MXPA00003726A - Absorbent article with enhanced elastic design for improved aesthetics and containment - Google Patents

Abstract

An absorbent article (10) which includes a backsheet layer (30) having a pair of laterally opposed and longitudinally extending side margins (20). Each side margin has an outwardly concave, terminal side edge contour (15) located at appointed leg opening regions (17) in an intermediate portion (16) of the side margin. Each concave side edge contour (15) has a selected longitudinal extent along a length dimension (26) of the article (10). A liquid permeable topsheet layer (28) is connected in a superposed facing relation to the backsheet layer (30), and an absorbent body (32) is sandwiched between the topsheet layer (28) and the backsheet layer (30). A separately provided gusset-flap composite member (19) is connected to at least one of the backsheet and topsheet layers along each of the leg opening regions (17). The gusset-flap member (19) provides a leg gusset section (142) and a containment flap section (144). The gusset-flap member includes a barrier layer (174) having a pair of laterally opposed, longitudinally extending, barrier layer side edges (140, 141), and has a first major facing surface (148) and a second major facing surface (149). A nonwoven fabric layer (176) is joined in facing relation with the first facing surface (148) of the barrier layer (174). The fabric layer (176) has a leg gusset region (136), an outboard side portion (170), a containment flap region (63), and an inboard side portion (62). The outboard side portion (170) of the gusset-flap fabric layer (176) is arranged to wrap around at least one side edge of the barrier layer (174) and to extend inboard therefrom along the second facing surface (149) of the barrier layer (174). A first arrangement of a first plurality of separate, longitudinally extending elastomeric members (138) are attached and interposed between the barrier layer (174) and the fabric layer (176) within the leg gusset section (142) of the gusset-flap member (19).

Description

ABSORBENT ARTICLE WITH IMPROVED ELASTIC DESIGN FOR AN AESTHETIC AND ONE IMPROVED CONTAINMENT Field of the Invention The present invention relates to an article having one or more elasticized peripheral margins. More particularly, the invention relates to an article which incorporates a distinctly elasticized restraint system in the leg and / or waistband portions of the article.

Background of the Invention Conventional absorbent articles, such as disposable diapers, have been constructed in various types of elasticated waistbands and leg cuffs or elasticized leg bands. Such article designs have also included additional elasticated barrier or containment fins in the leg and / or waist sections of the article. The particular article designs have incorporated a stretchable outer cover composed of an elastomeric woven material, such as a stretched / joined laminate which includes a layer of a non-woven fabric. Other conventional designs have included separate non-elastomeric or elastomeric side panel members connected to the lateral side edges of an outer cover or lower sheet member, and have included fastening systems and fastening appendages connected to the side panels for secure the article about a user.

The articles which incorporate the conventional elasticized margins and the conventional barrier fin configurations in their leg band sections have, however, exhibited several disadvantages. For example, it has been difficult to avoid red marking of the wearer's skin and it has been difficult to maintain the desired operation of the scavenging vanes when the articles are being used. Even though the barrier flaps are constructed of an elastomeric material they have otherwise elasticized it, it has been difficult to maintain contact between the mobile edge of the barrier flap and the user's body and it has been difficult to reliably maintain the open flap for effective reception and containment of urine and feces. As a result of this, there is a continued need for improved containment structures in the leg regions of the absorbent articles.

Brief Description of the Invention The present invention can provide a distinctive article which includes a bottom sheet layer having a pair of laterally opposite side margins, with each side margin having a terminal lateral edge contour located in a leg opening region designated at each end. one of the lateral margins. A liquid-permeable top sheet layer is connected in a superposed relation to the lower sheet layer, and an absorbent body is positioned and maintained between the upper sheet layer and the lower sheet layer. A separate elasticized gusset fin member is connected to the article along the designated leg opening regions, and each gusset-fin member has a leg shield section and a containment fin section. The leg shield section is configured to extend further and bridge between the opposite spaced apart portions of an associated edge contour of the lower sheet layer.

In particular aspects, the absorbent article may include a bottom sheet layer having a pair of side margins extending longitudinally and laterally opposite, with each lateral margin having an outwardly concave end lateral edge contour located in the aperture regions. of leg designated in an intermediate part of the lateral margin. Each concave side edge contour has a selected longitudinal length along a length dimension of the article. A liquid-permeable upper sheet layer is connected in a frontal relationship superimposed on the lower sheet layer, and an absorbent body is placed in the form of a sandwich between the upper sheet layer and the lower sheet layer. A separately provided composite fin-gusset member is connected to at least one of the lower sheet and upper sheet layers along each of the leg opening regions. The gusset-fin member provides a section of the leg gusset and a section of containment fin. The fin-gusset member includes a barrier layer having a pair of longitudinally extending, laterally opposite, laterally extending barrier layer sidewalls, and the sweeping layer has a first major surface and a second major surface. A nonwoven fabric layer is bonded in a frontal relationship with the first surface of the barrier layer, and the fabric layer has a leg gusset region, an outer side part, a containment fin region, and a lateral region inside. The outer side portion of the fin-gusset layer is arranged to wrap around at least one side edge of the barrier layer and to extend inwardly therefrom along the second surface of the barrier layer . A first array of a first plurality of elastomeric members extending longitudinally apart are joined and interposed between the barrier layer and the fabric layer within the leg gusset section of the gusset member.

The configurations and arrangements of the various aspects of the invention can provide an article that has a more conformable, gentle and soft leg fold, can provide a barrier fin structure that can more reliably and more effectively hold an open position when the article Associated absorbent is being used. In addition, the open fin configuration can be maintained while avoiding excessive irritation of the user's skin. The resulting article may exhibit less separation in the leg opening regions, and may provide a more cushioned appearance and operation. The article can also provide a leg fold which can be moved more independently of the main part of the absorbent article to provide a more conformable leg fold to the leg. In addition, the article can provide leg gusset and retainer flap configurations which provide a more tortuous path to better resist the runoff of any of the free liquids in the absorbent article. The arrangement of the constituent components and the combination of the operating parameters, such as the controlled rigidity and the controlled articulation of the barrier fin, can advantageously provide an improved absorbent structure which can have less runoff, and can provide a comfort increased to the user.

Brief Description of the Drawings This invention will be more fully understood and the additional advantages will become apparent when reference is made to the following detailed description and the accompanying drawings in which: Figure 1 representatively shows a top view partially in section of an article of the invention.

Figure 2 representatively shows an expanded and schematic cross-sectional view of the elastic waist system and the waist barrier flap system of the invention taken along a longitudinal center line of the article when the flap or bag section is in its uncontracted and flat condition.

Figure 3 representatively shows an expanded and schematic cross-sectional view of the elastic waist system and the waist barrier flap system of the invention taken when the bag or flap section is in its open and contracted condition.

Figure 4 is a schematic, expanded lateral cross-sectional view of a gusset-fin member taken through the crotch section of the article.

Figure 5 is a schematic, expanded, lateral cross-sectional view of one of the fin-gusset members and its adjacent containment fin section, taken through another section of the article.

Figure 6 is a schematic, expanded, lateral cross-sectional view of a configuration of the fin-gusset member wherein the gusset fin barrier layer extends into the containment fin section.

Figure 7 is an enlarged schematic side cross-sectional view of an alternate configuration of one of the fin-gusset members taken through the crotch section of the article.

Figure 8 is a side, expanded, schematic cross-sectional view of yet another arrangement of the fin-gusset member.

Figure 9 is a schematic of a portion of a side cross-sectional and expanded view showing the adhesive distributions joining the elastomeric yarns in the leg gusset part of said leg gusset member.

Figure 10 is a schematic of a portion of the expanded and lateral cross-sectional view of a distribution of the individual adhesive strips which hold the elastomeric threads in the shank escutcheon portion of the stern-cheek member; Y Figure 11 is a schematic of a portion of a side cross-sectional and expanded view of another pattern distribution of adhesive aggregates which are attached to the elastomeric yarns in the leg escutcheon part of the gusseted member.

Detailed description of the invention The present invention will now be described in relation to the production of an elasticized containment system for absorbent articles, particularly disposable absorbent articles. The articles may be placed against or in proximity to a user's body to absorb and contain the various exudates discharged from the body, and it is proposed that they be discarded after a period of limited use. Items are not intended to be washed or otherwise restored to reuse. Although the present description will be made particularly in the context of a diaper article, it should be understood that the present invention is also applicable to other articles, such as caps, gowns, surgical covers, covers, incontinence garments for adults, sanitary napkins , children's underpants, and the like.

In addition, the invention will be described in the context of its various configurations and aspects. It should be appreciated that the alternate arrangements of the invention may comprise any combination which includes one or more of the various configurations and aspects of the invention.

With reference to Figures 1, 2, 3 and 4, a representative "" u "" item, such as a diaper 10, includes a front waistband portion 12, a back waistband portion 14, and a intermediate part 16 which interconnects the front and rear waistband portions, and a pair of laterally opposite side margins 20. Extending along the side margins 20 are the integrally formed gusset-fin members 19 which include a region of containment flap 144 and a leg shield region 142. The article has a bottom sheet layer 30, and a liquid-permeable top sheet layer 28 connected in a superimposed relationship to the bottom sheet layer. 32 is sandwiched between the top sheet layer and the bottom sheet layer, and an elastomeric component, such as an elasticized waist bag member 80, can optionally be connected to at least one of the bottom sheet and top sheet layers along at least one end margin 22 of the article.

The representatively shown article includes a pair of longitudinally opposite end margins 22, and a pair of laterally opposed elastically sided margins 20. The elasticized waist bag member 80 is connected and attaches to at least one of the lower sheet layers and of top sheet along at least one end margin 22 of article. The waist bag member shown 80 includes an expandable flange section 82 and an extended bag section.

* A | Z_ 84. The bag section 84 of the belt member / belt member 80 includes an essentially fixed edge portion 102 secured to article, and includes a folded and elasticated movable edge portion 104 which is longitudinally separated from the belt portion. fixed bord part 102. The bag section also includes a bag barrier layer essentially impermeable to liquid 106, and a layer of bag fabric 108 connected in a laminated front relationship with the bag barrier layer. A plurality of spaced laterally extending elastic bag members 110 are sandwiched between the bag barrier layer 106 and the bag fabric layer 108 to provide an elasticized waist bag composite 112 which is essentially folded sideways.

A fastening system 40 is operably connected and attached to the article in either or both of the laterally opposite end regions 72 of at least one of the front and back waistband sections, such as the illustrated back waistband 14. A panel member cooperative lateral _ >; 56 may be associated with each fastening system and may be constructed to be non-stretched, or may be constructed to be elastomerically stretchable at least along the laterally extending transverse direction 24 of the article. In addition, a holding tab 36 may be held to extend laterally outward from each side panel member 56.

In a particular aspect of the invention, the diaper article shown representatively may have a lateral dimension in the transverse direction 24, a longitudinal dimension in the longitudinal direction 26, the laterally opposite side margins and the longitudinally opposite end margins. The article provides a front waistband part 12, a rear back waistband part 14 and an intermediate part 16 which interconnects the front and back waistband parts. The article includes a lower sheet layer 30 having a pair of longitudinally and laterally opposite side extending margins 20. Each lateral margin has an outward concave end lateral edge contour 15 located in the designated leg opening regions 17. in an intermediate part 16 of each of the lateral margins. Each concave side edge contour 15 has a selected longitudinal length 54 along a length dimension 26 of the article 10. A top sheet layer permeable to the porous liquid 28 has a laterally extending width and a longitudinally extending extension. , and is connected in a superposed relationship to the lower sheet layer 30. An absorbent body structure 32 is sandwich-shaped and operably secured between the lower sheet layer 30 and the upper sheet layer 28. A composite member fin-shield provided separately 19 is connected to at least one of the upper sheet and lower sheet layers along each of the leg opening regions 17. The scuff-fin member 19 provides a section of shank shield 142 and a containment fin section 144. Each leg shield section 142 is configured to extend beyond and bridge through e its lateral edge contour ends concave outwards correspondingly 15 of the lower leaf layer 30, and is configured to provide a folded and elasticized lateral margin of the article. Each containment retainer section 144 is integrally formed with a corresponding one of the leg shield sections 142 and is positioned relatively inward therefrom to provide the sash member 19. Each containment fin section 144 has an edge essentially fixed 64 located closely to one side of one of the elasticized side margins 20, and has a folded distal movable edge portion 66. The gusset-fin member 19 includes a barrier layer 174 having a pair of side edges of the layer longitudinally and laterally opposing barrier members 140 and 141, and has a first major front surface 148 and a second major front surface 149. A fin-gusset fabric layer 176 may be composed of a non-woven fabric, and is placed desirably and is connected in an intermediate frontal relationship with the first front surface 148 of the shield-gusher barrier layer 174. The fin layer 176 includes a leg shield region 136, an exterior side portion 170 of the leg shield region, a containment fin region 63 and an interior side portion 62 of the containment fin region. The outer side portion 170 of the fabric layer 176 is arranged to wrap around at least one side edge of the barrier layer 174 and to extend inwardly therefrom along the second front surface 149 of the barrier layer. barrier. A first array of a first plurality of elastomeric, longitudinally extending and spaced apart members 138 is fastened and sandwiched between the barrier layer 174 and the fabric layer 176 within the leg shield section 142 of the fin member. of gusset 19. A second array of at least one longitudinally extending elastomeric member 68 is attached to at least the fabric layer 176 within each containment fin section 144 of the gusset-fin member 19. The first arrangements and second of the elastomeric members 138 and 68 can therefore provide a composite, substantially longitudinally folded and elastomeric, gusseted member 19.

The leg shield section 142 of each gusset fin 19 is configured to extend further and pass the concave side edge contours 15 of the bottom sheet layer 30 to provide an elasticized leg cuff in at least the intermediate portion. from the article. Additionally, each escutcheon section 142 is configured to bridge between the spaced-apart and opposite portions 21 and -23 of an associated concave side edge contours 15 of the lower foil layer 30. In particular, each section of The leg gusset is configured to extend further and bridge between the opposite spaced and spaced apart portions 21 and 23 and thus extend through a "mouth" of a "C" shaped partition generally formed by the terminal edge of its corresponding side edge contour 15. Each gusset member 19 can be operably fastened to the side surface to the inner body of the top sheet 28.

The various configurations of the invention may include two or more cooperating gusset fins 19, such as the laterally opposed gusset-fin pair shown. With respect to each the gusset fins can be arranged to be parallel or non-parallel to each other and each individual gusset fin can be straight and / or curvilinear.

In a particular aspect of the invention, the inner side portion 62 of the gusset-flap fabric layer 176 is arranged to be folded and wrapped around a pointed bent line d or other region. The resultant folded part can then be arranged to have operatively shaped or otherwise to enclose the second arrangements 6 of at least one elastomeric member extending longitudinally. ___ In another aspect of the invention, the barrier layer 174 can be configured to extend into the containment fin section 144 of the gusset fin 19, and the interior side portion 62 of the gusset fin layer 176 can arranged to wrap around the second side edge 141 of the barrier layer 174 to extend along the second major surface 149 of the barrier layer. In addition, the second set 68 of the at least one longitudinally extending elastomeric member can be clamped between the containment fin region 63 of the fabric layer 176 and a containment fin region 61 of the barrier layer 174 within the retaining flap section 144 of each gusset fin member 19.

Additional aspects of the invention may provide an absorbent article in which the lower sheet layer 30 may include a crotch region thereof having a crotch width 31 which is particularly narrow. In particular aspects the crotch width of the lower sheet layer can be up to about 240 millimeters. Desirably the crotch width of the lower sheet layer may not be more than a maximum of about 160 millimeters. Other aspects of the invention may provide an article in which the absorbent body 32 is constructed with a crotch width thereof which is also quite narrow. Desirably the crotch region of the absorbent body may have a crotch width 33 which may not be more than about 102 millimeters, and optionally is not more than about 76 millimeters, and in addition, the crotch width of the body Absorbent may be at least about 25 percent (%) of the width of the lower sheet layer 30 in the crotch region of the article. In still other aspects of the invention, each folded and elasticized and separated gusset fin 19 can be connected to at least one of the upper and lower sheet layers with a gusset fastener 172 which extends along each of the designated leg opening regions. Each escutcheon fastener 172 may be spaced from a longitudinally extending side edge, closely adjacent and associated with the absorbent body 32 by a gusset spacing distance of no more than about 51 millimeters. Alternatively, the gusset spacing distance may not be more than about 25 millimeters, and optionally, may not be more than about 13 millimeters, at least when measured within the crotch region 18 of the article. The various aspects of the invention configurations can provide distinctive combinations of softness, conformation to the body, reduced bulging between the legs of the user, reduced red marking of the wearer's skin and improved drainage protection.

Figure 1 is a top plan view representative of the diaper 10 of the present invention in its non-contracted and planar state (for example with all elastic-induced folding and contraction removed). The parts of the structure are partially cut to show more clearly the inner construction of the diaper 10, and the diaper surface that contacts the wearer faces the observer. The outer edges of the diaper define a periphery in which the longitudinally extending side edge margins are designated with the number 20 and the laterally extending end edge margins are designated with the number 22. The lateral edges define the openings of leg for the diaper, and optionally curvilinear and contoured. The end edges are shown as straight, but optionally they can be curvilinear.

The diaper 10 typically includes a porous liquid permeable top sheet 28, a bottom sheet impermeable to the liquid essentially 30; an absorbent structure 32, positioned and connected between the upper sheet and the lower sheet; a part of emergence management 46; and elastomeric members for elasticizing the diaper margins in the leg band and waistband regions. The emergence management part is placed in a liquid communication with the absorbent structure, and the absorbent structure includes a retention portion 48. The topsheet 28, the bottomsheet 30, the absorbent structure 32, the emergence management part 46 and the elastic members can be assembled in a variety of well-known diaper configurations. In addition, the diaper may include a relatively inward barrier flap system, such as retaining flap sections 144, positioned closely to one side of the leg bands of the diaper.

As shown representatively, the topsheet 28 and the bottomsheet 30 may be generally coextensive and may have length and width dimensions which are generally larger than the corresponding dimensions of the absorbent structure 32. The topsheet 28 is associated with and superimposed on the lower sheet 30, thereby defining the periphery of the diaper 10. The waistband regions comprise those upper parts of the diaper 10, which when worn cover or completely or partially surround the lower middle waist or torso of the wearer The intermediate region 16 lies between and interconnects the waist regions 12 and 14, and includes a crotch region 18 which includes that part of the diaper 10 which, when worn, is placed between the legs of the wearer and covers the lower torso of the leg. . user. Thus, the crotch region 18 is an area where emergence of repeated fluid from the diaper or other disposable absorbent article typically occurs.

The upper sheet 28 has a surface facing the body which is docile, soft feeling and n irritating to the wearer's skin. In addition, the topsheet 2 may be less hydrophilic than the retention portion 48, and sufficiently porous to be permeable to liquid, allowing the liquid to penetrate through its thickness. A suitable top sheet 28 can be made from a wide selection of fabric materials, such as porous foams, cross-linked foam, perforated plastic films, natural fibers (for example cotton or wood fibers), synthetic fibers (for example polyester fibers or polypropylene), or a combination of synthetic natural fibers. The topsheet 28 is typically used to help insulate the wearer's skin from liquids maintained in the absorbent structure 32. Various woven and woven fabrics can be used for the topsheet 28. For example, the topsheet can be composed of a blown fabric co-melted or joined by spinning polyolefin fibers. The upper sheet may also be a carded-bonded fabric composed of natural and / or synthetic fibers.

For the purposes of the present description, # - term "non woven tel" means a fabric of material which is formed without the aid of a textile process. The term "fabrics" is used to refer to all woven fibrous tissues, tissues and nonwovens.

The top sheet fabrics can be composed of essentially non-wettable and essentially hydrophobic material, and the hydrophobic material can optionally be treated with a surfactant or otherwise processed to impart a wettability and hydrophilicity. . In a particular embodiment of the invention, the topsheet 28 may be a polypropylene fabric bonded by non-woven yarn composed of fibers of about 2.8-3.2 denier formed into a fabric having a basis weight of about 20 grams per square meter ( g / square meter) and a density of around 0.13 gm / cc. The fabric can be treated on the surface with a selected amount of surfactant, such as about 0.28 percent of a TRITON X-102 surfactant available from Union Carbide, a business having offices in Danbury, Connecticut. The surfactant can be applied through any conventional means, such as spraying, printing, brushing or the like, The surfactant material, such as a conventional wetting agent, can be applied to a medial section of the upper sheet layer 28 to provide a greater wetting of the middle section, as compared to the rest of the upper sheet layer 28. In the In particular configurations, the width in the transverse direction of the middle section may be essentially equal to or less than the width in the transverse direction of the emergence management part 46. In the alternate configurations, the width of the medi section may be essentially the same a or less than a spacing in the transverse direction between a pair of adhesive strips or other joints used to secure the fin sections 144 containment on the topsheet 28 and to form a barrier seal resistant to runoff on the lower sheet 30.

The middle section treated with surfactant may be approximately centered with respect to the longitudinal center line of the diaper, and may extend along essentially the entire length of the top sheet layer. Alternatively, the middle section treated with surfactant can be constructed to extend along only a predetermined part of a top sheet length.

In the various configurations of the invention, the fabric layer employed in the gussets-gussets 19 and / or the waist flaps 84 can, for example, be constructed of fibrous material which is similar to the material comprising the top sheet 28, or similar to the material comprising the emergence management part 46. Examples of these materials include but are not limited to materials joined by spinning, meltblown-bonded laminate-bonded with spunbond (SMS), meltblown, spin-bonded yarn-blown laminate, spunbond, bonded knitweave fabric, knitted fabric bonded through air, coform, and hydrotex. Other conventional materials such as polymer films may also be incorporated within such barrier fin components. In particular aspects of the invention, the components of the barrier flap can be constructed of a material which is permeable only to gas, such as ambient air. The alternate configurations of the invention may include the barrier fins which are constructed of a material which is resistant to the passage of the aqueous liquid, such as urine therethrough. For example, the barrier fin sections of the fin-gusset members may include a fabric layer which is constructed of a spin-melt-spunbonded (SMS) spunbond laminate. For example, the barrier fin sections of the fin-gusset members can be constructed of an SMS material having a basis weight of about 0.60-0.75 ounces / square yard (about 20-25 g / square meter). The spunbonded layers may be composed of polypropylene fibers, and the meltblown layer may be composed of meltblown polypropylene fibers. Alternatively, the barrier fins can be constructed using a layer of spunbonded fabric having a basis weight of about 0.4-1.0 ounces / square yard (about 13-33 g / square meter). The spunbond fabric layer may consist of fibers made of polypropylene or of a polypropylene / polyethylene copolymer composition.

Where a thermally bonded fabric was used as the fabric layer, it is desirable to minimize the amount of bonded area on the fabric to improve the visual and tactile softness characteristics of the gusset-fin member. Preferably, the bonded area of the fabric is less than 25 percent. More preferably, the bonded area of the fabric is less than 15 percent. The percentage of bound area can be measured by an analysis of an impression of the bonding pattern produced by means of the engraving / joining pattern matrix.

In the various configurations of the invention wherein the selected materials or components, such as the barrier fins provided by the containment flap sections 144 and / or the waist bag sections 84 are configured to make the gas permeable while having a resistance and permeability limited to the aqueous liquid, the liquid-resistant component or material can have a construction which is capable of holding a hydro head of at least about 45 centimeters of water essentially without a runoff therethrough. A suitable technique to determine the resistance of a material to the penetration of the liquid is the standard of federal test method FTMS 191, method 5514, dated December 31, 1968.

The lower sheet 30 may be composed of a liquid-permeable material, but preferably comprises a material which is configured to be essentially impermeable to liquids. For example, a typical bottom sheet can be made of a thin plastic film or other material impervious to flexible liquid. Such "flexible" materials are docile and will easily conform to the general shape and contours of the user's body. The lower sheet 30 can help to prevent the exudates contained in the absorbent structure 32 from wetting the articles such as the bed sheets and the overlays that make contact with the diaper 10.

In the particular embodiments of the invention, the bottom sheet 30 is a polyethylene film having a thickness of from about 0.012 millimeter (0.5 mil) to about 0.051 millimeter (2.0 mil). In the embodiment shown, for example, the bottom sheet is a film that has about 0.032 m (about 1.25 mil). The alternate constructions of the upper blade may comprise a layer of woven woven fibrous web which has been fully or partially constructed or treated to impart a desired level of liquid impermeability to selected regions of the adjacent lower blade. or close to the absorbent body. For example, a lower cloth type sheet may be composed of a polypropylene spunbonded cloth of approximately 0. ounces / square yard (about 17 g / square meter) of base weight, which is laminated and thermally bonded to a thin-stretched polypropylene film having a thickness of about 0.0006 inches (about 0.015 millimeters) and its base film weight of about 14.5 g / square meter. The upper sheet 30 typically provides the outer article cover. Optionally, however, the article may comprise a separate outer cover member which is in addition to the lower sheet.

The lower sheet 30 may optionally include a microporous "breathable" material which allows the vapors to escape from the absorbent structure 32 while still preventing the liquid exudates from passing through the lower sheet. For example, the lower sheet with breathing capacity can be composed of a microporous polymer film or a nonwoven fabric which has been coated or otherwise treated to impart a desired level of liquid impermeability. For example, a suitable microporous film is a PMP-1 material which is available from Mitsui Toatsu Chemicals, Inc., a company having an office in Tokyo Japan.; or a polyolefin film XKO-8044 available from 3M Company of Minneapolis, Minnesota. The lower sheet may also be engraved or otherwise provided with a matte finish to exhibit a more aesthetically pleasing appearance. The size of the lower sheet 30 is typically determined by the size of the absorbent structure 32 and the exact diaper design selected. The lower sheet 30, for example, may have a generally T-shape, a form generally of I or a modified hourglass shape, may extend beyond the terminal edges of the absorbent structure 32 for a selected distance, such as a distance within the range of about 1.3 centimeters 5.0 centimeters (about 0.5 to 2.0 inches) to provide lateral margins.

The top sheet 28 and the bottom sheet 30 are connected or otherwise associated together in an operable manner. As used herein, the term "associated" encompasses configurations in which the top sheet 28 is directly attached to the bottom sheet 30 by attaching the top sheet 28 directly to the bottom sheet 30, and configurations wherein the top sheet 28 is attached to the lower sheet 30 by attaching the upper sheet 28 to intermediate members which in turn are fixed to the lower sheet 30. The upper sheet 28 and the lower sheet 30 can be fixed directly to each other in selected regions, such as in areas along the periphery of the diaper, by means of a suitable fastening mechanism (not shown), such as an adhesive, sonic joints, thermal joints or any other fastening mechanism known in the art. For example, a continuous and uniform adhesive layer, a patterned layer of adhesive, a pattern of sprayed adhesive or an array of separate lines, swirls or adhesive construction points can be used to secure the top sheet 28 to the bottom sheet 30. It should be readily appreciated that the fastening mechanisms described above can also be used to interconnect and assemble together the various other component parts of the article described therein.

In the representatively shown embodiment of the invention, the top sheet layer 28 is positioned and secured in a front relationship with the bottom sheet layer 30 to retain and hold the retention portion 48 and the emergence management portion 46 between the layer of lower leaf and upper leaf layer. The marginal side regions of the top sheet layer 28 are operably connected to the corresponding marginal side regions of the bottom sheet layer 30. Each of the marginal side regions subject to the top sheet and bottom sheet layers are located laterally toward outside of its corresponding associated side edge region of the emergence management part 46. In the particular configurations of the invention, the topsheet 28 may include the attached marginal end regions, which are located longitudinally outward of the replenishing recesses. end edge of the retention portion 48 and / or of the emergence management portion 46. Similarly, the bottom sheet 30 may include the attached marginal end regions, which may be located longitudinally outside the end edge regions. of the retention part and / or the emergence management part.

The leg elastic members, such as those provided by the stretched leg gussets 142 are positioned on one side of the periphery of the diaper 10 along each of the longitudinal side edge regions 20. The elastic members of The leg can be connected to either or both of the upper and lower sheet layers to provide the elasticated side margins of the diaper article, and can be arranged to pull and retain the diaper 10 against the legs of the wearer to provide the leg cuffs or elastic leg bands. The elastic waist members, such as those provided by the flange section 82 of the waist member 80, may also be placed on one side of either or both of the end edges of the diaper 10 to provide the elasticated waistbands, The elastic members in the leg band and waistband sections of the article are secured to the article in an elastically contractible condition so that in a normal configuration under tension, the elastic members contract effectively against the article. The elastic members can be secured in an elastically contractible condition in a number of ways; for example, the elastic members can stretch and secure while the designated component of the article is in a non-contracted condition. Alternatively, the component can be contracted, for example, by folding, and the elastic members can be secured and connected to the component while said elastic members are in their relaxed and undrawn condition. Still other means, such as the heat shrinkable elastic material can be used to fold the designated component sections of the article.

The elastic members, such as the elastomeric members 110, 118, 138 and 68, can have any of a variety of configurations. For example, the width of the individual elastic members can be varied from about 0.08 millimeters (0.003 inches) to about 25 millimeters (1.0 inches) or more. The elastic members may comprise a single strand of elastic material, or may comprise several • • • parallel or non-parallel threads of elastic material, and the elastic members can be applied in a rectilinear or curvilinear arrangement. Where multiple threads are employed, individual threads can be constructed to provide essentially equal elastic forces, or can be constructed to provide different elastic forces. For example, the individual threads may be of a different diameter or of another size or may be configured with different amounts of elongation to thereby provide a gradient or other variation of the elastic stresses. Where the threads are not parallel, two or more of the threads may intersect or otherwise interconnect within the elastic member. The elastic members may be fixed to the designated diaper components in any of several ways which are known in the art. For example, the elastic members can be ultrasonically bonded, sealed with heat and pressure using a variety of bonding patterns, or adhesively bonded to the diaper 10 with selected models or patterns of hot melt adhesive or otherwise. For example, sprinkled or swirled adhesive patterns can be employed.

In the particular embodiments of the invention, for example, each elastic yarn is typically within the range of about 77-1050 decitex (dtx). In addition, the elastics can be generally straight or optionally curved. For example, the curved elastics can be arched inward toward the longitudinal centerline of the diaper. In particular arrangements, the curvature of the elastics can be configured or placed symmetrically in relation to the lateral center line of the diaper. The curved elastics can have a reflex type of arcuate curved inward curved outward, and the center longitudinally of the elastics can be off center by a selected distance to either the front or back diaper waistband to provide the desired notch and appearance .

Conventional articles have several barrier fin structures incorporated, such as containment fins 144 and waist bag sections 84, in their waistband and / or leg band regions. For example, such articles have typically incorporated a single layer piece of multiple layers of material, such as polymer films and non-woven film laminates, into the waistband portion of the article along the lateral transverse direction for form a dam or waist flap. The materials, however, typically exhibit similar behavior. When the materials are stretched, they have a tendency to narrow, thus reducing their effective widths. By tapering downwards, they tend to form relatively large corrugations or grooves which extend essentially along the direction of stretching. The presence of such corrugations can cause the barrier fins, particularly the waist flaps, to fold or collapse on themselves, thereby reducing the ability to remain open to receive and trap waste materials from the body. Additionally, when conventional materials contract, they tend to decrease in overall stiffness, and this decrease in composite stiffness can again allow the barrier fins to bend or collapse on themselves, thereby reducing their effectiveness. It has been discovered that the particular barrier fin structures, such as the laminates incorporating the individual spaced elastic threads, can provide structures which can overcome the disadvantages of the previous structures. When the laminates are stretched with yarns of the invention they essentially avoid the corrugation effect in the direction of the stretching typically seen through the plane of the barrier flap and along the proposed stretch direction. Desirably, the amount of stretching does not exceed the amount of elongation at which the elastic yarns were assembled in the laminate. When it is completely stretched and elongated, the laminate with wires can lie essentially flat. By elastically relaxing and contracting the yarn laminate, fine corrugations of sufficient size and frequency can be provided with the valleys or grooves of the corrugations generally aligned to extend essentially perpendicular to the direction of contraction. Fine corrugations can improve the rigidity of the fin structure and can improve its ability to remain open to receive waste materials.

The yarn laminates of the present invention essentially prevent shrinkage when stretched. Additionally, the geometry of the laminates with yarns themselves plays an important role in the operation of the materials when used as a barrier dam structure, such as the containment fin and / or belt dam structures shown. The placement of the threads can also play a role in the functionality of the various configurations of the sheets.

It has been found, however, that identifications of conventional types of materials or families of materials have not been adequate to derive barrier fin structures that are sufficiently effective and reliable. It has been found that the performance and effectiveness of the barrier fin structure depends on the particular combinations of properties and performance characteristics of the materials used to assemble and construct the composite barrier fins. For example, the incorporation of a fin composed of a polyurethane film or a film laminate in the waistband of the article, and the placement of a fin composed of a nonwoven SMS fabric laminate (joined by spin-blow with fusion- spun bonded) in the waistband of the article may not have reliably provided a sufficiently effective sweeping fin structure. It is also important to configure the materials with particular physical properties, m and one of the desired physical properties is the rigidity of the fin member.

The desired stiffness of the sweep member can be achieved in several ways. For example, the contributing factors include the basis weight of the fin materials, the rigidity or modulus of the individual components, the presence of the adhesive or other bonding materials added to the sheets within the fin member, the pattern and distribution of the adhesive. or of applied joints, the presence of welding or ultrasonic treatments, the number and elongation of the individual elastic threads used in the barrier fin structure, the geometry of the placement of the thread inside the barrier fin, the presence and alignment of the corrugations within the barrier fin, and the number of layers of components incorporated within the barrier fin.

Particular aspects of the invention may include distinctive combinations of component sizes and component rigidities. For example, the stiffness of the containment fin may have a Gurley stiffness value, as measured on a sample taken along the lateral transverse direction 24 of the article, which is at least about 10 milligrams. force (mgf). In other respects, the Gurley stiffness in the transverse direction in the containment flap section may not be more than about 250 mgf, and optionally, may not be more than about 1 d. 60 mgf to provide the improved benefits. In addition, the leg gusset section may have a rigidity value Gurley as measured in a sample taken along the lateral transverse direction 24 of the article, which is at least about 11 milligrams-force (mgf), desirably is at least about 30 mgf. In additional aspects, the Gurley stiffness in the transverse direction in the leg shield section may not be more than about 250 milligrams-force, and optionally, may not be more than about 120 milligrams-force pair i provide the improved benefits. In the various configurations of the invention, the Gurley stiffness of the leg gusset section (as measured with respect to the sample taken along the lateral transverse direction of the absorbent article) is essentially equal to or greater than the Gurley stiffness in FIG. the transverse direction of the containment section of the fin-gusset component.

Referring again to Figures 1, 2 and 3, the diaper article shown 10 may optionally have an elasticized waistband provided by a waist bag member 80 which may include a flange section extending laterally and longitudinally 82, and a longitudinally extending laterally extending barrier or bag section 84. The flange section may, for example be connected to the side surface to the body of the upper blade 28. The bag or fin section 84 of the member The waist bag 80 includes an essentially fixed edge portion 102 which is secured to the article along d immediately to one side of the boundary of the flange section 82 and includes a folded and elasticated movable edge portion 104 which is separate longitudinally of the fixed edge portion 102 by a selected distance. The po bag section thus provides an operable waist dam and a waist flap construction. The bag section may also include a bag barrier layer essentially impermeable to liquid 106, and a layer of bag fabric 108 which is connected in a front relationship with the bag barrier layer. The bag fabric can, for example, be composed of a woven or non-woven fabric, and in the arrangement shown, the fabric layer is desirably a nonwoven. A plurality of laterally extending elastic bag members 110 are placed in a sandwich shape operably connected between the bag barrier layer 106 and the bag fabric layer 108 to provide a composite elasticated waist bag 112, which is folded over. essentially along the lateral transverse direction 24 and is essentially stretchable at least along the transverse direction. Similarly, the elastic members 118 may be arranged within the composite 112 to operatively elastize the flange section 82. The arrangement shown includes the elastic members which are essentially aligned in parallel to one another, but optionally may include other separate configurations and alignments. d the elastics. Desirably, the fabric layer 108 is arranged to be positioned against the wearer's skin, even when the barrier layer 106 can optionally be designated to be immediately placed on one side of the wearer's skin. Some configurations for the waist bag member 8 are described in the United States of America patent application series number 560,525, which was filed on December 1, 1995 by DR Laux and was titled "ABSORBENT ARTICLE WITH ELASTIC MARGINS AND CONTAINMENT SYSTEM IMPROVED "(attorney's issue number 11,091), whose entire description is incorporated herein by reference in a manner that is consistent with the present disclosure.

The fin-gusset barrier layer 174 may be composed of a barrier of materials, such as polymer films, fabrics or combinations thereof, having a relatively low permeability to the aqueous liquid. The polymer films can, for example, be composed of polyolefins, polyesters, polyamides and the like, as well as combinations thereof. The fabrics may be woven or non-woven, and the nonwoven materials may include spunblown-melt-spunbonded (SMS) fabrics, meltblown fabrics, calendered nonwoven sheets and the like, as well as combinations thereof. . With respect to the passage of the liquid through its thickness, the barrier layer is constructed to exhibit a hydro head of resistance which is sufficient to provide an operably effective barrier against the passage of liquids, such as from urine.

The gusset-fin barrier layer 174 may, for example, be composed of a recorded and set film having a thickness of about 0.015 millimeters (about 0.0006 inches), such as a CT XEM400.1 film or a film; blown having a thickness of about 0.010 millimeters (about 0.0004 inches), such as an XSF-367 film. Suitable films are available from Consolidated Thermoplastics, a business having offices in Chippewa Falls, Wisconsin. The barrier layer may also be composed of a thin-stretched film having a thickness of about 0.0089 millimeters (about 0.00035 inches) such as an XP 1024A film available from Edison Plastics, a business having offices in Macalester, Oklahoma. Alternatively, the barrier layer can be constructed with a breathable film having a thickness of about 0.0050 millimeters (about 0.0002 inches) such as a BF-303 film available from Exxon Plastics, a company having offices in Houston, Texas .

The fin-gusset fabric layer 176 desirably has a substantially continuous spreading layer, and the gusset region 136 of the fabric layer is desirably contiguous with the containment fin region 63. In addition, the fabric layer 176 it can be a unitari layer essentially unsegmented. The fin-gusset fabric can be composed of a variety of materials, such as non-woven, low-weight, fine-denier fabric material Examples of suitable non-woven fabrics include materials bonded by polypropylene spinning; materiale joined by polypropylene-polypropylene bicomponent yarn meltblown materials, SMS materials, carded fabrics bonded through air, knitted and knitted carded fabrics and the like, as well as the combinations thereof. In particular arrangements, the fabric may be composed of a polypropylene bonded with yarn which includes about 0-8 percent of a polyethylene copolymer, desirably includes about 3 percent of a polyethylene copolymer.

In the desired arrangements, the fin-gusset fabric layer 176 may have a basis weight of not less than about 3.4 g / square meter (about 0.1 ounces / square yard). Alternatively, the basis weight may not be less than about 10.2 g / square meter (about 0.3 ounces / square yard), and optionally may not be less than about 13.6 g / square meter (about 0.4 ounces / yard) square). In other aspects, the fabric layer 136 may have a basis weight of no more than about 272 g / square meter (about 8 ounces / square yard). Alternatively, the base weight may not be more than about 136 g / square meter (about 4 ounces / square yard), and optionally it can be more than about 34 g / square meter) around an ounce / square yard).

For example, the fin-escudet fabric layer may be a non-woven fabric composed of polypropylene fibers wherein the fiber denier is no more than about denier, and the basis weight of the fabric is about 17 g / l. square meter (about 0.5 ounce / square yard). Alternatively, the fiber denier in the fabric layer may be more than about 3 denier, and optionally may not be more than about 2.5 denier.

The desired arrangements of the inventive article can be configured as each gusher-flap 19 directly or indirectly connects to a designated section of a face-to-face surface facing the inside of the top sheet 28 layer. Optionally, the escutcheon-flap can is connected directly or indirectly to a designated surface region of the lower sheet layer 30. In the embodiment illustrated in Figure 1, the elasticized gusseted fins 19 extend along essentially the entire length of the intermediate region 16 of the diaper 10. Alternatively, the fin-gusset members may extend to the entire length of the diaper 10, or any other suitable length that provides the desired elastically contractable line array for the particular diaper design.

In particular, each gusset fin is connected along its concave terminal side edge contour to outside of the bottom sheet layer. Each of the lateral edge contours may have a longitudinal extension 54 which desirably extends completely through the crotch region 18, and which may extend along at least about 20 percent of a longitudinal tram total 180 of the article. In the additional configurations, the longitudinal extension 54 of the lateral contour can be at least about 30 percent, alternatively it can be less than about 40 percent, and optionally it can be up to 100 percent of the longitudinal extent total 180 of the article.

The diaper leg elastics shown 10 can be provided by the distinctive leg escutcheon sections 142 of the gusset fins 19. Each leg gusset section 142 can have an extension thereof which extends along at least about 20 percent of the total longitudinal length 180 of the article. E other configurations, each gusset section 142 may extend for at least about 30 percent, and alternatively about at least about 40 percent of the longitudinal extent 180 of the article to provide improved effectiveness. If desired, each leg gusset section may extend along a length which may be up to 100 percent of the total longitudinal length of the article to provide additional packing and restraint. Alternatively, each leg gusset section may extend along a length which is not more than about 80 percent, optionally it is not more than about 70 percent of the total longitudinal length of the article to provide the desired operation.

Additionally, each leg gusset section 142 may be in a bridge configuration through its associated concave side edge contour 15 of the lower sheet layer along an extension 182 which is at least about 20 cm long. 20 percent of the longitudinal extension 180 of the article. In other configurations, each leg shield section 142 may be in a bridge configuration through its associated concave side edge contour 15 of the lower sheet layer along an extension 182 which is at least about 30 percent, and alternatively is at least about 40 percent of the length of the longitudinal section 180 of the article to provide improved effectiveness. If desired, each leg gusset section may be in a bight configuration along a length which may be up to 100 percent of the longitudinal extent of the article to provide containment and packing. Alternatively each leg gusset section may be in a bridge configuration along a length which is not more than about 80 percent, and optionally is not more than about 70 percent of the total length extension of the article to provide the desired performance cost effectiveness.

In particular aspects of the invention, the gusset fins 19 are configured to essentially avoid intersecting the locations of the waist bag members 80. Thus, the gusset fins can be constructed to end up in positions which are spaced apart from each other. the terminal edges of the bag sections 8 of the waist bag members.

With reference to Figures 1, 4 and 6, each of the lateral margins of the lower sheet layer 3 generally defines a plane thereof, and each of the leg shield sections 19 is constructed to extend beyond and pass through. of the associated concave side edge contour 15 of the lower sheet layer 30 at a selected distance 184, and in an array which lies essentially in and essentially parallel to the plane of its associated lower sheet side margin.

In the various arrangements of the invention, each leg gusset section 142 may include a leg gusset region 134 of the barrier layer 174, a leg gusset region 136 of the fabric layer 176 and a first array of one first plurality of longitudinally extending, spaced elastomeric members 138 sandwiched between the leg gusset region of the barrier layer and the corresponding cooperating portions of the leg gusset regions of the fabric layer to provide a composite elastomeric which is essentially longitudinally folded. In particular arrangements, the barrier layer region 134 and the cloth layer region 136 can be essentially coextensive. The elastomeric members may be arranged in any desired alignment or configuration, such as parallel, non-parallel, straight and curvilinear or a combination thereof. Alternatively, the full leg gusset portion of the gusset fin, or the gusset fin portion of the gusset fin, or the full gusset fin can also be placed in the absorbent article in a parallel, non-parallel, straight configuration , curvilinear or in «Any combination thereof. Desirably, the fabric layer region 136, particularly the folded outer side portion 170, is arranged to be positioned against the wearer's foot. Optionally, the barrier layer region 13 can be designed to be immediately placed on one side of the wearer's skin.

In particular aspects, the illustrated barrier layer region 134 is essentially coextensive with the corresponding leg shield section 142 at least the part of the leg shield section which bridges and extends through the spacing in C-shape formed by the terminal edge of the corresponding lateral contour of the lower sheet 30. The barrier layer 174 may or may not extend into the adjacent containment fin section 144 of the gusset-fin member as desired.

With reference to the representative arrangements shown in Figures 4 and 6, the leg gusset region 136 of the fabric layer 176 can be placed and immediately attached to one side of the first relatively interior surface 148 of the barrier layer 174. outer side portion 170 of the fabric layer extends beyond the first relatively outer side edge 140 of the barrier layer 174, and the fabric layer has a first region or fold line designated 188 which is generally placed on one side of the lateral edge 140 of the barrier layer. The fabric layer side part 170 is folded and operatively wrapped around the side edge of the barrier layer 14 to thereby enclose the wrapped edge resulting from the barrier cap. The side portion of the barrier layer 170 s extends along the second major surface 149 of the barrier layer 174 in a direction toward the article center. Desirably, the side cloth portion 170 lies on a substantial totality of the second major surface 14 of the barrier layer region 134 in the leg shield section 142, and substantially completely covers the second major surface of the backing portion. the barrier layer which is located in the leg shield section 142. Thus, the fabric side portion 170 may be interposed between the barrier layer and the wearer's skin.

The fold line 188 is spaced from the first edge 140 of the barrier layer by a distance 190 (FIG. 6) of no more than about 8 millimeters. Alternatively, the fold line 188 is separated from the first edge 140 of the barrier layer by a distance which is not more than about 4 millimeters and optionally is not more than about 2 millimeters to provide the desired operation. Desirably, the spacing distance 190 is essentially zero. If the separating distance 190 is very large, there may be excessive runoff or transmission of the liquids around the edge of the barrier layer.

Each of the elastic members 138 of the leg shield section 142 is sandwiched between the barrier layer 174 and at least a portion of the fabric layer 176 in the leg shield section of the fin. gusset 19. Structures erected together and each elastic member is attached to at least one of the sweeping and fabric layers with a selected bonding pattern, such as a pattern of adhesive. In particular arrangements, the elastic members 138 may be fastened with one or more individual adhesive strips 74, as representatively shown in Figures 9 and 10. Each strip of adhesive 74 is configured to hold one or more of the elastomeric members 138 to at least one d of the fabric and barrier layers.

In a particular aspect of the invention, the individual adhesive strip can be spatially separated from the adhesive strips adjacent laterally by a discrete distance, as representatively shown in Figure 10. With the arrangement illustrated, each adhesive strip 74 is configured to essentially hold to one of the elastomeric members 138 at least one of the barrier and fabric layers, and the barrier layer 174 and the fabric layer 176 in the leg shield section 142 are essentially not attached to each other in the regions intermediates 90 located between the immediately adjacent members of the first plurality of elastomeric members 138. Thus, each elastic member of the first plurality of elastomeric members 138 in each of the leg gusset sections 142 can be attached to at least one of the barrier layer 174 and / or the fabric layer 17 with a strip of adhesive provided in an essentially separate manner 74. The individual spatially separated adhesive strips essentially avoid touching each other. As a result of this, the essentially n-90 intermediate regions can fall into folds and more effectively inform a cushioned topography.

In other arrangements of the invention shown representatively in Figure 11, a pattern distribution with adhesive 76 can be configured to concentrate the placement of the adhesive at the locations of the elastic members 138, while delivering significantly reduced amounts of adhesive in the areas between the elastic members 138, in the space of the boundary 164 between the restraining fin elastics and the leg shield elastics, and / or in the fold line area 188. In additional aspects, the barrier layer 174 and the Fabric layer 176 in the leg gusset section 142 can be attached to each other with a smaller amount of reduced adhesive in one or more intermediate areas which are interposed between the immediately adjacent members of the first plurality of elastomeric members 138, in comparison with the amount of adhesive located in the positions of the first plurality of the elastomeric members to ensure and laminating the first plurality of the elastomeric members. Similarly, where the barrier layer extends into the containment flap section 144, the barrier layer 174 and the fabric layer 176 in the containment flap section 144 can be secured to each other with a reduced adhesive amount in the same manner. one or more intermediate areas which are interposed between the immediately adjacent members of the second plurality of elastomeric members 68, as compared to the amount of adhesive located at the positions of the second plurality of elastomeric members to ensure lamination of the second plurality of members elastomeric Regarding the containment flap section 144, the second array of at least one elastomeric member can be attached to at least one of the fabric layers and barrier-shield 174 and 176 with an increased amount of adhesive, as compared to the amount of adhesive located in the space of the adhesive. limit 164 between the first arrangement of the leg-gusset elastics 138 and the second arrangement of the containment tab elastics 68. Where the containment fin section 144 includes a second array having a second plurality of elastomeric members, the members elastomeric materials can be attached to at least one of the barrier and gusseted fabric layers 174 and 176 (particularly the fabric layer) with a greater amount of increased adhesive, compared to the amount of adhesive located in the intermediate regions. which are placed between the immediately adjacent members of the second plurality of the restraining fin elastic. Where the sweep layer 174 extends into the containment fin section 14 and the second array of restraining fin elastics includes a second plurality of elastomeric members 68, the second plurality of elastomeric members can be laminated to the barrier layers and gusset-fin fabric with a greater amount of adhesive compared to the amount of adhesive located in the intermediate regions that are placed between the immediately adjacent members of the second plurality of retaining tab elastics.

While such arrangements may or may not have discrete spacing between the area arrangement of the applied adhesive 76, it has been noted that this arrangement can provide a sufficient bond of adhesive without unduly poking the leg gusset part of the gusset-fin compound. This arrangement can also form a more cushioned topography on the escutcheon part of the stern-gusset leg.

Suitable techniques for applying a desired adhesive pattern are described in the United States patent.

U.S. Patent No. 5,340,648 entitled "LONG ELEMENT COMPRISING ADHESIVE HELICOIDALLY IN PATTERN" issued August 23, 1994 to N. Rollins et al .; U.S. Patent No. 5,501,756 issued March 26, 1996 to N. Rollins et al .; and U.S. Patent No. 5,507,909 issued April 16, 1996 to N. Rollins et al. The full descriptions of these documents are incorporated herein by reference in a manner that is consistent therewith.

All the elastomeric members 138 can be fastened on a single surface of the leg shield region 134 of the barrier layer 174. For example, all the elastomeric members 138 can be fastened on the first major surface 148 and covered by the primary base part. of the leg gusset region 134 of the fabric layer 176 (Figure 7). Alternatively, all of the elastomeric members 138 may be held on the second major surface 149 and covered by the outer side portion 170 of the fabric layer (Figure 8).

In another aspect, each of the leg gusset sections 142 may be configured with the first array of elastomeric members 138 including a first sub-set of spaced-spaced elastomeric members attached laterally to the first major surface 148 of the barrier layer 174, and a second sub-set of spaced apart laterally spaced elastomeric members attached to the second major surface 149 of the barrier layer (Figures 4 and 6). In the desired arrangements, the first sub-set of elastomeric members may be laterally offset and staggered with respect to the second sub-set of elastomeric members. More particularly the first subgame of elastomeric members can be arranged with a first set of gaps between the adjacent members and the second subgame of elastomeric members can be arranged with a second set of gaps between the adjacent members. When viewed through the thickness dimension of the barrier layer 174, the first subgame d elastomeric members are essentially aligned with the second set of separations, and the second sub-set of elastomeric members are essentially aligned with the first set of separations.

In yet another aspect of the invention, adjacent elastomeric members 138 may have a spacing distance 139 (Figure 6) therebetween which is not less than about 1 millimeter. Alternatively, the spacing distance may be no less than about 3 millimeters, and optionally may be no less than about 4 millimeters. In additional aspeof the invention, the adjacent elastomeric members 138 may have a spacing distance 139 therebetween which is not more than about 45 millimeters. Alternatively, the spacing distance may not be more than about 35 millimeters, optionally it may not be more than about 25 millimeters The elastomeric members 138 within the leg shield section 142 can be configured to provide a composite elastic tension which is not less than about 50 grams / force when the compound of the leg-shield section is stretched to a length which e 90 percent extended length not contracted essentially flat. The composite elastic tension may alternatively be less than about 75 grams / force and optionally may not be less than about 100 grams-force torque to provide an improved combination of comfort and containment. In other aspeof the invention, the elastomeric members 13 within each leg gusset section 142 can be configured to provide a composite elastic tension which is no more than about 300 grams-force when the composite leg gusset section is stretched to 90 percent of its length not contracted flat. The composite elastic tension may alternatively not be more than about 250 grams / force and optionally may not be more than about 200 grams / force to provide the desired combinations of comfort and containment.

In the various configurations of the invention, each leg gusset section 142 may have a width "Lateral 186 (Figure 6) which is not less than a minimum d around 13 millimeters. The lateral width of the leg gusset section can alternatively not be less than about 19 millimeters, and optionally it may not be less than 25 millimeters. In further aspects of the invention each leg gusset section 142 may have a lateral width 186 which is not more than about 104 millimeters. The lateral width of the leg gusset section may alternatively not be more than about 76 millimeters, optionally it may not be more than about 51 millimeters Additionally, particular aspects of the invention may be configured with each leg gusset section having a gusset width 186 which is greater than a lateral width of the fin section. corresponding containment 144.

In the desired configurations, each leg gusset section 142 may extend laterally beyond its associated lateral edge contour 15 of the inner leaf layer 30 by a skirt distance 184 of not less than about 3 millimeters. Alternatively, the distance d skirt may not be less than about 6 millimeters optionally it may not be less than about 9 millimeters, at least within the crotch section 18 of the article. In other aspects of the invention, each leg gusset section 142 may extend laterally beyond its associated lateral edge contour 15 of the backing sheet layer 30 by a skirt distance of no more than about 6 millimeters. Alternatively, the skirt distance 184 may be more than about 45 millimeters, and optionally may not be more than about 35 millimeters at least within the crotch section 18 of the article, as to provide comfort and packings. improved. It is also desirable to set the skirt distance to provide essentially complete coverage of the user's buttocks The various configurations of leg gusset section 142 can provide a plurality of elastomeric longitudinally extending elastomeric members which are laterally spaced apart from the longitudinally extending end lateral edge d of the lower sheet layer by a discrete distance, at at least within the crotch region of the article. Tale elastomeric laterally spaced members can essentially avoid having a direct connection to said lower leaf layer and can essentially avoid providing a direct folding of the lower sheet layer in their crotch region.

As shown representatively in Figures 4 and 6, each leg shield section 142 is connected to article, particularly the body facing surface d of upper sheet 28, with a leg shield fastener 17 which holds the gusset section 142 essentially parallel to a plane generally defined by its associated side margin of the lower sheet 30. More particularly, the gusset fastener 172 includes an article fastener which secures the leg gusset section 142 to the article beside the fastener. its associated concave end side edge contour 15 out of the bottom sheet layer 30 along essentially a full length of the side edge contour within which the leg shield 142 and its correspondingly associated side edge contour 15 are coextensive . In particular aspects of the invention, securing the escutcheon section to the article essentially ends in a luga which is laterally outside the absorbent body structure 32, at least within the crotch portion 1 of the article. Thus, securing the leg gusset section to the crotch part article essentially terminates at a location which is laterally outside the retention portion 48. Additionally, securing the crotch section 142 to the crotch portion d of the article can be terminated essentially at a location which is laterally outside the wrapping sheet 70. The arrangements shown, for example, the leg shield fastening 172 may have a generally U-shaped configuration, with the bottom of the last of U extending generally longitudinally and the arms of the U-shape generally extending laterally. The U shape shown is angular, but may not be angular if desired.

! With reference to Figures 1 and 4, additional aspects of the invention may include a gusset permeate joint 130 which holds a terminal side edge of the upper sheet 28 and / or the lower sheet 30 to the section d 5. leg gusset 142 at least within the crotch region of the article. The perimeter junction 130 may extend through the full longitudinal extension of diaper 10. The perimeter junction 130 may optionally be configured so as not to extend over the entire extension of the perimeter. overlaps the escutcheon section 142 with the terminal side bord margins of the upper and lower leaf layers which correspond to each of the sections of escutcheon 142. In particular aspects, the perimeter junction of escutcheon 130 has a longitudinal extension 132 of no more than about 90 percent of the total general length 180 of article. The longitudinal extension 132 of the gusset permeate joint may alternatively not be more than about 80 percent, and optionally it may not be more than about 60 percent of the length of the article. As a result d This, a part of either or both of the longitudinal extern portions 150 of each gusset section 142 can move its immediately adjacent portions of the lateral margin of the upper and lower leaf layers, essentially independent, while causing side margins of the top sheet and bottom sheet layers within the crotch section of the article move in substantial correspondence and compliance with the gusset section part 142 located in the crotch section.

The perimeter or gusset junction 130 may be an essentially continuous joint, or may be an alternately discontinuous joint composed of an irregular regular pattern of fasteners. In the illustrated configuration, for example, the gusset perimeter junction can be provided by a selected pattern of discrete sonic joints which are distributed over a selected joint area. The joint area can have a lateral width which is at least of about 0.2 centimeters, and alternatively e of at least about 1 centimeter. In other aspect the side width of the joint area can be up to about 8 centimeters, and optionally, it can be up to about 15 centimeters to provide an improved performance. The gusset perimeter joint can be essentially rect or can be curved for essentially follow the finishing edges of the top sheet and / or bottom sheet layers. In addition, the laterally outer edge of at least a portion of the perimeter junction 130, particularly within the crotch region of the article, can be essentially cotermined with the lateral edges of the top sheet and / or bottom sheet layers. to provide an improved performance aesthetics.

Each leg gusset section 142 includes a first array of a first plurality of two or more longitudinally extending elastomeric members 13 which are laterally spaced outwardly from the edge of the side edge 15 of the bottom sheet layer 30 a distance Discreet, at least within the region d crotch 18 of the article. In the desired arrangements, the laterally spaced elastomeric members essentially prevent having a lamination on or other direct or intermediate connection to the lower sheet layer 30 and therefore essentially avoid providing a direct folding of the lower sheet layer, at least within the crotch region 18 of the article.

In particular aspects of the invention, the leg shield section 142 may have a composite rigidity which is not less than about 5 mg. The composite stiffness may alternatively be of not less than about 10 mg, and optionally may not be less than about 15 mg. In other aspects of the invention, the leg shield section 142 may have a composite stiffness which is no more than about 250 mg. The composite stiffness may alternatively not be more than about 200 mg, and optionally may not be more than about 170 mg.

The rigidity of the various components and section of the article of the invention can be determined by using the TAPPI test methodology T543 om-94, and using a Gurley digital stiffness tester, model 4171-D, a device available from Teledyne Gurley, a business with offices in Troy, New York. Therefore, the stiffness values of the various sections of the article, such as the waist bag member 80, are bend stiffnesses. Rigidities can be expressed as milligrams (mg) to which they correspond to milligrams-force or can be expressed in terms of numerically equivalent values of standard Gurley units (SGU) For the purposes of the present invention, the axis around which a bend moment is applied to the sample during the stiffness test is a bending axis which is aligned essentially parallel to the direction of stretching and elastic gathering provided by the members. associated elastics, such as the elastic members 138 and / or 68. For example, the rigidity of the leg shield section 142 is taken with respect to the transverse dimension of the article. The stiffness was determined with respect to the bending moment which is applied about the bending axis which is generally aligned along the longitudinal direction 26 of the article. One suitable device for taking stiffness measurements is a Gurley digital stiffness tester, model 4171-D, available from Teledyne Gurley, a business having offices in Troy, New York; or an equivalent device. A suitable test procedure is a TAPPI T543 om-94.

The various configurations of gusset fins 1 may advantageously include the elasticized barrier fins such as the containment fin sections illustrated 144 in the leg band regions of the diaper. The configurations shown, for example, include two containment fin sections 144 which are operably connected to extend above and on the side surface to the body of the upper sheet layer 28. Alternatively, the constructions and arrangements for the fin sections containment 144 are, for example, described in U.S. Patent No. 4,704,116 issued November 3, 198 to K. Enloe, the description of which is incorporated herein by reference in a manner that is consistent with the same (n contradictory). Other alternative configurations of the containment fin sections 144 are described in US Pat. No. 5,562,650 entitled "ABSORBENT ARTICLE HAVING IMPROVED SURFACE MANAGEMENT" which was granted on October 8, 1996 to R. Everett et al. (Attorney's issue number 11,375) whose description is incorporated herein by reference in a manner that is consistent with same.

The containment fin sections 144 can be attached to the upper sheet layer 28 along the fixed longitudinally extending regions, such as the fixed edges 64, of the fin sections. A moving edge 66 of each containment fin section includes a second selected arrangement of the elastic fin member 68 which may comprise one or more individual threads of elastomeric material. For example, a plurality of elastic yarns may be configured in a spatially spaced apart generally parallel array, and a suitable elastic yarn may, for example, be comprised of an LYCRA elastomer of 470 decitex which is available from the DuPont de Nemours, a trade having offices in Wilmington, Delaware. Alternatively, the elastic yarns can be composed of a Spande GLOSPAN S7 700 denier elastomer which is available from Glob Manufacturing, a business having offices in Fall River, Massachusetts.

Each resilient member 68 is connected to the moving binder of the containment flap section 144 in an elastically contractible condition so that the contraction of the elastic components thereof folds and shortens the edge d of the containment flap section. As a result of this, the movable edge of each containment flap section tends to place itself in an outwardly spaced relation of the side-to-body surfaces of the topsheet 28 and / or of the emergence management part 46 toward a generally vertical and approximately perpendicular configuration especially in the crotch section 18 of the diaper. In the embodiment shown, for example, the movable edge of the containment fin section is operatively connected to the fin elastic by partially bending or otherwise bending the fin material back onto itself by a limited amount which it is sufficient to enclose the selected arrangement of the elastics 68 located in the section d fin 144. More particularly, the inner side portion 62 d of the fabric layer can otherwise be folded around a second fold line designated 189. The elastomeric members 68 can then be placed in sandwich form or otherwise contained between two laminations of the fabric 176. In addition, the inner side portion 62 of the fabric cap and the primary base portion of the containment fin section d 63 of the fabric layer can essentially be attached to each other in the intermediate regions 90 located between the members. immediately adjacent to the first plurality of elastomeric members 138. For example, the elastic member of the first plurality of elastomeric members 68 in each of the containment flap sections 144 can be fastened to its corresponding portions of the fabric layer 176 with a strip of adhesive essentially separated. The spatially separated adhesive strips are individual essentially without touching each other. As a result of this, the essentially un-clamped intermediate regions 90 may fall into folds and more effectively form a cushioned topography, In other arrangements of the invention, an adhesive spray may be configured to concentrate the spray d adhesive at the positions of the elastic members 68 while depositing minimal amounts of adhesive in the spaces 9 between the elastic members 68, in space 164 separating the containment flaps 68 of the leg gusset elastics 138 and / or in the fold line area 189. While there may not be a discrete spacing between the adhesive areas applied in this particular arrangement, it has been noted that this arrangement provides a sufficient adhesive bond without unduly poking the containment fin portion of the d-scutellum compound. This arrangement also helps to form a more cushioned topography in the fin-gusset containment fin part.

At least a pair of the containment barrier fin sections 144 are connected and positioned along the longitudinally opposite extending regions of the upper sheet layer 28, and the connected upper sheet regions are generally located at a side of the laterally opposite side edge regions of the middle section of the upper sheet layer 28. The connected upper sheet regions are located essentially laterally inward of the leg shield sections 142 of the diaper article 10, but parts of the connected regions of the upper sheet may optionally be located outside the leg shield sections.

Each containment fin section 144 includes at least one of the elastomeric members 68 attached to the containment fin section at a location which is close to the movable edge 66 of the containment fin section. * In particular configurations, at least one of the elastomeric members 68 is attached to the containment fin section at a location which is close to the essentially fixed edge 64 of the containment fin section.

With reference to Figure 6, each containment fin section 144 may include one or more elastomeric members with at least one base elastomeric member 68a which is attached to. the containment flap section 144 at a location which is between the movable edge portion 66 and the essentially fixed edge 64 of the containment flap section. In the particular configurations, the base elastomeric member 68a can be attached to the containment fin section 144 at the location which is close to the movable edge portion 66 of the containment fin section. The base elastic member may have a spacing distance 166 with an upper joint which is not more than 37 millimeters from the fixed edge 64 of the retaining section section, at least within the crotch portion 18 of the article. In particular arrangements, the at least one base elastomeric member can be fastened essentially immediately to one side of the fixed edge 64 of the containment fin section 144.

In particular aspects of the invention, the adjacent elastomeric members 68 may have a spacer distance 60 which is not less than about 2 millimeters. The spacing distance between the adjacent elastomeric members 68 may alternatively be no less than about 2 millimeters, and optionally may not be less than about 4 millimeters. In other aspects, the adjacent elastomeric members 68 may have a spacing distance 60 which is no more than about 2-5 millimeters. The spacing distance between adjacent spacer members 68 may alternatively not be more than about 13 millimeters, and optionally may not be more than about 8 millimeters to provide the desired effectiveness.

In the desired arrangements, each containment fin section 144 can have a side width dimension 58 (Figure 6) of at least about 13 millimeters, and in particular aspects of the invention, the width of the containment fin is less than the width 186 of the corresponding leg shield section 142. Additionally, each containment fin section 144 may have a longitudinal extension which is essentially equal to the overall overall length 180 ( Figure 1) of the article. Alternatively, each containment flap section may have an extension which is less than the overall overall extent of the article, and the shorter containment flap section may be configured with a zoned placement at a selected location along a part designated the general length of the article. For example, the length of the containment flap section can be essentially centrally located along the length of the article, or it can be positioned with an offset toward the front or back waistband of the article. Optionally, each containment fin section can have a length which is essentially equal to or less than the overall overall length of the absorbent body structure 32, and the relatively shorter containment fin section can be configured with a zoned placement in a selected location along a designated portion of the overall length of the absorbent body structure.

The containment flap sections 144 are operably secured in the designated sections of the article, such as the laterally opposite sections of the top sheet layer 28, with a suitable fastening mechanism 172. In the arrangements shown, for example, the fasteners The containment flap may be similar to those used with the waist bag member 80. The fasteners may generally have a U-shaped configuration, with the bottom of the U-shape generally extending longitudinally and the two arms of the form of U extending generally in lateral form. The U-shape shown is angular, but may not be angular if desired. As illustrated in the indicated arrangements, the flap fasteners can be operatively combined and integrated with the leg gusset fasteners 172. Alternatively, the flap fasteners can be distinct and separate from the leg gusset fasteners if desired.

With reference to Figure 6, a further aspect of the invention may have an optional configuration wherein the barrier layer 174 is extended in the containment fin section 144 of each leg shield 19. As a result of this, the Second relatively inner side edge 141 of the barrier layer 174 is located within the containment flap section 144. With this arrangement, the inner part 62 of the fabric layer 176 extends beyond and passes from the second side edge 141 which it extends longitudinally correspondingly of the barrier layer. The fabric side portion 62 is designed to be folded and wrapped around its second fold line or region designated 189 to extend through and over at least the portion of the second main surface 149 which is located in the fin section of containment 144. Accordingly, the relative arrangements of the barrier layer region 61, of the fabric layer region 63 of the second array of elastomeric members 68 within the containment fin sections 144 may be similar to the arrangements of similar components provided in the leg shield section 142. For example, the fabric side part 62 can cover a substantial totality of the second major surface 149 of the sweep layer region 61 in the fin section 144, and can essentially cover the complete second main surface of the part of the layer and barrier which is located in the containment section 144. By t Thus, the side part of fabric 62 can be placed between the barrier layer and the wearer's skin.

The arrangement of the elastomeric members 68 and each containment fin section 144 can be attached to at least one of the barrier layer and cloth regions 61 and 63, respectively, with a suitable securing mechanism, such as a selected pattern. of adhesive or other type d binder. For example, the adhesive can be applied by spraying filaments or discontinuous drops of adhesive and / or it can be applied by arranging generally continuous lines of adhesive in a selected pattern, such as a swirl pattern. Alternatively, the hot melted spray pattern d can be concentrated in the vicinity of the elastomeric yarns, even when a limited and limited amount of adhesive may be in the interstitial spaces between the elastomeric yarns. Alternatively, the elastomeric members 68 may be attached to at least one of the barrier and fabric layers with a plurality of longitudinally extending individual adhesive strips. The individual adhesive strip is spatially separated from the adjacent adhesive strips immediately by a discrete distance, and each strip of individual adhesive is arranged to essentially hold an individual one of the elastomeric members 68 to at least one of the barrier layers and the web. ! In the arrangements shown, for example, the adhesive strips can be aligned essentially parallel to one another.

In a particular aspect of the invention, the fabric layer 176 and the barrier layer in the containment fin section 144 are essentially not attached to one another in the intermediate regions 90 (Figure 6) located between the immediately adjacent members of the second plurality of elastomeric members 68. In another aspect of the invention, each resilient member of the second plurality of elastomeric members 68 of the containment fin sections 144 can be attached to at least one of the fin region 61 of the cover layer. barrier and / or the containment flap regions of the fabric layer 176 with an essentially separate strip of adhesive in a shape similar to that employed in the construction of the leg escutcheon section 142. Thus, the adhesive strips spatially separate and individual substantially avoid touching each other, and intermediate regions essentially not subject to 90 may fall into folds and more effectively to form a poor topography.

In another aspect of the invention, the fabric layer 176 and the barrier layer in the containment fin section 144 can be lightly held with a hot melt adhesive in the intermediate regions 90 located between the immediately adjacent members of the second plurality of elastomeric members. 68, but with the volume of the hot melt adhesive concentrated in the locations of the elastomeric yarns 68. In another aspect of the invention, each elastic member of the second plurality of the elastomeric members 68. of the containment flap sections 144 can be attached to at least one of the fin regions 61 of the barrier layer and / or the containment fin regions of the fabric layer 176 with a heavier concentration of adhesive 74 in the elastomeric yarns 68 in a manner similar to the employed in the construction of the leg shield section 142. Thus, the intermediate regions held lightly 90 can more easily e fall into folds and more effectively form a cushioned topography.

All the elastomeric members 68 can be fastened on a single surface of the containment fin region 61 of the barrier layer. For example, all the elastomeric members 68 can be fastened on the first main surface 148 and covered by the primary base part of the containment fin region 63 of the fabric layer (Figur 7). Alternatively, all the elastomeric members 68 can be fastened on the second main surface 149 and covered by the inner side portion 62 of the fabric layer (Figure 8).

The second array of elastomeric members 68 may also include a second first sub-set of individual elastomeric members attached to the first main surface 148 of the barrier layer 174 and a second sub-set of individual elastomeric members attached to the second main surface 149 of the layer barrier (Figures 4 and 6). In addition, the first and second sub-sets of the elastomeric members can be arranged in a laterally offset and stepped configuration.

In other arrangements of the invention, the elastic members 68 in the containment fin section 144 can be spaced from the closest elastic members 138 in the shield section 142 by a predetermined limit space 164 (Figure 6) which provides a Minimum separation distance of at least about 2 millimeters. In particular aspects, the separation distance provided with the spacer distance of limits of at least about 8 millimeters, and optionally is of at least about 16 millimeters. The separation distance provides an amount of insulation which effectively allows the resilient fin members 68 to operate essentially separately from the elastic gusset members 138. Thus, the folding provided by the restraining fin elastics can essentially separate from the folding provided by the escutcheon elastics.NM.

In particular aspects of the invention, each containment fin section 144 has a composite stiffness of at least about 5 mg, taken with respect to the transverse dimension of the article. For the purpose of the present invention, the stiffness of the containment fin section is determined with respect to a bending moment which is applied about a bend axis that is aligned essentially along the longitudinal dimension 26 of the article. . Desirably, the containment fin section has a composite stiffness which is not less than about 10 mg, and alternatively is not less than about 15 mg to provide improved containment. In additional aspects, the containment flap section may have a composite stiffness which is not more than about 250 mg. The composite stiffness may alternatively not be more than about 200 mg and optionally may not be more than about 170 mg to provide the desired performance. If the stiffness of the containment fin section 144 is very low, the containment fin section can collapse excessively on itself. If the stiffness of the containment flap section is very high, there may be excessive irritation of the user's skin.

As shown representatively, the article of the invention can be configured with each gusset fin 19 directly or indirectly connected to a designated face facing surface of the top sheet layer 28. Each gusset member 19 it may have a longitudinal extension thereof which (as an approximate lower limit) extends along at least about 20 percent of the total longitudinal extent 180 (Figure 1) of the article. In other configurations, each gusset member 19 may extend along at least about 30 percent, and alternatively at least about 40 percent of the longitudinal extension 180 of the article to provide improved effectiveness . As illustrated in the representatively shown configurations, each gusset-fin member may extend along a longitudinal extension which (as an approximate upper limit) may be up to about 100 percent of the total longitudinal length of the article for provide additional containment and packing. Alternatively, each shank-flap member may extend along an extension which is not more than about 80 percent, and optionally is not more than about 70 percent of the total longitudinal length of the article to provide e desired operation.

Each section of escudete 142 of the fin-escudet 19 may be in a bridge configuration through the associated concave side edge contour 15 of the lower leaf layer along an extension 182 which is at least about 20 percent of the length 180 from the article. In other configurations, each gusset section may be in a bridge configuration through its associated concave side edge contour 15 of the lower sheet layer along an extension 182 which is at least about 30 percent, and alternatively is at least about 40 percent of the length of the longitudinal extension 180 of the article to provide improved effectiveness. If desired, each leg gusset section 142 may be in a bridge configuration along an extension which may be up to 100 percent of the longitudinal length of the article to provide additional containment and packing. Alternatively, each gusset section may be in a bridge configuration over an extension which is not more than about 80 percent, and optionally is not more than about 70 percent of the longitudinal extent of the article. provide the desired performance and cost effectiveness.

As previously described, each fin-escudet 19 may have a general longitudinal extension which is essentially equal to the overall total extension of the article. Alternatively, each gusset fin may have an extension which is less than the overall overall length of the article, and relatively shorter gusset-fin may be configured with a sonded placement at a selected location along a designated portion of the overall length from the article. Optionally, each gusset fin 19 may have a total length which is essentially equal to or less than the overall overall length of the absorbent body structure 32, and the relatively shorter containment fin section may be configured with a sonded placement in a selected location along a designated portion of the overall length of the absorbent body structure.

In order to further control the operation of the gusset fin 19, the arranged assembly of the gusset elastic members 138 and / or the array of the fin elastic members 68 can be evenly spaced across the full width of the gusset section of the gusset. leg 142 and / or of the containment fin section 144, respectively (as determined along a dimension which is essentially perpendicular to the stretch dimension of the elastic member). Alternatively, the arrangement of the gusset elastics 138 and / or the arrangement of the fin elastics 68 can be grouped into discrete and discrete functional sets. In addition, groups of discrete and multiple elastics can be placed in either or both of the containment flap or leg gusset sections of the gusset-fin member 19 to control the operation of the gusset-fin and improve its operation.

In further aspects of the invention, the resilient members in either or both of the containment fin and gusset sections 142 and 144 respectively, may be operably tensioned by zone. Desirably, the zone tensioning is configured to substantially limit the elasticized folding to a longitudinally central and middle section of the gusseted member. Zone tensioning can be achieved in several ways. For example, the elastic contraction of the elastic members 138 and 68 in the appropriate end regions of the leg shield and retaining fin sections 142 and 144, respectively, can be operably killed, such as by mechanical, ultrasonic treatment. or thermal which effectively "matte" or otherwise deactivate the elasticity or contraction in the selected regions. Alternatively, an adhesive or other binder mechanism can be applied only in areas where the retraction of the elastic members is attempted to fold the fin composite. In regions where the joints are absent, the remaining elastic members can essentially contract without folding the selected sections of the fin composite. In the further configurations, the longitudinally distal end regions of the containment or leg shield sections may be substantially completely immobilized such as by operably securing the end regions on top sheet layer 28 (or other part of the backing layer 28). article) with adhesive, sonic joints or other fastening mechanisms.

Typically, the assembled gusset fin 19 can be attached to the absorbent article 10 while the gusset fin member 19 extends to approximately the same extent as was present in the gusset member when the elastomeric yarns 68 and 138 were assembled and fastened in the construction of the gusset-fin composite. Thus, the gusset-fin member can be attached and incorporated into the article while the fabric and barrier layers of the gusset-fin member are effectively fully extended to their essentially non-folded flat conditions., and the elastomeric yarns 68 and 138 are essentially in their initially stretched conditions. Alternatively, the composite gusset member can be folded and gathered by a selected amount of elastomeric retraction of the elastomeric fastened threads 68 and 138, which is allowed to occur prior to clamping and incorporation of the composite gusset member 19 in the article 10. The amount of retraction will allow and the pre-withdrawal can be expressed in terms of a percentage based on the initial unfolded length of the composite fin-gusset member 19, using the formula: where : Lt = the initial unfolded length of the composite fin-gusset, and Lf = the final folded length of the composite fin-gusset.

In particular aspects of the invention, the amount of retraction and recollection allowed above may be within the range of about 0-50 percent. The amount of prior retraction and collection allowed, in other aspects, may be at least about 10 percent, and in additional aspects may not be more than about 25 percent to provide the desired benefits and performance. The selected amount of the previous or previous folding may advantageously help to reduce the amount of folding force that is transmitted - initially to the upper sheet and lower sheet layers of the article during manufacture and may help to be in the upper sheet layers and bottom sheet of the stretching and contraction movements of the fin-gusset member 19 which may occur while the article is being used.

With reference to Figures 1, 2 and 4, the bag section 84 of the waist member 80 may be configured to bridge and extend over the side surfaces to the body inwardly of the containment flap sections that extend longitudinally 144. Desirably, the movable edge portions 104 of the bag section 84 are essentially disconnected and not attached to the distal moving edges 66 of the containment flap sections 144 to thereby reduce the interaction between the containment flap sections. elasticized section 144 and elasticized bag section 84. In addition, it may be desirable to sonify the stretched elastic tension by elastic members 68 employed to elastinate containment flap sections 144. More particularly, the elastic tension in the flap sections of containment may be restricted essentially to a longitudinally middle section of each containment fin section tion. Thus, the end regions of each containment fin section, particularly the fin end regions generally adjacent to the bag section 84, can be essentially free of elastic tension exerted by the elastic members 68. The distal edges 66 they may also be secured to the upper sheet layer 28 with a suitable fastening mechanism to further isolate the distal edges 66 of the containment flap sections outward from the operation and opening of the bag section 84. Other techniques for producing The desired zoning stress of the containment flap sections 144 has been previously described here.

In particular aspects of the invention, the fin-gusset members 19 can be configured to essentially avoid intersecting the locations of the waist bag members 80. Thus, each of the gusset-fin members can be constructed to end in positions which are associated and separated from the terminal edges of the bag sections 84 of the waist bag members. In other aspects, the fin-gusset members 19 may be configured to lie on a side-to-body surface facing inward from the waist bag members 80. The gusset-fin members 19 may then terminate in an area that starting from the foldable movable edge of the waist pouch 104 to the longitudinal end margin 22 of the absorbent article 10. In still other aspects, the gusset-fin members 19 can be configured to lie underneath, and to one side of a face surface toward outside the waist bag members 80. The gusset-fin members 19 can terminate in an area starting from the foldable movable edge of the waist bag 104 to the longitudinal end margin 22 of the absorbent article 10.

In the various arrangements of the invention, the selected absorbent composite system such as a system which includes the emergence management part 46 and the absorbent body structure 32, is positioned and operably secured between the upper sheet 28 and the lower sheet 30 to form the diaper 10. The absorbent system has a construction which is generally compressible, conformable, non-irritating to the user's skin, and is capable of absorbing and to retain liquid exudates from the body. It should be understood that, for the purposes of the invention, any of the components of the absorbent system may comprise a piece of integral and single material or alternatively, may comprise a plurality of individual separate pieces of material which are operably assembled together. Where the absorbent component, such as the absorbent body 32, comprises a piece of essentially integral and unique material, the material can include the desired structural characteristics formed in the selected spatial regions thereof. Where the absorbent components comprise multiple pieces, the pieces may not be configured as discrete layers or as other shapes and configurations that are not layered. In addition, the individual pieces can be coextensive or non-coextensive, depending on the requirements of the product. It is preferred, however, that each of the individual pieces be arranged in an intimate and operable contact along at least a portion of its boundary with at least one other adjacent part of the absorbent component. Preferably, each piece is connected to an adjacent part of the absorbent component by means of a suitable fiber linkage and / or entanglement mechanism, such as an ultrasonic or adhesive joint, or a mechanical or hydraulic perforation.

In the representatively shown embodiments, the absorbent body structure 32 has a liquid acquisition zone, a target zone, and a contoured and curvilinear periphery, particularly along its side edges. The two side edges, arched inwardly, of generally identical image provide a narrower intermediate section suitable for being placed in the wearer's crotch. In the absorbent structure shown 32, a front section thereof includes two transversely spaced ear regions and a central region. The target zone encompasses the area where repeated liquid surges typically occur in the absorbent structure 32. When the diaper is worn, the ear regions are configured to generally engage the sides of the wearer's waist and torso, and a The central region is configured to make contact generally with the middle part of the user's waist and torso.

The absorbent structure 32 can be manufactured in a wide variety of sizes and shapes (e.g. rectangular, trapezoidal, T-shaped, I-shaped, hourglass-shaped, etc.) and a wide variety of materials. The size and absorbent capacity of the absorbent structure 32 must be compatible with the size of the intended use and the liquid load imparted by the intended use of the absorbent article. In addition, the size and absorbent capacity of the absorbent structure 32 can be varied to accommodate users varying from infants through adults. Furthermore, it has been found that with the present invention, the base densities and / or weights of the respective emergence management parts 46 and retention parts 48, as well as their relative proportions, can be varied. In a particular aspect of the invention, the absorbent structure has an absorbent capacity of at least about 300 gm of synthetic urine. Alternatively, the absorbent structure may have an absorbent capacity of at least about 400 gm of synthetic urine to provide improved operation.

Various types of wettable hydrophilic fibrous material can be used to form the component parts of the absorbent structure 32. Examples of suitable fibers include naturally occurring organic fibers composed of an intrinsically wettable material, such as cellulosic fibers; synthetic fibers composed of cellulose or cellulose derivatives, such as rayon 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 polyamide polyester fibers; and synthetic fibers composed of a non-wettable thermoplastic polymer such as polypropylene fibers, which have been hydrophilized through appropriate media. The fibers can be hydrophilized, for example by treatment with silica, treatment with either a material which has a suitable hydrophilic moiety and is not easily removable from the fiber, or by sheathing the hydrophobic fibrium not moistened with a hydrophilic polymer during later of fiber formation. For the purposes of the present invention, it is contemplated that mixtures selected from the various types of fibers mentioned above may also be employed.

As used herein, the term "hydrophilic" describes fibers or fiber surfaces which are wetted by aqueous liquids in contact with the fibers.The degree of wetting of the materials can, in turn, be described in terms of contact and the surface tensions of the liquids and materials involved Equipment and techniques suitable for measuring the wettability of the particular material fibers or the fiber material blends used for the emergence management part 46 can be provided by an analyzer system of surface strength of CAHN, SFA-222, or an essentially equivalent system.When measured with this system, fibers having contact angles of less than 90 degrees are designated "wettable" or hydrophilic, while fibers having angles of contact greater than 90 degrees are designated "non-humidifying" or hydrophobic.

The retention portion 48 may comprise a matrix of hydrophilic fibers, such as a cellulose fluff fabric, mixed with particles of high absorbency material. In particular arrangements, the retention portion 48 may comprise a mixture of superabsorbent hydrogel forming particles and blown fibers with synthetic polymer melt, or a mixture of superabsorbent particles with a fibrous coform material comprising a mixture of natural fibers and / or of synthetic polymer fibers. The superabsorbent particles may be mixed homogeneously in essential form with the hydrophilic fibers, or they may be mixed non-uniformly. For example, the concentrations of superabsorbent particles may be arranged in a gradient in a non-stepped direction through a substantial part of the thickness (z-direction) of the absorbent structure, with the lowest concentrations towards the body side of the absorbent structure. and the relatively higher concentrations towards the outside of the absorbent structure. Suitable z-gradient configurations are described in U.S. Patent No. 4,699, issued on October 13, 1987 to Kellenberger et al., The disclosure of which is incorporated herein by reference in a manner that is consistent with the present description. The superabsorbent particles may also be arranged in a generally discrete layer within the hydrophilic fiber matrix, or may be configured as separate and discrete bag regions of superabsorbent material. In addition, two or more different types of superabsorbent can be selectively placed at different places within or along the fiber matrix.

The high-absorbency material may comprise absorbent gelation materials such as superabsorbents. The absorbent gelation materials can be polymers and natural, synthetic and modified natural materials. In addition, the absorbent gelation materials can be inorganic materials such as silica gels, or organic compounds such as crosslinked polymers. The term "crosslinked" refers to any means for effectively making materials normally soluble in water essentially insoluble but swellable in water. Such means may include, for example, physical enredad, crystalline domains, covalent bonds, complexes and ionic associations, hydrophilic associations, such as hydrogen bonding, and hydrophobic associations or Van der Walls forces.

Examples of the synthetic absorbent gelling material polymers include the alkali metal and ammonium salts of poly (acrylic acid) and poly (methacrylic acid), poly (acrylamide), poly (vinyl ethers), maleic anhydride copolymers with vinyl ethers and alpha olefins, poly (vinyl pyrrolidones), poly (vinyl morpholinone), poly (vinyl alcohol), and mixtures and copolymers thereof. Additional polymers suitable for use in the absorbent structure include natural and modified natural polymers, such as hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, methyl cellulose, carboxymethyl cellulose, hydroxypropyl cellulose, and natural gums , such as alginates, xanthan gum, locust bean gum and the like. Mixtures of fully or partially synthetic absorbent polymers may also be useful in the present invention. Other suitable absorbent gelation materials are described by Assarsson et al. In U.S. Patent No. 3,901,236 issued August 26, 1975. The processes for preparing the synthetic absorbent gelation polymers are discussed in the US patent. United States of America number 4,076.66 granted on February 28, 1978 to Masuda and others and the patent of the United States of North America number 4,286,082 granted on August 25, 1981 to Tsubakimoto et al.

Synthetic absorbent gelation materials are typically xerogels which form hydrogels when wetted. The term "hydrogel", however, has been commonly used to refer to both the wetted and unmoistened forms of the material.

As previously mentioned, the high absorbency material used in the retention portion 48 is generally in the form of discrete particles. The particles may be of any desired shape, for example, spiral or semi-spiral, cubic, rod-type, polyhedral, etc. Shapes having a larger dimension / smaller dimension ratio, such as needles, leaflets and fibers are also contemplated for use here. The particle conglomerates of absorbent gelation material can also be used in the retention portion 48.

Preferred for use are the particles having an average size of from about 20 microns to about 1 mm. The "particle size" as used herein means the heavy average of the smallest dimension of the individual particles.

Suitable high-absorbency materials may have particular characteristics of the Absorbent Capable (sometimes referred to as "AC"), Bajq_Carga Deformació (sometimes referred to as "DUL"), and the index d TES- Transmission (sometimes referred to as "Wl"). These parameters are described in detail in the patent application of the United States of America series number 757.787 of S. Byerly et al., Entitled ABSORBENT COMPOUNDS AND ABSORBENT ARTICLE CONTAINING THEMSELVES and filed on September 11, 1991 (attorney's case number 10,174 ), which description is incorporated herein by reference in a manner that is consistent with the present specification.

In a particular aspect of the invention, the absorbent retention portion 48 comprises a matrix of essentially hydrophilic fibers having an amount of high absorbency material distributed therein. Selected superabsorbent polymers having improved absorbent properties can be important to maximize performance while retaining the desired thinness of the absorbent article. To provide improved performance, the particles of superabsorbent material can be selected to provide an absorbency value under load (AUL) which is within the range of about 25-40, and provide an absorbent capacity value (AC) which is within the range of around 32-48. The liquid intake rate for the superabsorbent material is within the range of about 3-15 g / g (liquid grams per gram of superabsorbent) to 30 seconds of absorbency under load, 6.5-21 g / g to 5 minutes of low absorbance charge and 25-40 g / g 60 minutes of absorbency under load. , A suitable method for determining the absorbency value under load is described in detail in U.S. Patent No. 5,147,343 issued to Kellenberger on September 15, 1992 and entitled ABSORBENT PRODUCTS CONTAINING HYDROGELS WITH ABILITY TO BREATHE IN AGAINST PRESSURE (attorney's case number 8786.1); and also published November 2, 1989 as the European patent application number EP 0 339 461 Al; the description of which is incorporated herein by reference in a manner that is consistent with the present specification.

An example of a superabsorbent polymer suitable for use in the present invention is the SANWET IM 3900 polymer available from Hoechst Celanese, a business having offices in Portsmouth, Virginia. Other suitable superabsorbents may include the DOW DRYTECH 2035LD polymer obtained from Dow Chemical Company, a business having offices in Midland, Michigan; a FAVOR SAB 870M polymer available from Stockhausen, Inc., a business having offices in Greensboro, North Carolina.

The hydrophilic fiber matrix comprising the retention portion 45 can be a pulp fluff layer of cellulose wood., and the superabsorbent polymer particles may be distributed within the hydrophilic fiber matrix. The hydrophilic fibers and the high absorbency particles can be provided in a fiber to particle ratio which is not other than about 75:25, alternatively, it is not more than 70:30, and optionally it is not more than about 55:45 by weight. In particular aspects of the invention, the fiber to particle ratio is not less than about 25:75, preferably it is not less than about 30:70, and more preferably it is not less than about 45:55, weight. Such particle fiber proportions may be particularly desirable in the target area of the absorbent structure. In particular embodiments of the invention, the fiber particle weight ratio is not more than about 65:35 and is not less than about 50:50 to provide the desired performance.

Hydrophilic fibers and high absorbency particles can form an average composite basis weight which is within the range of about 4Q0-10Q0 grams per square meter. Again, such a basis weight is particularly desirable in the target area of the absorbent structure. In certain aspects of the invention, the average composite basis weight is within the range of about 500-950 grams per square meter, and preferably is within the range of about 550-900 grams per square meter to provide the desired performance.

To provide the desired thickness dimension to the various configurations of the absorbent article of the invention, the retaining portion 48 can be configured with a volume thickness which is not more than about 0.6 centimeters. Preferably, the volume thickness is not more than about 0.53 centimeters and more preferably is not more than about 0.5 centimeters to provide the desired benefits. The volume thickness was determined under a restriction pressure of 0.2 pounds per square inch (1.38 kPa).

The density of the retention portion 48 or other component of the absorbent article can be calculated from its basis weight and thickness. With respect to diapers, for example, weight and thickness are measured on newly unpacked diapers, unfolded and dried at a restriction pressure of 0.2 pounds per square inch (1.38 kPa). Conventional thickness measuring devices can be used to determine the thickness needed to calculate the density.

In the illustrated embodiments of the invention, the absorbent retention portion 48 includes 4-22 grams of wood pulp, preferably includes about 8-18 grams of lint and more preferably includes about 12-14 grams of lint to provide The desired benefits. L erased from wood pulp generally provides contour shape to diaper 10; and carries and places the particles of the superabsorbent polymer or other high-absorbency material. The retention portion 48 may contain about 7-12 grams of superabsorbent polymer, and in the embodiment shown, it contains about 8 grams of the superabsorbent polymer. A sufficient superabsorbent polymer is incorporated in the retention portion 48 to provide a suitable total absorbent capacity of at least about 300 gm of synthetic urine. For example, a medium-sized diaper for an infant weighing 16-28 pounds (about 7-13 kilograms) can typically have a total retention capacity of about 400 grams of synthetic urine.

"The fluff and superabsorbent particles can be selectively placed in the desired zones of the retention portion 48. For example, the base weight of fluff can vary across the width dimension of the retention portion 48. Alternatively, the amounts relatively larger debris may be placed towards the front waistband end of the retaining portion, eg, see U.S. Patent No. 4,585,448 issued April 29, 1986 to K. Enloe. illustrated embodiment, the majority of superabsorbent material may be distributed downwardly in an average region of retention portion 48 which extends along the length dimension of the retention portion and measures about 3.5-4.5 inches (about In addition, the superabsorbent material may have a zoned placement selected to reduce the amount of superabsorbent material located in the rca of the end and side edges of the retention part. The reduced amounts of the superabsorbent material at the edges of the retention portion can improve the containment of the superabsorbent particles within the stripping matrix fibros of the retention portion 48. The zoned and pulsed placement of the superabsorbent material can, for example, be achieved by the method and apparatus described in United States of America Patent No. 5,028,224 issued to C. Pieper et al. entitled METHOD AND APPARATUS FOR DEPOSITING INTERMITTENTMENT OF PARTICULATE MATERIAL IN A SUBSTRATE and granted on July 2, 1991 ( Attorney's Issue No. 8761), whose description is incorporated herein by reference in a manner that is consistent therewith.

In a particular aspect of the invention, the absorbent structure 32 can be generally T-shaped with the transverse bar extending laterally from the "T" generally corresponding to the front waist portion of the absorbent article for improved performance especially for male infants In the illustrated modes, for example, the retention portion through the ear section of the front waistband region of the article has a width in the transverse direction of about 9. inches (about 22.9 centimeters), in the The narrowest section of the crotch section has a width of about 3.5 inches (about 8.9 centimeters) and the region of the rear waist band has a width of about 4. inches (about 11.4 cm).

The complete absorbent structure 32, any individual portion thereof, such as the retention portion, may be over wrapped in a high hydrophilic moisture resistance envelope fabric, such as a high moisture resistance tissue or a fibrous tissue. synthetic. The overwrapping fabric can also increase the integrity in the use of the absorbent structure. The fabric or fabric can be suitably bonded, such as with adhesive, to the absorbent structure 32, and the other components of the product construction.

Due to the high concentrations of superabsorbent particles, or other high-absorbency material, in the retention portion 48, there may be an increased difficulty with respect to the containment of the high-absorbency particles within the retention portion and to restrict movement. or migration of the superabsorbent on the diaper body side. To improve the containment of the high-absorbency material, the absorbent structure 32 may include an improved overwrap, such as a wrapping sheet 70, placed immediately on one side and around the retention portion 48. The wrapping sheet is preferably an adhesive. cap of absorbent material which covers the side-to-body and side-to-main surfaces of the retention portion, and preferably essentially covers all peripheral edges of the retention portion to form a complete envelope essentially around them. Alternatively, the wrapping sheet may provide an absorbent wrapper which covers the side-to-body and main-to-exterior surfaces of the retaining portion, and essentially covers only the side-side edges of the retaining portion. Therefore, both inwardly curved and linear portions of the lateral side edges of the wrapping sheet can be closed around the retaining portion. In each arrangement, however, the end edges of the wrapping sheet may not be completely closed around the end edges of the retaining portion in the waistband regions of the article.

The absorbent envelope 70 may comprise a multi-element wrapping sheet which includes a separate side-to-body wrapping layer and a separate outer-side wrapping layer, each of which extends beyond or to some of the outer wrapping layers. the peripheral edges of the retaining portion 48, as representatively shown in FIG. 1. Such a configuration of the wrapping sheet may, for example, facilitate the formation of an essentially complete seal and seal around the peripheral edges of the retaining portion. 48. In the posterior waistband portion of the illustrated cloth, the absorbent wrap may also be configured to extend for an increased distance outwardly from the periphery of the retaining portion to add opaque strength to the posterior ear sections of the diaper. In the illustrated embodiment, for example, the side-to-body and side-to-side layers of the absorbent wrap 70 extend at least or about 1/2 inch (about 1 centimeter) beyond the peripheral edges of the absorbent wrapper. the retaining portion to provide a rebord-type bonding area projecting outwardly on which the periphery of the part on the side of the body of the absorbent wrapper can be fully or partially connected to the periphery of the side-to-side portion of the absorber. the absorbent wrap.

The side-to-body and side-to-side layers of the wrap sheet 70 may be composed of essentially the same material, or they may be composed of different materials. For example, the outer side layer of the wrapping sheet may be composed of a relatively lower basis weight material having a relatively higher poroside, such as a cellulose tissue moisture resistance composed of soft wood pulp. The side-to-body layer of the wrapping sheet may comprise one of the wrapping sheet materials described above which has a relatively low porosity. The low porosity body layer can better prevent migration of the superabsorbent particles onto the wearer's skin, and the low poroside base-to-outer layer can help reduce costs and facilitate the processing of the product. absorbent pad.

To provide the joint between the body-side and side-to-side parts of the absorbent wrapper 70, an adhesive, such as the NATIONAL STARCH 72-3723 adhesive can be printed over the designated joint areas of the absorbent wrapper with, for example , a rotogravure type d system. With alternate arrangements having an absorbent wrapper composed of a woven fibrous web with a woven n-melt, the peripheral sealing of the wrap layers d side to the outside and side to body can be achieved by employing hot calendering to provide a sealed strip region. around the periphery of the holding part Due to the thinness of the retention portion 4 and the higher superabsorbent concentrations within the retention portion, the liquid intake rates of the retention part, by themselves, may be very low, or may be adequately supported. over multiple liquid discharges into the absorbent structure. The addition of a liquid-impermeable emergence management material layer, however, can advantageously improve the overall take-up rate of the composite absorbent structure. The emergence management part 46 is typically less hydrophilic than the retention portion 48, and has an operable level of density and base weight to quickly and temporarily collect the liquid surges, to transport the liquid from its initial entry point. and to essentially release the liquid to other parts of the absorbent structure 32, particularly the retaining portion 48. This configuration can help prevent the liquid from becoming clogged and collecting on the part of the absorbent garment placed against the skin of the absorbent garment. user, thereby reducing the user's feeling of humidity.

Various woven and non-woven fabrics can be used to construct the emergence management part 46. For example, the emergence management part can be a cap composed of a fabric joined by spinning or blowing with polyolefin fiber fusion. The emergence management layer may also be a carded-attached fabric or an air-laid fabric composed of natural and synthetic fibers. The carded-attached fabric can, for example, be a carded fabric-bound with powder a carded fabric linked with infrared or a carded fabric-attached through air. Carded fabrics or fabrics attached through infrared air may optionally include different fibers, in the fiber lengths within a selected tel fabric may be within the range of about 1.0-3. inches The emergence management part may be composed of an essentially hydrophobic material, and the hydrophobic material may optionally be treated with a surfactant to be processed in another manner to impart a desired level of wettability and hydrophilicity.

The representative diaper 10 may include an emergence management part 46 which is arranged in a direct liquid contacting communication with an adjacent absorbent retention portion 48. As shown representatively, the emergence management part 46 may be configured to be placed on one side of the outer side d facing outwardly of the topsheet 28. Optionally, the emergence management part may be placed on one side of a surface from side to body facing inwardly of the top sheet cap 28. The configuration shown of the emergence handling part is operably connected to the top sheet layer with a conventional adhesive pattern, such as a swirl adhesive pattern. In addition, the emergence management part can be operably connected to the side-to-body layer of the wrapping sheet 70 with a conventional adhesive pattern. The amount of adhesive added should be sufficient to provide the desired levels of bonding, but should be sufficiently low to prevent excessive retraction of liquid movement from the top sheet layer through the emergence management part and through the cap wrapping sheet.

The retention portion 48 is placed in liquid communication with an emergence management part 4 to receive the liquids released from the emergence management part and to retain and store the liquid. In the embodiments shown, the emergence management part 4 comprises a separate layer which is placed on another separate cap comprising the retention portion, forming by a dual layer arrangement. The emergence management part served to collect, quickly and temporarily contain the discharged liquids, to transport such liquids from the initial contact part and to spread the liquid to other parts of the emergence management part and then to release essentially complete such liquids inside the cap or layers comprising the retention portion 48.

The configuration shown representatively of the emergence management part is essentially free of absorbent gelation material. The emergence management part 46 may, however, contain a small amount of particulate gelation material to assist in acquiring an initial liquid surge, but the quantity n must be excessive. When excessive amounts of the particulate absorbent gelation material are held in the target zone, however, the particles can cause the structure to retain and contain unacceptably high amounts of liquid. In addition, the transport of the liquids out of the target area to other sections of the absorbent structure 32, particularly the retaining portion 48, may be undesirably impaired.

As previously mentioned, the emergence layer 46 can be a separately formed layer, which lies on one side of the face-out surface of the topsheet 28 between the retaining portion and the topsheet. Therefore, the emergence management part 46 does not require understanding the full thickness of the absorbent structure 32. The retention portion may optionally include a recessed area which totally or partially surrounds the emergence management part 46, or the retraction part. Retention may be placed completely below the emergence management part. The arrangement which includes the recess in the retention portion 48 can advantageously increase the contact area and the liquid communication between the retention portion and the emergence portion 48. It should be understood, however, that the emergence management part. 46 may optionally be constructed to extend through full thickness of the absorbent structure 32 so that the capillary flow of the liquid into the retaining portion 48 occurs primarily in a generally sideways (XY) direction.

The emergence management part can be any desired shape consistent with the absorbency requirements of the absorbent article 32. Suitable shapes include, for example, circular, rectangular, l triangular, trapezoidal, oblong, bone form d dog, the hourglass shape, or the oval. The preferred forms of the emergence management part are those which increase the surface area communicating the liquid and d contact between the emergence management part 46 and the retention portion 48 so that the relative capillary difference between the parts can be utilized. completely. In certain embodiments, for example, the emergence management part may be generally rectangular in shape.

In the various configurations of the invention, the emergence management part 46 may extend over the entire length of the retention portion 48, or may extend over only a portion of the length of the retention portion. Where the emergence management part extends only partially along the length of the retention portion, said emergence management part can be selectively placed on either side along the absorbent structure 32. For example, the emergence management part 46 can operate more efficiently when it is off-centered towards the front garment of the garment and transversely centered within a front section of the absorbent structure 32. Thus, the emergence management part 46 can be approximately centered to about the longitudinal center line of the absorbent structure 32, and placed primarily in a central region of a front section of the absorbent structure 32.

In other aspects of the invention, the end edges of the emergence management part can be spaced longitudinally inward from the end edges of the retaining portion 48. In particular configurations of the invention, the corresponding relatively adjacent front end edge. from the emergence management part 46 can be separated by a predetermined discrete distance from a waistband end edge of the retaining portion 48.

It has been found that an effective fabric for constructing the emergence management part can be distinctly characterized by particular parameters. Such parameters include, for example, the basis weight, the permeability, the porosity, the surface area per hollow volume (SA / W), the elasticity under compression and the saturation capacity. Additional parameters may include a binding matrix which may help to stabilize the pore size structure, and hydrophilicity. The bond matrix and fiber fiber mixture can advantageously provide and essentially maintain a desired pore size structure.

Additional details regarding the materials of emergence and any suitable techniques for determining the parameters described above are set forth in U.S. Patent No. 5,486,166 issued January 23, 1996 to C. Ellis et al. NON-WOVEN FIBROUS FABRIC FABRIC SURFACE FOR ABSORBENT PERSONAL CARE AND SIMILAR ITEMS, (lawyer's issue No. 11,256); . in U.S. Patent No. 5,490,846 issued on February 13, 1996 to C. Ellis et al., entitled FIBROUS NON-WOVEN FABRIC OF IMPROVED EMERGENCY MANAGEMENT FOR ABSORBENT PERSONAL CARE AND SIMILAR ITEMS (subject of lawyer No. 11,387); the descriptions of which are incorporated herein by reference in a manner that is consistent therewith.

In the desired configurations of the invention, the emergence material may include natural fibers, synthetic fibers, such as synthetic polymer fibers, and combinations thereof. The fabric may, for example, be composed of polyolefin fibers and in particular configurations, the fibers may include bicomponent fibers. For example, the polypropylene / polyethylene bicomponent fibers may be used to form the bicomponent fiber part of any of the fabrics described In addition, the bicomponent fibers can be curly flat curls helically.

In the shown configuration of the article, the side panel members 56 are separately provided members which are operably connected to the laterally opposite end sections of the rear waistband portion of the bottom sheet 30. E particular, each side panel is fixed to extend outwardly from a corresponding terminal edge of the lower leaf layer. The side panels may be composed of essentially non-elastomeric material, such as polymer films, woven fabrics, non-woven fabrics and the like, as well as combinations thereof. In particular aspects of the invention, the side panels are composed of an elasticized material such as a stretched-bonded-laminate (SBL), a bonded-bonded laminate (NBL), an elastomeric film, an elastomeric foam material or the like . For example, suitable melt blown elastomeric fibrous fabrics are described in U.S. Patent No. 4. 663,220 granted on May 5, 1987 to T. Wisneski et al., The description of which is incorporated herein by reference. Examples of composite fabrics comprise at least one layer of a non-woven textile fabric secured to a fibrous elastic layer are described in European Patent Application No. EP 0 110 010 published on April 8, 1987 as EP 0 217 032 A2 with the inventors listed as J. Taylor et al., The description of which is incorporated herein by reference. Examples of laminated-stretched-tapered materials are described in United States Patent No. 5,226,992 issued July 13, 1993 to M. Mormon, the disclosure of which is incorporated herein by reference.

Examples of the articles which include the elasticized side panels and the selectively configured fastener appendages are described in the United States patent application Serial No. 168,615 of T. Roessler et al. Entitled "DIAPER". OF DYNAMIC ADJUSTMENT, and presented on December 16, 1993 (attorney's case No. 10,961). Various techniques for forming the desired fastening systems are described in U.S. Patent No. 5,399,219 to T. Roessler et al., Entitled METHOD FOR MAKING A DRAWING SYSTEM FOR A DYNAMIC ADJUSTMENT DIAPER and granted March 1995 (lawyer's case No. 11,186); in U.S. Patent No. 5,540,796 which was granted on July 30, 1996 to D. Fries, entitled A PROCESS FOR ASSEMBLING ELASTICIATED EARS, (attorney's issue No. 11,169); in U.S. Patent No. 5,595,618 which was granted on January 21, 1997 to D. Fries, entitled "A ASSEMBLY PROCESS FOR A LAMINATED TAPE" (attorney's matter No. 11,950); and in U.S. Patent No. 5,549,592 which was granted on August 27, 1996, to D. Fries, entitled "ABSORBENT ARTICLE WITH A LAMINATED TAPE," (pleading issue No. 11,990). All of the descriptions of the documents described above are incorporated herein by reference in a manner that is consistent (not in conflict) with the same.

The fastener system may optionally include a separately provided reinforcing strip which is composed of a reinforcing and / or stiffening material and is laminated to a first designated surface of each of the side panel members 56 in the outer region of the panel lateral The reinforcing strip shown extends along essentially the entire extension of the outer end portion of the panel member 56. In addition, the reinforcing strip has a length which is greater than the length dimension of the securing mechanism 44. on the user attachment portion 38 of the fastener appendix 36. The reinforcement strip may, for example, be composed of a release tape, and the release tape may include a substrate composed of a polymer film, such as a polypropylene film.

The appropriate release tape materials are available from Avery Corporation, a business having offices located in Painesville, Ohio.

In particular, the reinforcing strip may be operably joined and laminated to the outer region of the panel member 56 along the first surface of the panel member. The reinforcing strip shown can be configured with its terminal outer edge essentially coterminous with essentially the outer edge of the panel member 56. In addition, the width of the release tape along the transverse direction 24 is desirably equal to or greater than the width of the securing mechanism 44 provided on the user attachment region 38 of the fastening tab 36.

The illustrated fastening system includes a pair of opposed and complementary fastener appendages 36, which provides a mechanism for holding the article on the user. Each of the fastener appendages includes an appendage substrate 86, which may be composed of several substrate materials. For example, the shown embodiment of the appendage substrate may be composed of a polymer film, such as a polypropylene film. Suitable film materials are available from Avery Corporation, a business having offices located in Painesville, Ohio. Alternatively, the securing fabric may include a woven or non-woven fabric, such as a spun-bonded non-woven fabric.

The appendage substrate shown representatively 86 includes a designated securing surface and an opposing user surface and includes selected securing means which are placed on the securing surface of the appendage substrate. The securing means can be provided by an adhesive, a cohesive material, a cooperating component of an interenganchante mechanical fastener, boteroles, pins or buckles and the like, as well as combinations thereof. For example, the securing means may include a hook component (eg mushroom head) or a curl component of a hook and loop fastener. In the configuration shown, the securing means are provided by a layer of primary adhesive distributed over the designated securing surface, and the fastening system provides an adhesive fastener appendage. The fastening appendages may be constructed to releasably adhere to a designated positioning zone patch 92 which is attached to the diaper front waistband section to provide a mechanical or adhesive fastening system which is resilient.

With the adhesive securing means, the primary adhesive layer can be used for laminating * v operably and fixing the designated factory attachment region 39 of the fastener appendage 36 to the outer region of the panel member 56 along a second designated surface of the panel member. Other types of connection means, such as thermal links, sonic joints, mechanical sewing, stapling and the like, as well as combinations thereof, can alternatively be used to permanently attach the fastening tab to the panel member. For example, ultrasonic bonds can be employed to provide a selected complementary bond.

With reference to Figure 1, the fastener appendage 36 includes a factory attachment section 39 which covers the outer edge of the panel member 56, and extends beyond the panel member to provide the user attachment region of the bra appendage In the particular arrangements of the invention, the fastener appendage may have a relatively broad user attachment section in combination with a relatively narrower intermediate section. The intermediate section is positioned between the user attachment and factory attachment sections of the fastener appendage. In additional aspects of the invention, the fastening tab 36 may optionally include a finger appendage region. The finger appendage can be essentially non-assuring, and can provide an area that can be easily gripped by the user without contaminating or in a manner adversely affecting the securing means.

Various types and arrangements of interlocking mechanical securing means may be employed to provide an operable fastening system for the various configurations of the invention. Representative examples of suitable mechanical fastener configurations are described in U.S. Patent No. 5,605.73 which was granted on February 25, 1997 to G. Zehner et al. entitled HIGH-FELT APPENDIX BRAZIER, (attorney's case No. 11,571); and the patent application of the United States of America Series No. 421,640 of P. VanGompel et al., and entitled MULTIPLE JOINT CLAMPING SYSTEM filed on April 13, 1995 (attorney's case No. 11,430), whose full descriptions are incorporated herein by reference in a manner that is consistent therewith.

Having described the invention in considerable detail, it will be readily apparent that various changes and modifications can be made without departing from the spirit of the invention. All such changes and modifications are contemplated as being within the scope of the invention as defined by the attached clauses. »«.

Claims (25)

R E I V I N D I C A C I O N S

1. An absorbent article having a longitudinal extension dimension, a lateral transverse dimension, a front waist portion, a rear waist portion, and an intermediate portion which interconnects said front and rear end portions, said article comprises: a lower sheet layer having a pair of laterally extending laterally extending side margins, each lateral margin having an outwardly concave terminal lateral edge contour located in the leg opening regions designated in an intermediate portion of each lateral margin, each concave side edge contour has a selected longitudinal length along said length dimension of said article; a liquid-permeable top sheet layer connected in a front relation superimposed with said bottom sheet layer; an absorbent body placed in the form of a sandwich between said upper sheet layer and said lower sheet layer; Y a member provided with fin-gusset provided separately connected to at least one of said lower sheet and upper sheet layers along each of said leg opening regions, said gusset-fin member providing a gusset section of piern and a section of containment fin; where each leg gusset section is configured to extend further and bridge through its concave end side edge contour towards corresponding edge of said bottom sheet layer, and to provide a folded and stretched lateral margin of said article; each containment flap section is integrally formed with a corresponding one of the leg shield sections and positioned relatively inward therefrom to provide said flapper member; Y each containment flap section has an essentially fixed bord located near one side of one of the elastified side margins, and has a distal, folded and elasticated moving edge portion; and where the fin-gusset member includes a barrier layer having a pair of barrier layer side edges extending longitudinally and laterally opposite and the first and second major facing surfaces, a first layer which is attached to a facing relationship with said first front surface of said barrier layer, said barrier layer having a region of 10 leg gusset, an outer side portion, a containment fin region, and an inner side part, said outer side portion is arranged to wrap around at least one lateral edge of said outer layer. 15 barrier and extend inwardly therefrom along the second facing surface of said barrier layer, a first arrangement of a first 20 plurality of elastomeric members extending longitudinally and apart joined and placed in the form of a sandwich by said barrier layer and said layer of fabric within said leg gusset section of said leg member. 25 fin-gusset; and a second array of at least one longitudinally extending elastomeric member attached to at least said fabric cap within each fin section of said fin-gusset member, said first and second elastomeric member arrangements providing for both u composed of fin-gusset essentially longitudinally folded and elastomeric.

2. An article as claimed in clause 1, characterized in that said inner side portion d said fabric layer is arranged to wrap around to have in the form of a sandwich said second arrangement of at least one elastomeric member extending longitudinally.

3. An article as claimed in clause 1, characterized in that said inner side portion of said fabric layer is arranged to wrap around a second side edge of said barrier layer and said at least one elastomeric member extending longitudinally joined between said fabric layer and said barrier layer within said containment fin section of said gusset-fin member.

4. An article as claimed in clause 1, characterized in that said first arrangement of elastomeric members includes a first set of laterally spaced elastomeric members attached to said prime main surface of said barrier layer and a second elastomeric member spaced apart from said elastomeric members. and laterally separated joined to said second main surface of said barrier layer.

5. An article as claimed in clause 4, characterized in that said first set of elastomeric members are laterally offset and staggered with respect to said second set of elastomeric members.

6. An article as claimed in clause 1, characterized in that: said barrier layer extends into the containment flap section of said escutcheon member, and said second array of at least one elastomeric member includes a second plurality of elastomeric members with a first set of spaced apart laterally spaced elastomeric members attached to said first main surface of said barrier layer and a second set of elastomeric members spaced apart laterally attached to said second main surface of said barrier layer.

7. An article as claimed in clause 6, characterized in that said barrier layer and dich fabric layer are essentially not attached to one another in the intermediate regions located between the immediately adjacent members of said second plurality of elastomeric members.

8. An article as claimed in clause 1, characterized in that the barrier layer and the fabric layer are essentially not subject to one another in intermediate regions located between the immediately adjacent members of said first plurality of elastomeric members.

9. An article as claimed in clause 8, characterized in that said first plurality of elastomeric members is attached to at least one of the fabric and barrier-fin layers with an essentially separate adhesive strip.

10. An article as claimed in clause 8, characterized in that each of the second plurality of elastomeric members is fastened to at least one of the fender-shield and fabric barrier layers with an essentially separate adhesive strip.

11. An article as claimed in clause 1, characterized in that each leg gusset section is connected to a side surface to the body of the top sheet layer, each of the concave terminal edge contours facing outwards has a longitudinal extension l which extends along at least about 20% d a total longitudinal extension of said article, and the leg gusset section is in a bent configuration through at least about 20% of the total length d the lower sheet layer.

12. An article as claimed in clause 1, characterized in that each of the lateral margins of the lower sheet generally defines a plane thereof and each of the leg gusset sections is constructed to extend beyond its contour. Associated concave side bord of said lower sheet layer in an arrangement which lies essentially within the plane of the associated lower leaf lateral margin.

13. An article as claimed in clause 1, characterized in that said leg gusset section has a composite rigidity of not less than about 5 mg.

14. An article as claimed in clause 13, characterized in that said leg gusset section provides a member having a composite rigidity of no more than about 250 mg.

15. An article as claimed in clause 1, characterized in that each section of escutcheon d leg has a lateral width not less than about 13 millimeters.

16. An article as claimed in clause 1, characterized in that each leg gusset section is connected to said article with a gusset fastener for holding said leg gusset essentially parallel to said plane of its associated lower leaf side margin.

17. An article as claimed in clause 16, characterized in that said fin-gusset fastener includes an article edge fastener which secures said leg gusset to said article on one side of its concave end lateral edge contour. associated with said lower sheet layer along essentially a complete section of said lateral edge contour within which said leg shield and said lateral edge contour are coextensive.

18. An article as claimed in clause 13, characterized in that each section of containment fin has a composite stiffness of not less than about 10 mg.

19. An article as claimed in clause 18, characterized in that each containment fin section has a composite stiffness of no more than about 250 mg.

20. An article as claimed in clause 1, characterized in that at least a part of each leg gusset section extends laterally beyond its corresponding concave end lateral edge contour corresponding to said lower sheet layer in its narrowest point in the crotch area by a distance of not less than about 3 millimeters.

21. An article as claimed in clause 1, characterized in that said barrier layer and said layer of fabric have a reduced amount of adhesive in intermediate areas which are located between the immediately adjacent members of said first plurality of elastomeric members, in comparison to a quantity of adhesive located at the positions of said first plurality of elastomeric members.

22. An article as claimed in clause 4, characterized in that said barrier layer and said layer of fabric have a reduced amount of adhesive in intermediate areas which are located between the immediately adjacent members of said first plurality of elastomeric members, in comparison to a quantity of adhesive located at the positions of the first plurality of the elastomeric members.

23. An article as claimed in clause 1, characterized in that said second arrangement of at least one elastomeric member is attached to at least one of said fabric and barrier-fin layers with an increased amount of adhesive, in comparison to an amount of adhesive located in said boundary space between said first array of the elastomeric members and said second array of at least one elastomeric member.

24. An article as claimed in clause 6, characterized in that each of said second plurality of elastomeric members is laminated to at least one of the fabric gusset-fin barrier layers with an increased amount of adhesive, in comparison to an amount of adhesive located in the intermediate regions which are placed between the immediately adjacent members of said second plurality of elastomeric members. fi

25. An article as claimed in clause 1, characterized in that said fin member, escudet has been folded for a selected amount before incorporating each member of the gusset fin into the article. SUMMARY An absorbent article which includes a lower sheet layer having a pair of lateral margins extending longitudinally and laterally opposite. Each lateral marge has a concave terminal lateral edge contour to the outside located in the pierced opening regions designated in an intermediate part of the lateral margin. The concave lateral edge contour has a longitudinal length selected along a length dimension of the article. A lower liquid permeable sheet layer is connected in a facing relationship and superimposed with the lower sheet layer, an absorbent sheet body is Place in sandwich form between the upper sheet layer and the lower sheet layer. A separately provided composite fin-gusset member is connected to at least one of the lower sheet and upper sheet layers along one of the leg opening regions. The fin-gusset member provides a leg gusset section and a containment flap section. The fin-gusset member includes a barrier layer having a pair of side edges of barrier layer that extend longitudinally and laterally opposite, and has a first principal facing surface and a second major opposing surface. A nonwoven fabric layer is bonded in a facing relationship with the first facing surface of the barrier layer. The fabric layer has a leg gusset region, an outer side portion, a containment fin region, and an interior edge portion. The outer side portion of the fin-gusset fabric layer is arranged to wrap around at least one side edge of the barrier layer and to extend inwardly therefrom along the second front surface of the barrier layer. barrier. A first array of a first plurality of elastomeric members extending longitudinally and spaced apart are interposed between the barrier layer and the fabric layer within the leg gusset section of the gusset member.