiver as to their location. For example, in one embodiment, the secondary fasteners are of a different color than that of the outer surface of the diaper 20 to allow the caregiver to easily determine the location of the secondary fasteners 66.
Suitable materials for use as the adjustable fastening belt 64 of the various aspects of the present invention are similar to those materials described above, being suitable for the outer cover 42. Desirably, the adjustable belt 64 is made of an elastic material which is capable of elongating at least about 50 percent and more desirably at least about 100 percent to improve the notch around the wearer's waist. For example, the adjustable belt 64 may comprise a bonded and tapered laminate which includes a KRATON film material commercially available from the Dow Chemical Company, a business having offices located in Midland, Michigan. Alternatively, the adjustable belt 64 may include parts which include the elastic material and parts which include an inelastic material.
Desirably, the adjustable belt 64 is made of a latent elastic material which can be activated after the diaper 20 is manufactured. The use of such a latent elastic material eliminates the need to keep the adjustable belt 64 in a stressed condition when manufacturing the diaper. Suitable latent elastic materials are known to those skilled in the art. For example, suitable latent elastic materials are commercially available from Exxon under the trade designation EXXON601. Alternate latent elastic materials are described in United States of America patent apation number 08 / 854,934 filed May 13, 1997 and entitled "IMPROVED COMPOSITE ELASTIC MATERIAL AND PROCESS FOR PRODUCING THE SAME", the description of which it is incorporated here by reference. The latent elastic material can be activated by a variety of methods known to those skilled in the art. For example, the latent elastic adjustable belts can be activated by heating the diaper after its manufacture to cause the material to retract.
The primary fasteners 62, the adjustable belt 64 and the secondary fasteners 66 can be incorporated into the diaper 20 of the different aspects of the present invention in a variety of different ways known to those skilled in the art. For example, in the illustrated embodiments and as described above, the diaper 20 may also include a pair of belt loops 70 which define a pair of longitudinally opposite end portions 72. In the illustrated embodiments, the end portions 72 of The portions of belt loops 70 are attached to the face facing surface of the outer cover 42 so that the portions of belt loops 70 are located in the diaper 20 on the body facing surface of the outer cover 42 of the belt. facing the absorbent frame 44 in one of the waist regions 22 and 24. Thus, the adjustable belt 64 is slidably contained within the belt loop portions 70, the end portions 72 and the outer cover 42. The longitudinal ends 72 of the belt loop portions 70 can suitably be attached to the diaper 20 using the joining methods described herein. For example, the ends 72 of the belt loop portions 70 can be ultrasonically bonded to the outer cover 42.
In such a configuration, the face-to-body surface of the belt loop parts 70 desirably provide the primary fasteners 62 for improved manufacturing efficiency and reduced cost. Alternatively, the primary fasteners 62 may be attached to the portions of belt loops 70 or other parts of the diaper 20. The primary fasteners 62 may be adhered to the belt loop portions 70 by any means known to those skilled in the art such as adhesive joints, sonic joints or thermal joints. The secondary fasteners 66 can also be suitably connected to the end portions of the adjustable belt 64 using similar means. As described above with respect to aspects of the method of the invention, the adjustable belt 64 can be lengthened before the belt loop parts 70 are attached to the outer cover 42 or the adjustable belt 64 can comprise a latent elastic material which can be subsequently activated to provide a pretension to the adjustable belt 64 between the parts of belt loops 70.
In the illustrated embodiments, the majority of the adjustable belt 64 extends along the inner surface of the outer cover 42 between the outer cover 42 and the absorbent frame 44. Alternatively, the adjustable belt 64 may extend between the absorbent frame 44 and the user or between any of the layers of the absorbent frame 44. As illustrated, the secondary fasteners 66 are desirably configured to be positioned laterally away from and to one side of the side edges of the outer cover 42, the parts of belt loops 70 and of the primary fasteners 62 for improved control and ease of fastening.
A portion of the adjustable belt 64 between the side edges of the outer cover 42 can be secured to the other parts of the diaper 20 such as to the inner surface of the outer cover 42 to provide a bonded portion 74 as illustrated in Figure 4. attached portion 74 of adjustable belt 64 can be secured using methods known to those skilled in the art such as with adhesive, sonic or thermal bonding. Desirably, the bonded portion 74 defines the attached extension 76 as illustrated in Figure 4 which is less than about 75 percent and more desirably less than about 50 percent of the total length of the adjustable belt 64. Such length attached provides sufficient securing of the adjustable belt of the diaper 20 without adversely affecting the ability of the adjustable belt to conform to the wearer's waist to provide the improved notch.
The adjustable belt 64 can define any length and width which provide the desired improved fastening and notch around the wearer. For example, the adjustable belt 64 can define a length which is from about 7 to about 35 centimeters and a width which is from about 1 to about 10 centimeters. Desirably, the adjustable belt 64 defines a length which is slightly less than the width of the diaper 20 of the respective waist region so that the adjustable belt 64 is stretched slightly to pre-tension in the waist region. The distance between the joined portions of the longitudinal ends 72 of the belt loop parts 70 is greater than the width of the adjustable belt 64 so that the adjustable belt is slidably contained between the belt loop parts 70. The secondary clips 66 on the ends of the adjustable belt 64 desirably define a width which is greater than the width of the adjustable belt 64 so that the secondary clips 66 can prevent the belt 64 from passing through the belt loop parts 70.
The materials suitable for use as the belt loop parts 70 of the various aspects of the present invention are similar to those materials described above as being suitable for the outer cover 42. As discussed above, the belt loop portions 70 can including a fastener material, such as a hook material, on a surface thereof to provide the primary fasteners 62. Fastener materials suitable for use as the belt loops 72 are set forth above as being suitable for fasteners 62 and 66. The belt loops 7 may be a single material such as the hook material may include a composite of materials.
If it is desired for the absorbent article of the present invention to be presumed, the absorbent article of the present invention may further include a pair of releasable side links (not shown) for improved reliability to keep the article in the presumed condition particularly when It is raised or lowered over the user's hip. Absorbent articles including such releasable side-pieces are further described in the patent application of the United States of North America entitled "DISPOSABLE ABSORBENT ARTICLES HAVING PASSIVE SIDE UNIONS AND ADJUSTABLE CLAMPING SYSTEMS" filed in the name of Elsberg on the same date as this application and that has the matter of lawyer number 13,611, the description of which is incorporated herein by reference. For example, the diaper 20 can include a pair of releasable side seams which releasably connect the side edges 30 of the diaper in the front and back waist regions 22 and 24 of the diaper 20. In such a configuration, the releasable side seams can assist the fastening system 60 for maintaining diaper 20 in a presumed condition when diaper 20 is raised or lowered over the wearer's hips. In addition, the releasable side links can prevent movement and change of the waist regions 22 and 24 in relation to one another for improved notch and operation. The releasable side links can also prevent the winding or bending of the side edges 30 and the waist edges 32 of the diaper 20 when it is placed on the wearer's hips.
The different aspects of the present invention advantageously provide disposable absorbent articles having a fastening system which includes an adjustable belt and the methods for making same. The fastening system can be presumed to releasably engage the front and back waist portions to allow the absorbent article to be raised or lowered over the user's hips such as conventional training pants. In addition, the adjustable belt of the restraint system can be used to further shape the front and back waist portions of the absorbent article to hold the absorbent article around the user's waist after the article has been raised in a manner similar to diapers. conventionalAs a result, the absorbent article of the present invention is designed to conform to the wearer's body to effectively contain exudates from the body while still being able to be reliably raised or lowered over the wearer's hips to aid in toilet training. of the user. In addition, similarly to conventional diapers, the absorbent article of the present invention can be advantageously applied and removed from the user with relative ease and cleanliness.
Even though the invention has been described in detail with respect to the specific aspects thereof, it will be appreciated by those skilled in the art, to achieve the understanding of the foregoing, that alterations, variations and equivalents of these aspects can easily be conceived. Therefore, the scope of the present invention should be established as that of the appended claims and any equivalents thereof.