HK1017984A - An absorbent article with improved waist elastic and containment system - Google Patents

Description

Absorbent article having improved waistband member elastication and sealing system

Technical Field

The present invention relates to articles having one or more elastic perimeters. In particular, the present invention relates to articles incorporating a special elastic barrier or sealing system in the waistband portion thereof.

Background

Conventional absorbent articles, such as diapers, have been constructed with various elastic waistbands and elastic leg bands or elastic cuffs. Such articles also include an elasticized sealing element or a barrier flap attached to the leg and/or waist portions thereof. Extensible outer covers comprising elastic webs, such as those comprising a nonwoven layer of stretch bonded sheet material, are incorporated into articles of particular design. Other conventional designs include separate elastic or inelastic side panel members attached to the lateral side edges of the backsheet member or the outer cover member, as well as fastening systems and fastening tabs associated with the side flaps for fastening the article to the wearer.

However, articles incorporating conventional waist cap configurations exhibit various disadvantages. For example, it is difficult to maintain the desired operation of the waist cover when the article is worn. Even if such waist covers are constructed of elastic materials or otherwise elasticized, it is difficult to maintain contact between the movable edge of such waist covers and the wearer's body, and it is also difficult to reliably maintain such covers in an open condition to effectively receive and seal urine and feces. As a result, there remains a need for improved containment structures in the leg and waist regions of absorbent articles.

Brief description of the invention

The present invention can provide a distinctive article having a longitudinal dimension, a lateral dimension, a front waistband portion, a rear waistband portion, an intermediate portion connecting the front and rear waistband portions, and a pair of laterally opposing elastic side edges. The article has a backsheet and a liquid pervious topsheet joined in superposed relation to the backsheet. The topsheet and the backsheet sandwich the absorbent body therebetween and a waist pocket member is attached to at least one of the backsheet and the topsheet along at least one end edge of the article. The waist pocket includes an extended wing portion and an extended pocket portion. The pocket portion of the waist pocket includes a substantially fixed side portion fastened to the article, and an elastic, gathered movable side portion longitudinally spaced from the fixed side portion. In some particular forms, the bag portion may also include a substantially liquid-impermeable bag barrier layer and a bag fabric layer attached in facing relation to the bag barrier layer. In other versions, a separate array of laterally extending bag elastics may be sandwiched between a bag barrier layer and a bag fabric layer to provide a generally laterally gathered elastic waist bag composite.

The present invention, in its various aspects, provides a barrier cover structure that is more reliably and efficiently maintained in an open position while an associated absorbent article is worn. In addition, such an open-lid configuration can maintain the site open without unduly irritating the wearer's skin. With respect to the arrangement of the component parts and the operating parameters such as controlled stiffness and controlled attachment of the barrier cover, an improved absorbent structure that provides less leakage while providing increased wearer comfort can be advantageously provided.

Brief description of the drawings

The present invention and other advantages of the invention will be more fully understood by reference to the following detailed description and the accompanying drawings, in which:

FIG. 1 representatively illustrates a partially cut away top view of an article of the present invention;

FIG. 2 representatively illustrates a cross-sectional expanded view of the waistband article elastic system and waistband article barrier cover system of the present invention taken along the longitudinal centerline of the article with the article of the invention having its cover or pocket portion in its extended uncontracted condition;

FIG. 3 representatively illustrates a cross-sectional view in open extension of the elastic system and the waistband article barrier cover system of the present invention with the cover or pocket portion thereof in a contracted and open condition;

FIG. 4 representatively illustrates an enlarged top view of the waistband portion of an article of the present invention;

FIG. 5 representatively illustrates an enlarged top view of another waistband section of an article of the present invention having a notch formed in the waistband of the backsheet of the article;

fig. 6 representatively illustrates a partially cut away top view of another article of the present invention having two sets of elastic strands in the pocket of the barrier cover system.

Detailed description of the invention

The present invention is described below in connection with the production of elastic sealing systems for absorbent articles, particularly disposable absorbent articles. Such articles are intended to be placed against or in proximity to the body equipment of the wearer to absorb and contain the various exudates of the body, and are intended to be discarded after a defined period of time. Such articles are not intended to be laundered or otherwise restored for reuse. Although the description herein is made specifically in the context of diaper articles, it should be recognized that the present invention is equally applicable to other articles such as caps, pajamas, drapes, covers, adult incontinence garments, sanitary napkins, child's training pants, and the like.

In addition, the present invention will be described in connection with various configurations and styles thereof. It should be understood that other alternative versions of the invention can be combined as a result of including one or more of the various configurations and versions of the invention.

Referring to fig. 1, 2 and 3, a representative article such as a diaper 10 is shown to include a longitudinal dimension 26, a transverse width dimension 24, a front waistband portion 12, a back waistband portion 14, an intermediate portion 16 connecting the front and back waistband portions together, and a pair of laterally opposing elastic edges 20. The article has a backsheet 30 and a liquid pervious topsheet 28 joined in superposed relationship to the backsheet. An absorbent body 32 is interposed between the topsheet side and the backsheet side, and an elastic waist pocket 80 is attached to at least one of the backsheet and topsheet layers along at least one end edge 22 of the article.

The article representatively shown in the figures includes longitudinally opposing end edges 22 and a pair of laterally opposing elastic edges 20. The elastic waist pouch member 80 is attached to at least one of the backsheet and topsheet along at least one end edge 22 of the article. The illustrated waist pocket 80 includes an extended wing portion 82 and an extended pocket portion 84. The pocket 84 of the waist pocket 80 includes a substantially fixed hem 102 secured to the article and an elastic, gathered, movable hem 104 longitudinally spaced from the fixed hem 102. The bag portion 84 further includes a substantially liquid impermeable bag barrier layer 106 and a bag fabric layer 108 attached in facing relationship to the barrier layer. A plurality of spaced apart transversely extending bag elastic members 110 are sandwiched between the barrier layer 106 and the fabric layer 108 to form a substantially transversely gathered, elastic waist bag composite 112.

There is a fastening system 40 associated with the article on one or both of the laterally opposing end regions 72 on at least one of the front and back waistband portions. Each fastening system 40 may incorporate a cooperating side panel 56 which may be configured to be inelastic or elastically extensible at least in the transverse article direction 24.

Figure 1 is a diaper 10 of the present invention in its flat-out, uncontracted state (i.e., with all elastic induced gathering and contraction results eliminated). Portions of the structure of the diaper 10 have been cut away to more clearly show the interior thereof, with the wearer-contacting surface of the diaper facing the viewer. The outer edges of the diaper define a periphery in which two longitudinally extending side edges are indicated at 20 and two transversely extending end edges are indicated at 22. These side edges define the leg openings for the diaper and may optionally be curved or contoured. The end edges are here indicated in the form of straight lines, but can also be chosen arbitrarily, for example in the form of curved lines.

The diaper 10 generally includes a porous, liquid pervious topsheet 28, a substantially liquid impervious backsheet 30, an absorbent member 32 positioned and joined between the topsheet and the backsheet, a surge management portion 46, and elastic members such as leg elastics 34 and waist elastics 42. The treated cushioning portion 42 is positioned in fluid communication with the absorbent member 32, which includes a retention portion 48. The topsheet 28, backsheet 30, absorbent member 32, surge management portion 46 and elastic members 34 and 42 may be joined in a variety of known diaper configurations. In addition, the diaper 10 may also include a system of leg containment covers such as the sealing cover 62.

As representatively shown in the figures, the topsheet 28 and the backsheet 30 may be generally coextensive and have a length and width dimension generally greater than the corresponding dimension of the absorbent structure 32. The topsheet 28 is attached to and overlies the backsheet 30, thereby defining the periphery of the diaper 10. The waistband region comprises the upper portion of the diaper which will wholly or partially cover or encircle the waist or mid-lower torso of the wearer when the diaper 10 is worn. The intermediate zone 16 is located between and connects the belt zones 12 and 14. It includes a crotch portion 18 which itself comprises that portion of the diaper 10 which, when worn, is positioned between the legs of the wearer and covers the lower torso of the wearer. As such, the crotch region 18 is the area of the diaper or other disposable absorbent article where fluid surges typically repeat.

The topsheet 28 has a body-facing surface that is comfortable, soft, and non-irritating to the wearer's skin. In addition, the topsheet 28 is less hydrophilic than the retention portion 48 and has sufficient apertures to permit liquid to pass through its entire thickness. A wide selection of textile materials, such as porous foams, reticulated foams, apertured plastic films, natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers), or a combination of natural and synthetic fibers, can be used to make a suitable topsheet. The topsheet 28 generally serves to isolate the wearer's skin from liquids held in the absorbent structure 32. Various woven and nonwoven fabrics can be used as the topsheet 28. For example, such topsheets may be constructed from meltblown or spunbonded fabrics of polyolefin fibers, as well as bonded-carded-fabrics constructed from natural and/or synthetic fibers.

In the context of the present invention, "nonwoven fabric" refers to a fabric material formed without a fabric weaving or knitting process. "Fabric" is used to refer to all woven, knitted, and nonwoven fibrous fabrics.

The topsheet web may be constructed of a substantially hydrophobic and substantially non-wettable material, the hydrophobic material beingThe material may be treated with a surfactant or otherwise as necessary to impart a desired level of wettability and hydrophilicity. In a particular embodiment of the invention, the topsheet 28 may be a nonwoven, spunbond polypropylene fabric comprised of about 2.8 to 3.2 denier fibers forming a basis weight of about 20g/m²And a density of about 0.13gm/cc of the fabric material. Such fabrics may be treated with a selected amount of surfactant, such as about 0.28% triton x-102 surfactant, available from union carbon, commercially available from Danbary, connecticut. Such surfactants may be applied by any conventional means such as spraying, printing, brushing or the like.

Such surface active materials, such as conventional humectants, may be employed in the central portion of the topsheet 28 to render the latter more wettable than the other remaining portions. In particular configurations, the lateral width of this intermediate portion may be substantially equal to or less than the lateral width of the cushioning treatment portion 46. In another configuration, the width of the intermediate portion may be approximately equal to or less than the lateral spacing between a pair of adhesive strips used to secure the sealing cover 62 to the topsheet 28 to form an anti-leak barrier seal on the backsheet 30.

The surfactant treated intermediate portion may be approximately centered with respect to the longitudinal centerline of the diaper and may extend along substantially the entire length of the topsheet; alternatively, the intermediate portion may be configured to extend along only a predetermined portion of the length of the topsheet.

Various configurations of the present invention may include an elastic leg band barrier cover, such as the illustrated sealing cover 62. In the configuration shown, for example, two sealing covers 62 are included that are attached to the body side of the top sheet 28. Suitable constructions and arrangements for the sealing cap 62 are described, for example, in U.S. patent No. 4704116 to k.ellue, 11/3/1987, the disclosure of which is incorporated herein by reference in its entirety as if fully and unequivocally consistent herewith. Other configurations for the seal cap 62 are described in Everett, entitled "absorbent article with improved cushioning treatment", filed on 3/4 of 1994 (attorney docket No. 11375), the disclosure of which is incorporated herein by reference in a manner consistent herewith.

Such a seal cover may be attached to the topsheet 28 at a fastening region extending along its length, such as fastening edge 64. The movable edge 66 of each seal cover includes a cover spring 68 comprised of one or more spring wires. For example, a supply of elastic filaments may be arranged substantially parallel spaced apart from one another, a suitable elastic filament being formed, for example, from 470 dtex Lyc' RA elastane yarn available from P.E.I. DuPond de Nemours, having a trade name of Wilmington, Del. Alternatively, the elastic filaments may be formed from 700 denier spandex from GLOSPAN S7 available from Globe manufacturing, Inc. commercially available from Fall River, Mass. The elastic member 68 is connected to the movable edge of the sealing cover in an elastically contractible state so that contraction of its elastic member causes the edge of the sealing cover to gather and shorten. As a result, the movable edges of each seal cover often position themselves in spaced relation to the body-facing surface of the topsheet 28 and/or the surge management portion 46, tending to assume a generally upright and nearly vertical configuration, particularly in the crotch portion of the diaper. For example, in the illustrated embodiment, the movable edge of the seal is attached to the cover elastic by partially folding the seal material back onto itself by an amount sufficient to enclose the beneficial elastic 68.

At least one pair of seal barrier covers 62 are attached to the topsheet 28 at laterally opposite longitudinally extending regions adjacent to the laterally opposite side regions of the central portion of the topsheet 28. The attached topsheet extension is located substantially laterally inboard of the leg elastics of the diaper article 10, but may alternatively be located outboard of such leg elastics.

In various configurations of the present invention, the desired barrier covers, such as the sealing cover 62 and the waist cover 84, may be constructed, for example, from a fibrous material similar to the material comprising the topsheet 28 or similar to the material comprising the cushion treatment 46. Other conventional materials such as polymer films may also be used. In other versions of the invention, the barrier cover is constructed of a material that is permeable only to gases, such as ambient air. Other configurations of the invention may include those that prevent the passage of aqueous liquids such as urineA barrier cover of material. For example, such a barrier cover may be constructed of a spunbond-meltblown-spunbond (SMS) laminate material. In the illustrated embodiment, the barrier cover may be formed, for example, from a basis weight of about 0.75osy (about 25 g/m)²) Is made of the SMS material of (1). Wherein the spunbond layer is comprised of polypropylene fibers and the meltblown layer is comprised of meltblown polypropylene fibers.

In various configurations of the present invention wherein the selected material or components such as barrier covers 62 and/or 84 are configured to be permeable to gas while blocking and restricting the passage of aqueous liquids, such liquid barrier materials are configured to support a liquid level difference of at least about 45cm without substantial leakage of water therethrough. A suitable method for measuring the stability of a material to fluid penetration is federal test method standard FTMS191 method 5514(1968, 12 months 31 days).

The backsheet 30 can be constructed of a liquid permeable material, but preferably comprises a material that is constructed to be substantially liquid impermeable. For example, a typical backsheet may be made of a thin plastic film or other flexible liquid impervious material. This "soft" material is conformable and can quickly conform to the body of the wearer. The backsheet 30 prevents the exudates contained in the absorbent structure 32 from wetting articles which contact the diaper 10, such as bed sheets and gowns.

In a specific embodiment of the present invention, the backsheet 30 is a polyethylene film having a thickness of about 0.012 to 0.051mm (0.5 to 2.0 mil). In the illustrated embodiment, the back sheet is a film having a thickness of about 0.032mm (about 1.25 mil). Another type of structure for the backsheet may include a woven or nonwoven fibrous web layer that is constructed or treated, in whole or in part, to impart a desired degree of liquid impermeability to selected regions of the backsheet that are adjacent to the absorbent body. For example, a fabric-like backsheet having a basis weight of about 0.5osy (about 17.7 g/m) may be used²) A polypropylene spunbond fabric was constructed by laminating and heat bonding a layer of a stretched, thinned polypropylene film having a thickness of about 0.0006 inch (about 0.015mm) and a basis weight of about 14.5g/m²A film of (2). Alternatively, however, such articles may include a separate outer cover member over and above the backsheet.

The backsheet 30 may optionally include a breathable material of the microporous type which permits vapors to escape from the absorbent structure 32 but which still prevents liquid exudates from passing through the backsheet. For example, such a breathable backsheet may include a microporous polymer film or nonwoven fabric that has been coated or otherwise treated to impart a desired level of liquid permeability. For example, one suitable microporous membrane is PMP-1 material available from Mitsui Joatsu chemical company, a business having a business in Tokyo, Japan; or an XKO-8044 polyolefin film, available from 3M company, Minne apolis, Minnesota. The backsheet may be embossed or otherwise rendered to have a matte finish to exhibit a more aesthetic appearance.

The size of the backsheet 30 is generally determined by the size of the absorbent structure 32 and the appropriate diaper design selected. For example, the backsheet 30 may be generally T-shaped, generally I-shaped, or modified hourglass-shaped and may extend a selected distance [ e.g., about 1.3 to 2.5cm (about 0.5 to 1.0 inch) ] beyond the end edges of the absorbent structure 32 to provide side edges.

The topsheet 28 is joined or otherwise combined with the backsheet 30 into a practical form. The term "combination" as used herein includes configurations wherein: the topsheet 28 is joined directly to the backsheet 30 by being secured directly to the backsheet 30; and configurations wherein the topsheet 28 is joined to the backsheet 30 through an intermediary member secured to the backsheet 30. The topsheet 28 and the backsheet 30 may be secured directly to each other in selected regions, such as along the marginal regions of the diaper, using securing means (not shown) such as adhesives, sonic bonds, thermal bonds, or any other securing means known in the art. For example, the topsheet 28 may be secured to the backsheet 30 by a uniform continuous layer of adhesive, a patterned layer of adhesive, a spray pattern of adhesive, or an array of separate lines, spiral stripes, or dot patterns of adhesive. It will be apparent that the securing means described above may also be used to connect and assemble various other components of the articles described herein.

In this representatively illustrated embodiment of the invention, the topsheet 28 is disposed and secured in facing relation to the backsheet 30 with the retention portion 48 and the cushioning treatment portion 46 retained and contained therebetween. The side edge regions of the topsheet 28 are operatively joined to the corresponding side edge regions of the backsheet 30. Each of the joined side edge regions of the topsheet and backsheet is located laterally outward of the corresponding joined side edge region of the surge management portion 46. In particular configurations of the present invention, the topsheet 28 may include a joined end edge region longitudinally outboard of the retention portion 48 and/or the surge management portion 46. similarly, the backsheet 30 may include a joined end edge region longitudinally outboard of the retention portion and/or the surge management end edge region.

The elastic members 34 are disposed adjacent to the periphery of the diaper 10 along each longitudinal side edge 20. The leg elastics 34 can be joined to either or both of the topsheet and backsheet to provide elasticized edges to the diaper article, and can also be arranged to pull the diaper 10 toward the legs of the wearer to form elasticized leg bands or cuffs. Waist elastic 42 may also be provided adjacent one or both end edges of the urine portion 10 to provide an elastic waistband.

The elastic members 34 and 42 are secured to the diaper 10 in an elastically contractible condition so that in a normally strained configuration, the elastic members are effectively contracted toward the diaper 10. The two elastic members can also be fixed in an elastically contractible state in various ways; for example, they may be stretched and secured while the diaper 10 is in an uncontracted state. Alternatively while the elastic members are in a relaxed or stretched state. The diaper 10 may be contracted, for example, by folding the diaper 10 and securing and attaching the two elastic members to the diaper 10. This allows the article to be gathered by additional means such as heat-shrinkable elastic materials.

In the embodiment shown in fig. 1. The leg elastic members 34 extend substantially the entire length of the intermediate region 16 of the diaper 10. Alternatively, the elastic members 34 may extend along the entire length of the diaper 10 or any other suitable length of elastically contractible line structure as desired for a particular diaper design. The resilient members 34 and 42 can have a variety of configurations. For example, the width of each elastic member 34 may vary from 0.25mm (0.01 inch) to 25mm (1.0 inch) or more. Such elastic members may comprise a single strand of elastic material or may comprise several strands of elastic material, parallel or not, and the elastic members may also be applied in a straight or curved configuration. Where multiple filaments are employed, each filament may be configured to provide substantially equal spring forces or configured to provide different spring forces. For example, the individual elastic filaments may have different diameters or other dimensions, or may be configured to have different draw lengths to provide a gradient or other varying elastic tension. When the filaments are non-parallel, two or more of the elastic filaments intersect or are otherwise connected to each other within the elastic member. The elastic members may be secured to the diaper by any means known in the art. For example, the elastic members may be ultrasonically bonded, heat and pressure sealed using a variety of bonding patterns, or bonded to the diaper 10 using a selected pattern of hot melt or other type of adhesive. For example, a spray or swirl adhesive pattern may be used herein.

In the illustrated embodiment of the invention, the leg elastic 34 may comprise, for example, a carrier sheet to which is attached an elastic member comprised of a collection of elastic filaments. These elastic threads may be crossed or connected, or may be completely separated from each other. The carrier sheet shown may comprise, for example, 0.002cm of virgin, unembossed polypropylene film. The elastic strands shown may be composed of, for example, LyCRA elastic material available from DuPont. In embodiments of the present invention employing 3-4 filaments for each elastic leg band, each elastic filament is typically in the range of about 470-1880 decitex (dtex), and preferably at a value of about 940 dtex or equivalent; another example of suitable elastic filaments is GLOSPAN elastic material available from Globe manufacturing, where each elastic filament may typically be about 240 to 1920 denier (den), preferably about 1400den or an equivalent.

In addition, the leg elastic 34 may take a generally flat or selected arcuate form. For example, such elastic members in the form of arcs may curve inwardly toward the longitudinal centerline of the diaper. In particular configurations, the curvature of such elastic members need not be symmetrical about the transverse centerline of the diaper. The curved elastic members may have a reflective curvature with inward and outward curves, and the longitudinal centers of such elastic members may be offset toward the front or back waistband of the diaper by a selected distance to provide the desired fit and appearance.

Conventional such articles are provided with various barrier flap configurations in the waistband or leg band region thereof. Such articles typically include, for example, single or multiple layers of materials such as polymeric films and film-nonwoven laminates at the waistband portion along the lateral side direction thereof to form a waist cover or screen. The materials described above generally exhibit similar characteristics. As the pieces of material spread apart, they tend to neck down and reduce their effective width. They form large corrugations or furrows extending generally in the direction of stretch during necking. The presence of such creases can cause the barrier flaps, and particularly the waist flap, to collapse upon themselves, reducing their ability to maintain an opening for receiving and capturing bodily waste. In addition, when conventional pieces of material contract, they generally weaken their stiffness, and weakening the stiffness in the composite pieces also causes the barrier cover to fold or collapse upon itself, reducing its effectiveness.

It has been found that a particular barrier cover construction, such as a laminate including individual and separate elastic bands, provides a structure that overcomes the deficiencies of the existing construction. The laminate of elastic filaments of the present invention substantially avoids the undesirable effect of wrinkling in the direction of stretch, typically seen over the entire surface of the barrier cover and along the direction of desired stretch, when stretched. It is desirable that the amount of deployment not exceed the amount of stretch of the elastic wire when assembled in the laminate. Such a laminate with elastic filaments can be made substantially flat when fully extended and extended, and when it is relaxed and elastically contracted, it is possible to produce thin corrugations of sufficient size and sufficient frequency, the grooves or recesses of the corrugations being generally aligned substantially perpendicular to the direction of contraction. Such fine corrugations can improve the stiffness of the barrier cover structure and improve its ability to remain open to receive body exudates. Furthermore, the geometry of the elastic thread laminate itself can also make the properties of the material concerned play an important role when used as a barrier cover structure, such as the waist cover shown. The provision of elastic threads also enables various configurations of such laminates to perform their respective functions.

However, it has proven to be unsuitable for producing therefrom a sufficiently effective and reliable waist cover structure of the conventional type or family of materials. It has been found that the performance and effectiveness of such waist cap barriers depends on the particular combination of properties and behavioral characteristics of the materials used to assemble and construct such composite barrier caps. For example, the incorporation of a polyurethane film or a cover composed of a film laminate in the waistband of an article, while a cover composed of a SMS (spunbond-meltblown-spunbond) nonwoven fabric laminate is placed at the waistband, does not reliably provide a sufficiently effective barrier cover structure. It is important to further configure the material to achieve specific physical properties, one of which is the stiffness of the cover, which can be achieved in a variety of ways. For example, the factors that influence include the basis weight of the cover material, the stiffness or touch of the various sections, the adhesive added on the laminate within the cover, the pattern and distribution of the applied adhesive, the use of welding or sonication, the number of poles of each elastic wire used in the structure of the barrier cover, the geometry of the arrangement of the elastic wires within the barrier cover, the presence and arrangement of the corrugations of the barrier cover, and the number of component layers included within the barrier cover.

The present invention can provide a distinctive article, such as a diaper 10, having a widthwise lateral dimension 24 and a lengthwise longitudinal dimension 26. The representative diaper 10 has a front waistband portion 12, a rear or back waistband portion 14, and an intermediate portion 16 interconnecting the front and back waistband portions. Such an article includes a backsheet 30 having a transverse width and a longitudinal extent. The topsheet 28 is apertured, liquid permeable, has a transverse width and a longitudinal length, and is joined in a superposed relationship to the backsheet 30. An absorbent member, such as an absorbent body 32, is sandwiched between and operatively secured to the backsheet 30 and the topsheet 28.

As shown in fig. 1, 2 and 3, the diaper 10 may have a waist pocket 80 which can include laterally and longitudinally extending wing portions 82 and laterally and longitudinally extending barrier cover or pocket portions 84. The wing portion 82 may be attached to the body side of the topsheet 28, for example. The covering or pouch portion 80 of the waist pouch member 84 includes a substantially fixed edge 102 which is secured to the article along and immediately adjacent to the edge of the flap 82 and includes an elastic, gathered, movable edge 104 which is longitudinally spaced a selected distance from the fixed edge 102. The pocket 84 thus provides an effective waist screen and waist cover structure. The bag portion 84 further includes a substantially liquid impermeable bag barrier layer 106 and a bag fabric layer 108 attached in facing relationship to the barrier layer. The bag fabric layer 108 may comprise, for example, woven and non-woven fabrics, and in the arrangement shown herein, the fabric layer is preferably non-woven. A plurality of spaced apart transversely extending bag elastic members 110 are sandwiched between and operatively connected to the bag barrier layer 106 and the bag fabric layer 108 to form an elastic waist bag composite 112 which is substantially gathered in the transverse direction 24 and is elastically extensible in at least the transverse direction. The arrangement shown includes the elastic members arranged substantially parallel to each other, but may include other spaced apart elastic member configurations and arrangements as desired. The fabric layer 108 is preferably disposed against the skin of the wearer, but the barrier layer 106 may alternatively be placed in close proximity to the skin of the wearer.

In a particular configuration of the invention, the wing portion 82 of the wing pouch member 82 may include a substantially liquid-impermeable wing barrier layer 114 and a wing fabric layer 116 operatively attached and secured in facing relation to the barrier wing. The wing fabric layer may be comprised of, for example, woven or non-woven fabric, and is preferably non-woven in the construction shown herein. A plurality of separate, laterally extending flap elastic members 118 are sandwiched and operatively joined between the flap barrier layer 114 and the flap fabric layer 116 to form an elastic flap composite 120 that is substantially transversely gathered and elastically stretchable at least in the cross machine direction 24 due to the flap elastic members. The elastic members in this illustrated construction are substantially parallel to each other, but may alternatively comprise other independent configurations of elastic members that are not parallel. The fabric layer 116 is preferably applied to the skin of the user, and the barrier layer 114 may be disposed adjacent to the skin of the user if desired. The wing portion 82 can take a particular configuration and be disposed substantially coterminous with the associated end edge 22 of the article.

In a particular configuration of the present invention, such as that shown in figures 2 and 3, the pocket portion 84 of the waist pocket 80 may be integrally formed with the wing portion 82 of the waist pocket. In this configuration, the pocket barrier layer 106 and the wing barrier layer 114 integrally form a combined wing-pocket barrier layer, while the fabric pocket layer 108 and the fabric wing layer 116 integrally form a combined wing-pocket fabric layer. In this representative illustrated construction, a wing-pocket barrier layer is also included that is substantially coextensive with the wing-pocket fabric layer.

In other configurations of the present invention, the elastic member 118 in the wing portion 82 is separated from the elastic member 110 in the pocket portion 84 proximate thereto by a predetermined boundary gap 122 forming a separation distance of at least about 2 mm. In some particular cases, the separation distance formed by this boundary gap distance is at least about 8mm, and alternatively, may be at least about 16 mm. This separation distance effectively provides an isolation distance that allows the flap elastic member to operate substantially independently of the pocket elastic member. Thus, the gathers provided by the flap elastic member can be substantially separated from the gathers provided by the pocket elastic member.

Referring to fig. 4, the fastening tabs 36 on the laterally opposite sides of the diaper 10 are preferably substantially aligned along a central lateral alignment line 130. In particular aspects of the present invention, this alignment 130 is substantially coincident within the boundary gap 122 which separates the set of pocket elastics 110 from the set of wing elastics 118 in the lumbar pocket 80. In a preferred arrangement, the distal edge 105 of the pocket may be aligned with or positioned closer to a central line of force 130 that is created when tension F is applied to the fastening sheet. When the distal edge is substantially aligned with the line of force 130, the bag 84, and in particular the moveable edge portion 104 of the bag, is effectively stretched and separated from the article. In particular, the pouch portion can be more effectively urged to separate from the body side of the topsheet 28 in use to form a more effective pouch or waist cap structure to retain bodily fluids and excretions. In addition, this cover element configuration of the waist pocket 84 also provides more effective maintenance of contact with the wearer's body throughout the range of motion imparted by the wearer and provides an improved seal in the area of the movable edge portion 104.

Referring again to FIG. 2, another version of the present invention may include a configuration wherein one of the elastic members 110 of the pocket 84 is located proximate to the substantially fixed edge portion 102. Here, this abutting elastic member is located between the substantially fixed edge 102 and the movable edge 104 of the pocket, and is separated from the edge 102 by an abutment gap distance 124 of not less than about 2mm, and optionally not less than about 4 mm. In other versions of the invention, this abutment gap distance 124 is no more than about 13mm, and alternatively may be no more than about 8 mm. A suitable choice of the gap distance 124 helps to maintain the pocket 84, and in particular its active edge region, in an open position spaced from the top sheet of the article. If this distance is too small, the bag portion may not be reliably opened. If this distance is too great, the bag must adequately resist excessive collapse.

Referring to fig. 2 and 3, the pocket 84 of the waist pocket 80 may be secured to a designated area of the article, such as the topsheet 28, by a bonded region 126. In the configuration shown, bonded regions 126 extend beyond boundary gap 122 to secure flap 82 to the topsheet. Alternatively, the bonded region 126 may be substantially limited to the near-edge gap 122, at least within a section of the edge gap 122 that is laterally centered on the article, with a separate bonding element securing the wing 82 to the article such that the bonded region 126 effectively provides a substantially fixed edge 102 of the pocket 84. Further, the pocket 84 of the waist pocket 80 has laterally opposite ends 128 secured substantially flat against the topsheet 28. As a result, the pocket portion 84 of the waist pocket is secured to the topsheet 28 with a bonding element that may be in a generally U-shaped configuration (FIGS. 1, 4 and 6).

Referring to fig. 5, certain specific configurations of the present invention can have the backsheet 30 formed with at least one longitudinally terminal waistband edge 94 having an inwardly extending notched area 96 formed thereon. The wing portion 82 of the waist bag member 80 is configured to span this notched area 96. Further, the edge portion of the backsheet immediately adjacent to this relief area may be operatively connected to a corresponding portion of the wing portion.

In various configurations of the present invention, the relief area 96 may have various shapes and sizes. The cut-out region may have a curved shape, a linear shape, or a combination thereof. The notch area 96 is preferably positioned generally laterally centrally of the backsheet 30. In various configurations of the present invention, the notched area 96 has a lateral extent that is no more than about 80%, and preferably no more than about 40%, of the total lateral extent of the entire article, which may improve performance. In addition, the lateral extent of the relief area 96 should not be less than about 10% of the total lateral extent of the entire article, and preferably should not be less than about 20% of the latter, so as to provide the desired level of comfort and containment of fecal matter. In other aspects, the depth of the relief areas 96 is in the range of about 2% to about 15% of the total longitudinal extent of the article. In a diaper-type article, for example, the notched area 96 may have a maximum longitudinally inward extent of at least about 9 mm. Alternatively, the inward extent of the relief area 96 is at least about 12.5mm, and optionally at least about 15 mm. In other constructions, the inward extent of the relief area 96 is no more than about 65 mm. Alternatively, this maximum inward extent cannot exceed about 55mm, and may alternatively be no more than about 45 mm. In measuring the dimensions of the notched area 96, the article is laid down in a substantially flat, uncontracted state and the elastic gather at the waistband of the article is substantially removed.

Referring to fig. 2 and 3, one of the bag elastics 110 is located proximate the terminal edge 105 of the movable side portion 104 of the bag portion 84 and is separated therefrom by a gap distance 107 of no more than about 13 mm. Alternatively, the edge gap distance is no more than about 7mm, and may alternatively be no more than about 1 mm. In other cases, the terminal edge 105 is not substantially folded. In special cases, the terminal edge portion of the pouch portion does not fold back on itself to enclose the one or more pouch elastic members. Positioning the elastic member in close proximity to the terminal edge 105 helps maintain the open position of the pocket 84 across substantially the entire width of the pocket. As a result, the pocket portion can better provide a functional type of barrier screen structure.

Various configurations of the present invention provide the desired stiffness of each of the wing portion 82 and the pocket portion 84. Specifically, either or both of the wing portion and the pocket portion may have a stiffness of at least 5 mg. Alternatively, the stiffness may be at least about 15mg, and may be selected to be at least about 30mg for improved performance. In other versions of the invention, either or both of the wing portion and the pocket portion may have a stiffness of no more than about 250 mg. Alternatively, the stiffness should not exceed about 200mg, but may be selected to not exceed about 170mg for improved performance. When the stiffness is too low, the bag part is easy to collapse. When the stiffness is too high, the pouch or flap portion may be excessively irritating to the wearer.

The stiffness of the wing and pocket portions of the waist bag member 80 can be measured using test method TAPPIT543om-94 and a Garley digital stiffness tester (model 4171D, available from Teledyne Gurley, Inc., having a trade name of Troy, N.Y.). Thus, the stiffness of each portion of the waist bag 80 is the bending stiffness. In the present invention, the axis about which bending moments are applied to a test specimen in a stiffness test is the axis of bending that is substantially parallel to the direction of elastic stretch and gathering provided by the associated elastic member, such as elastic members 110 and/or 118. For example, in the case of the stiffness test of the bag portion 84, the bending axis of the bag portion sample would be along an axis that is substantially aligned with the transverse direction 24 of the article as viewed when the bag portion is initially assembled to the article.

The barrier layer may be provided by a liquid impermeable polymer film or fabric or combination thereof for either or both of the wing portion 82 and the pocket portion 84 of the waist pocket 80. The polymer film may be, for example, polyolefin, polyester, polyimide, and the like. The nonwoven material may then comprise spunbond-meltblown-spunbond (SHS) fabric, meltblown fabric, calendered nonwoven sheet, and the like. The barrier layer is constructed such that its hydraulic resistance is sufficient to effectively block the passage of liquid such as urine, in terms of its thickness through which liquid passes.

For example, the barrier layer may comprise a 0.0006 inch (0.015mm) baked cast film such as CT (XEM 400.1.1), or a 0.0004 inch (0.010mm) blown film such as XSF-367 available from ConsolidatedTexp/asfics, Inc., Chippewa Falls, Wis. The barrier layer may also comprise a 0.00035 inch (0.0089mm) stretched, thinned film such as XP1024A, available from Edison plastics, Inc. of Macalesfer, Oklahoma.

For the flap and pocket portions 82 and 84 of the waist pocket, the fabric layers 108 and/or 116 may comprise a fine denier, low basis weight nonwoven material. Examples of such nonwoven materials are polypropylene spunbond, bicomponent polypropylene/polyethylene spunbond, meltblown, SMS material, through-air bonded carded webs, point bonded-carded webs, and the like.

The fabric layer may comprise, for example, a 0.5osy (17gsm) polypropylene spunbond fabric comprised of fibers having a denier of less than about 4. The fabric layer may be either a fiber having a denier of less than about 3, or optionally, a fiber having a denier of less than about 2.5.

Either or both of the bag elastics 110 and the flap elastics 118 can be composed of natural or synthetic elastic materials such as filaments of natural or synthetic rubber. In particular versions of the invention, the elastic member may comprise a filament having a denier of not less than about 100. Alternatively, such elastic members may have filaments of no less than about 280 denier, and may alternatively be filaments of no less than about 360 denier. In still other versions of the invention, such elastic members may have filaments having a denier of no more than about 1920. Alternatively, the elastic member may have filaments having a denier of no more than 1140 denier, and optionally filaments having a denier in excess of about 560 denier. For example, the bag elastics 110 and/or the flap elastics 118 may comprise 360 denier GLOSPANSJ elastic filament available from Glohe Manufafchurng, Inc.

To manufacture the wing and pocket portions of the waist pocket 80, the pocket elastics and/or wing elastics may be extended 50-350% relative to the unstretched length of such elastics prior to assembly into the waist pocket to form the pocket composite 112 and/or wing composite 120. For example, the flap elastic 118 may be constructed at an elongation of about 150%, while the pocket elastic 110 may have an elongation of about 175%.

The number of elastic filaments and the spacing between the elastic filaments may be selected and arranged to achieve desired properties. For example, the elastic members may be selectively configured to provide the desired sealing properties against the skin of the wearer while avoiding excessive irritation or formation of red indicia thereon.

In some particular versions of the invention, the number of elastic filaments in each wing 82 and/or pocket 84 is at least 2 or alternatively at least 3. In still other versions of the invention, the number of elastic filaments in each wing and/or pocket should not exceed about 25. Alternatively, the number of elastic threads in each portion should not exceed about 20, but may be selected to be not more than 15. A laminate with too much elastic thread over the entire depth of the pocket may detrimentally cause the respective lid structure to be in a closed state, lying substantially flat against the top sheet of the article; conversely, when the laminate has too few elastic filaments, the laminate will collapse and fold against itself. The appropriate number of elastic strands, the appropriate spacing between the strands, and the appropriate spacing between the strands and the fixed and movable edges of the pocket portion will depend on the physical properties of the individual laminate components and the size of the associated flap.

In other versions of the invention, the elastic elements of the wing portion 82 and/or the pocket portion 84 may have an elastic spacing 132 of at least about 2 mm. Alternatively, the spring spacing 132 may be at least about 3mm, and may be selected to be at least about 4 mm. In still other versions, the elastic members of the wings 82 and/or pockets 84 may have an elastic spacing 132 of no more than about 13 mm. Alternatively, the spring spacing 132 may be no more than about 11mm, and may be selected to be no more than about 8mm to improve operational control of the barrier cover structure.

To further control the operation of the blocking cover structure, such as the pocket 84. The pocket elastics 110 may be evenly spaced across the width of the laminate (defined in a direction substantially perpendicular to the direction of stretch of the elastics), or the pocket elastics may be separated into discrete, distinct functional groups. For example, fig. 6 typically illustrates a bag spring 110 having more than one functional group. Such multiple sets of structures may be provided in either or both of the pocket or waist portion of the waist pocket 80 to control the operation of the barrier cover to improve performance.

In some particular versions of the invention, the flap elastic member 118 may be configured to provide a flap contractive force, while the bag elastic member 110 may be configured to provide a bag contractive force. In a particular version of the invention, the contractive force exerted by the flap elastic members is designed to be greater than the contractive force exerted by the bag elastic members. As representatively shown in fig. 1 and 4, for example, the flap elastic members may be longer or more contracted or stronger than the bag elastic members. The above design can provide the desired relative contraction between the wing and pocket portions of the wing pocket member 80 when the waist pocket is effectively assembled to the final product, while helping to maintain the desired open state of the pocket portion 84 when in use by the wearer.

In a preferred form of the invention, the elastic members in either or both of the waist and pouch regions may be effectively tensioned as shown in figures 1 and 4. To tension such pressure, various methods may be employed. For example, adhesive or other bonding methods may be applied only in the areas intended to be retracted to gather the coversheet composite described above. In the unbonded areas, the remaining elastic members can then shrink significantly without pleating the cover composite. Alternatively, other techniques, such as ultrasonics, may be used to effectively release the elastic in areas where elastic contraction is not desired.

The elastic members 110 and/or 118 may be attached to either or both of their associated barrier and fabric layers with suitable fastening means such as a selected pattern of adhesive or other type of bonding. For example, by spraying the adhesive as discrete droplets or filaments, or by arranging it in generally continuous lines in a selected pattern, such as a spiral pattern. Alternatively, the elastic members 110 and/or 118 may be attached to at least one of the barrier layer and the fabric layer by a plurality of longitudinally extending adhesive strips. The adhesive strips are spaced apart, each of the adhesive strips being arranged to substantially bond a separate one of the elastic members to at least one of the barrier layer and the fabric layer. For example, in the arrangement shown, the adhesive strips may be arranged substantially parallel to each other.

Referring to fig. 1 and 4, the pocket portion 84 of the waist pocket 80 can be configured to straddle the inwardly facing longitudinally extending bodyside surface of the sealing flap 62. The movable lip 104 of the pocket 84 is preferably substantially unattached and unattached to the distal movable edge 66 of the sealing flap 62 to reduce interaction of the flexible sealing flap 62 with the flexible pocket 84. Furthermore, the elastic tensioning zone is preferably formed by an elastic element 68 for elastifying the sealing flap 62. In particular, the elastic tension in the sealing flaps is substantially limited to the longitudinal middle of each sealing flap. Thus, the end regions of each sealing flap, particularly those generally adjacent the pockets 84, are substantially free of the resilient tension caused by the resilient members 68. The distal edge 66 may also be secured to the topsheet 28 by a suitable joining method to further release the distal edge 66 of the sealing flap from the influence of the relevant operation and open the pocket 84.

The zoned tensioning of the sealing flap 62 described above can be achieved in a number of ways. For example, the elastic members 68 may be effectively weakened by elastic contraction in the appropriate end regions of the sealing flap, such as by mechanical, ultrasonic or heat treatment, effectively "nullifying" or otherwise weakening the elasticity or contractibility in selected regions, or the elastic members 68 in the end regions of the flap may be caused to substantially release from the sealing flap material. In this way, the resilient member of the end region of the sealing flap can be resiliently retracted without substantially building up tension on the end region of the sealing flap 62. In other configurations, the distal end region of the sealing flap may be substantially completely immobilized, such as by adhesive, sonic bonding, or other attachment means effective to secure the end region to the topsheet 28.

In various configurations of the present invention, selected absorbent members, such as the absorbent member 32 provides absorbent members, are positioned and operatively secured between the topsheet 28 and the backsheet 30 to form the diaper 10. The absorbent structure is generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining body fluid exudates. It is to be understood that the absorbent structure of the present invention may comprise a single unitary piece of material or may comprise several separate pieces of material that can be effectively assembled together. When the absorbent member comprises a single, substantially unitary piece of material, such material can provide the desired structural characteristics within selected spatial regions thereof. When the absorbent member is composed of multiple pieces, these material pieces may be in a discrete layer configuration or other non-layered forms and configurations. Further, the pieces may be co-extensive or non co-extensive, depending on the requirements of the article. It is preferred that each element be arranged along at least a portion of its periphery in effective intimate contact with at least one other adjacent element of the absorbent structure. Also, the elements are preferably joined to adjacent portions of the absorbent member by suitable bonding and/or fiber entangling machines such as ultrasonic or adhesive bonding or mechanical or hydraulic needling.

In the exemplary embodiment shown, the absorbent member 32 has a target area available for liquid and has a curvilinear perimeter contoured, particularly along its lateral edges. The two generally mirror-image inner curved lateral edges form a narrower central portion adapted to be positioned at the crotch of the wearer. The target area includes areas where repetitive fluid surges typically occur in the absorbent member 32. The ear regions are configured to generally engage the sides of the waist and torso of the wearer when the diaper is worn, while the central region is configured to generally engage the waist and torso of the wearer.

The absorbent member 32 may be formed in a variety of sizes and shapes (e.g., rectangular, trapezoidal, T-shaped, I-shaped, hourglass-shaped, etc.) and from a variety of materials. The size and absorbent capacity of the absorbent member 32 should be matched to the size of the intended wearer and the liquid loading provided by the intended absorbent article. In addition, the absorbent capacity of the absorbent structure 32 can be varied to accommodate wearers ranging from infants through adults. It has also been found that in the present invention, the density and/or basis weight of each of the buffer treatment section 46 and the retention section 48 and their relative proportions. In a particular form of the invention, the absorbent structure has an absorbent capacity of at least about 300gm for synthetic urine. Alternatively, the absorbent structure may have an absorbent body with at least about 400gm of synthetic urine to provide improved performance.

Various types of wetted hydrophilic fibrous materials may be used to form the components of the absorbent structure 32. Fibers suitable for this purpose include inherently wettable materials composed of naturally occurring organic fibers, such as cellulose fibers; synthetic fibers composed of cellulose or cellulose derivatives, such as rayon; inorganic fibers composed of inherently wettable materials, such as glass fibers, synthetic fibers made of inherently wettable thermoplastic polymers, such as special polyester or polyimide fibers; and synthetic fibers composed of an unsoluble thermoplastic polymer such as polypropylene fibers, which have been hydrophilically treated by an appropriate method. Such fibers may be hydrophilized, for example, by treatment with silica, by treatment with a material which is suitably partially hydrophobic and which is not immediately removed from the fiber, or by jacketing the hydrophobic, non-wettable fibers with a hydrophilic polymer during or after their formation. In the present invention, the above-mentioned various types of fibers can be used as a selective mixing result.

As used herein, "hydrophilic" means that the fibers or the surface of the fibers are wettable by aqueous liquids in contact with the fibers. The degree of wetting of a material of interest can be characterized by the contact angle of the liquid with the material of interest and the surface tension. Measuring equipment and techniques suitable for the wettability of the particular fibrous material or mixture thereof used in the buffer treatment 46 may be provided by the CAHN, SFA-222 surface force analysis system or a system substantially equivalent thereto. Fibers having contact angles less than 90 ° are considered "wettable" or hydrophilic, while fibers having contact angles greater than 90 ° are considered "non-wettable" or "hydrophobic" when measured with such a system.

The retention section 48 may be composed of a particulate of a hydrophobic fibrous matrix such as a web of cellulosic fluff mixed with a highly hygroscopic material. In particular configurations, the retention portion 48 may comprise a mixture of superabsorbent hydrogel-forming particles and synthetic polymer meltblown fibers, or a mixture of superabsorbent particles and a fibrous coform material comprising natural fibers and/or synthetic polymer fibers. Such superabsorbent particles may be substantially homogeneously mixed with the hydrophilic fibers, or may be non-homogeneously mixed. For example, the concentration of superabsorbent particles may be graded in a non-stepped manner throughout a substantial portion of the thickness (Z-direction) of the absorbent structure, with a lower concentration on the body side toward the absorbent structure and a higher concentration on the outer side toward the absorbent structure. Suitable Z-shaped gradient structures are described in U.S. Pat. No. 4699823 to Kellenberger et al, 1987, 10, 13, the disclosure of which is incorporated herein by reference in a manner consistent with the present invention. The absorbent particles may also be disposed in generally discrete layers within the matrix of hydrophilic fibers, and the absorbent material may also be formed into discrete, individual pockets. Further, two or more different types of superabsorbent material may be disposed at selectively different locations within or along the fibrous matrix.

The acoustically absorbent material may comprise an absorbent gelling material such as a superabsorbent. Such absorbent gelling materials can be natural, synthetic and modified natural polymers and materials. In addition, such hygroscopic gelling materials can be inorganic materials such as silica gel; or organic compounds such as crosslinked polymers. The term "cross-linking" refers to any means for rendering normally water-soluble substances effectively substantially water-insoluble but swellable. Such means include, for example, physical entanglement, crystalline domains, covalent bonds, ionic complexes and associations, hydrophilic associations such as hydrogen bonding, and hydrophobic bonding or von der Walls forces.

Examples of synthetic hygroscopic cement polymers include alkali metal and ammonium salts of poly (acrylic acid) and poly (methacrylic acid), poly (acrylamide), poly (vinyl ethyl ether), maleic anhydride photopolymers with vinyl ethyl ether and alpha-olefins, poly (vinyl pyrrolidone), poly (morpholinone), poly (vinyl alcohol), and mixtures and polymers thereof. Other polymers suitable for use in such absorbent structures 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, synthetic biopolymer gums, locust bean gum, and the like. Natural and wholly or partially synthetic hygroscopic polymers may also be used in the present invention. Other suitable hygroscopic gelling materials are disclosed in U.S. patent No. 3901236 to assasrsson et al, 1975, 8, 26. Processes for preparing synthetic absorbent gelling polymers are disclosed in U.S. Pat. No.4076663 to 1978.2.28 Masuda et al and U.S. Pat. No.4286082 to 1981.8.25 to TsuhaKimoto et al.

Synthetic hygroscopic gelling materials are typically xerogels which form hydrogels when wetted. The term "hydrogel" has been used generically to refer to both the wet and non-wet forms of such materials.

As previously mentioned, the highly hygroscopic material used in the retention portion 48 is typically in the form of discrete particles. Such particles may take any desired shape, such as helical or semi-helical, cubic, rod-shaped, polyhedral, etc. Shapes with a large maximum/minimum size ratio such as needles, flakes and fibers are also suitable for this. Aggregates of particles of hygroscopic gelling material may also be used in the retention portion 48.

Most suitable pellets have an average particle size of from about 20 μ to about 1 mm. As used herein, "particle size" refers to the weighted average of the smallest dimension of the individual particles.

Suitable superabsorbent materials may have the following characteristics: hygroscopicity (sometimes referred to as "AC"), rate of deformation under load (sometimes referred to as "DUL"), and wicking index (sometimes referred to as "WI"). These parameters are detailed in U.S. patent application serial No. 757787, 1991, 11, 11 to s.byerly et al, entitled "absorbent composites and absorbent articles incorporating such composites" (attorney's docket No. 10174), the disclosure of which is incorporated herein by reference in its entirety in a manner consistent with this specification.

In one particular version of the invention, the hygroscopic retention portion 48 comprises a matrix of substantially hydrophilic fibers having a plurality of highly hygroscopic materials distributed therein. The superabsorbent polymers selected for improved absorbency play an important role in maximizing performance while maintaining the desired thinness of the absorbent article. To improve performance, the particle size of the absorbent material may be selected to provide an Absorbency Under Load (AUL) of about 25 to 40 and an absorbency under load (AC value) of about 32 to 48. The liquid absorption rate of the liquid absorbed by the superabsorbent material under load is 3-15 g/g (g of liquid per g of superabsorbent material) at 30 seconds, 6.5-21g/g at 5 minutes, and 25-40 g/g at 60 minutes.

Suitable methods for determining AUL are described in detail in 1992, 9, 15 to S.Kellenberger, U.S. Pat. No.5147343 entitled "absorbent articles containing aqueous gels resistant to crushing and swelling" (attorney docket No. 8786.1), and also in 1989, 11, 2 as published in European patent application No. EP0339461Al; the contents of which are incorporated herein by reference in a manner consistent with the present specification.

Examples of superabsorbent polymers suitable for use in the present invention are SANWET IM3900 polymer available from Hoechst Celanese, Inc. having a trade designation of Portsmouth, Va, and other suitable superabsorbent materials can include DOW2035 polymer available from Dow chemical, Inc. having a trade designation of Hidland, Mich.

The hydrophilic fibrous matrix comprising the retention portion 48 can be a layer of cellulosic wood pulp fluff, and superabsorbent polymer particles can be distributed within the hydrophilic fibrous matrix. The hydrophilic fibers and high moisture absorbing pellets may be provided in a fiber to pellet weight ratio of no more than about 75: 25, alternatively no more than about 70: 30, and optionally 55: 45. In some aspects of the invention, the weight ratio of fiber to pellet is not less than about 25: 75, preferably not less than about 30: 70, and more preferably not less than about 45: 55. Such fiber to particulate material ratios are particularly suitable for use in the target zone of the absorbent structure. In particular embodiments of the invention, the weight ratio of such fibers to pellets is no more than about 65: 35, while not more than about 50: 50 in order to provide the desired properties.

The above described firephilic fibers and high moisture wicking granules may form an average combined basis weight in the range of about 400 to 900 gsm. Such a basis weight is particularly desirable in the target area of the absorbent member. In some instances of the present invention, such average composite basis weight is in the range of about 500 to 800gsm, and preferably in the range of about 550 to 750gsm in order to provide the desired performance.

In order to provide the desired single thickness dimension for various configurations of the absorbent articles of the present invention, the retention portion 48 may be configured to have a lofty caliper of no more than about 0.6 cm. It is preferred that the texturized thickness be no more than about 0.53cm, and more preferably no more than about 0.5cm for further improvement in performance. This loft thickness was measured at a confining pressure of 0.2psi (1.38 kpa).

The density of the retention portion 48 or other portion of the absorbent article can be calculated based on its basis weight and caliper. For diapers, the relative weight and caliper were measured on a freshly opened, unfolded dry diaper at a restraining pressure of 0.2psi (1.38 kpa). Conventional thickness measuring devices can be used to determine the thickness required to calculate the density.

In the illustrated embodiment of the invention, the moisture retentive portion 48 includes 4 to 22 grams of wood pulp fluff, preferably 8 to 14 grams of wood pulp fluff, and more preferably about 10 to 12 grams of wood pulp fluff to provide the desired benefits. Such wood pulp fluff generally provides the shape and form basis for the diaper 10, as well as carrying ice and positioning superabsorbent polymer pellets or other highly absorbent materials. The retention portion 48 may contain about 7 to about 12 grams of superabsorbent polymer, and in the illustrated embodiment about 8.5 grams of superabsorbent polymer. Sufficient superabsorbent polymer is added to the retention portion 48 to provide a total absorbency of at least about 300 grams of urine. For example, a medium size diaper for infants weighing about 13 to 23 pounds (about 6 to 10.5kg) may typically have a total retention performance of about 500 grams of urine.

Fluff and superabsorbent particles may be selectively placed on desired regions of the retention portion 48. For example, the basis weight of the fluff may vary across the width of the retention section 48. Alternatively, a larger amount of fluff may be provided at the front waistband end towards the retention portion. See, for example, U.S. patent No.4585448 to k.eloe, 1986, 4, 29. In the illustrated embodiment, the majority of the superabsorbent material can be distributed up to the intermediate region of the retention portion 48, extending along the lengthwise dimension of the retention portion and reaching about 3.5-4.5 inches (about 8.9-11.4 cm) in width. In addition, the absorbent material may be selectively zoned to reduce the amount of superabsorbent material adjacent the end edges of the side edges f of the retention section. Reducing the number of pockets at the above-mentioned edge portions of the pockets improves retention of the absorbent granules within the fibrous fluff matrix of the pockets 48. Pulsed zoned placement of superabsorbent material can be accomplished, for example, by U.S. patent No.5028224 (attorney docket No. 8761) entitled "method and apparatus for intermittently depositing particulate material in a matrix," 1991, 7, 2 to Pieper et al, the contents of which are incorporated herein by reference in a manner consistent with this application.

In a particular form of the invention, the absorbent structure 32 may be generally T-shaped, whereby the transverse arms of the T-shape correspond to the front waistband portion of the absorbent article to improve performance, particularly for male infants. For example, in the illustrated embodiment, the retentate through the front waistband region of the article has a transverse width of about 9.0 "(about 22.9cm), the narrowest portion of the crotch portion has a width of about 3.5" (about 8.9cm), and the back waistband region has a width of about 4.5 inches (about 11.4 cm).

The entire absorbent structure 32, or any single portion thereof, such as the retention portion, can be overwrapped with a hydrophilic, very high wet strength, cover web, such as a high wet strength tissue or synthetic fiber web. The overwrapped web may also improve the integrity of the absorbent structure in use. Such a web can be suitably bonded, for example, with an adhesive to the absorbent structure 32 and other portions of the article components.

Because of the high concentration of superabsorbent particles or other highly absorbent materials in the retention portion 48, it is more difficult to contain the acoustically absorbent particles within the retention portion and limit their migration to the body side of the diaper. To improve the retention of such high absorbency materials, the absorbent structure 32 may include an improved overwrap, such as wrap sheet 70, disposed about the retention portion 48. The wrapper 70 is preferably a layer of absorbent material which covers a substantial portion of the body-side and outer-side surfaces of the retention portion and preferably surrounds substantially the entire periphery of the retention portion to form a substantially complete peripheral enclosure. Alternatively, the cover sheet may be provided by an absorbent cover sheet covering most of the body-side and outer-side surfaces of the retention portion while substantially enclosing only the lateral side edges of the retention portion. Therefore, the straight portions and the inflected portions of the lateral side edges of such a wrapping sheet will close around the holding portion, but in such a structure, the two end edges of the wrapping sheet are not necessarily completely closed around the end edges of the retention portion in the waistband region of the article.

The absorbent wrap 70 may comprise a multi-piece wrap having separate body side and outer side wraps extending beyond all or some of the periphery of the retention portion 48, as representatively illustrated in fig. 1. Such a flap configuration can, for example, facilitate a complete seal and closure around the periphery of the retention portion 48. In the back waistband portion of the illustrated diaper, the absorbent wrap 70 may be configured to extend an increased distance from the periphery of the retention portion to add opacity and strength to the back ear portion of the diaper. For example, in the illustrated embodiment, the body side and outer side layers of the absorbent wrap 70 extend at least about 1/2 inches (about 1.3cm) beyond the periphery of the retention portion to provide an outwardly convex wing-shaped bonded region where the periphery of the body side portion of the wrap 70 may be fully or partially attached to the periphery of the outer side portion of the absorbent wrap 70.

The bodyside and outer layers of the wrapper 70 may be substantially the same or composed of different materials. For example, the outer layers of the wrapper may be composed of a lower basis weight material having a higher porosity, such as a wet strength cellulosic tissue composed of softwood pulp. The body side layer of the sheet may comprise the aforementioned lower porosity clad material. The low porosity body side layer provides better protection against migration of the superabsorbent particles to the wearer's skin, while the high porosity, low basis weight outer layer helps to reduce costs.

To bond the body side portion to the outer side portion of the absorbent wrap 70, an adhesive such as NATIONAL STARCH72-3723 adhesive may be printed onto designated bonding regions of the absorbent wrap, for example, using a gravure roll printing system. In other constructions having absorbent wraps comprised of nonwoven meltblown fiber webs, the peripheral sealing of the body side to the outer wrap may be accomplished by using hot calendering to provide a sealing band around the periphery of the retentate.

Due to the thinness of the retention portion 48 and the acoustic absorbent concentration therein, the retention portion itself may have too low a liquid intake rate to sustain liquid damage to the absorbent structure thereon. However, the addition of a porous, liquid-permeable, cushioning material layer is beneficial in improving the overall absorbency of the composite absorbent structure. The treated portion 46 is generally less hydrophilic than the retention portion 48 and has an effective level of density and basis weight to quickly collect and temporarily hold the surge of liquid and to transport the liquid from its initial point of entry until substantially completely releasing the liquid to other portions of the absorbent structure 32, particularly the retention portion 48. This configuration helps prevent liquid from pooling on the portion of the absorbent garment positioned relative to the wearer's skin, which can reduce the wearer's perception of moisture.

The cushioned treatment 46 may be constructed from a variety of woven and nonwoven fabrics. For example, the buffer treatment may be a laminate composed of a meltblown or spunbond fabric of polyolefin fibers. The cushion coat may also be a bonded carded or air-laid web of natural and synthetic fibers. Such bonded carded webs can be, for example, powder bonded carded webs, infrared bonded carded webs, or through-air bonded carded webs. The infrared bonded and through air bonded carded webs can optionally include a mixture of different fibers, and the fiber length in the selected web can be in the range of about 1.0-3.0 ". The buffer treatment may be formed of a substantially hydrophobic material which may be treated with a surfactant or otherwise as necessary to achieve the desired level of wettability and hydrophilicity. The representative diaper 10 may include a surge 46 disposed or in direct fluid communication with an adjacent absorbent retention portion 48. As representatively illustrated herein, the cushion treatment 46 may be configured to be disposed adjacent an outwardly facing outer layer of the topsheet 28.

Alternatively, the cushioning treatment may be disposed adjacent the inwardly facing body-side surface of the topsheet 28. The configuration shown for the cushion treatment can be effectively attached to the topsheet using a conventional adhesive pattern, such as a swirl adhesive pattern. Further, the cushion-treated portion may also be effectively attached to the body-side layer of the wrapping sheet 70 with a usual adhesive pattern. The amount of adhesive added is sufficient to provide the desired bond strength, but is low enough to avoid excessively restricting the movement of liquid from the topsheet layer through the cushioning treatment and through the wrapper sheet.

The retention portion 48 is positioned in fluid communication with the buffer treatment portion 46 to receive liquid released from the buffer treatment portion and retain such liquid. In the illustrated embodiment, the buffer treatment section 46 includes a separate layer stacked on another separate layer constituting the retention section, thereby forming a double-layer structure. The buffer treatment serves to quickly collect and temporarily hold the discharged liquid and to transport it from the point of initial contact and spread it to other parts of the buffer treatment, and then release it substantially completely onto the layer or layers making up the retention section 48.

The illustrated exemplary configuration of this buffer treatment is substantially free of hygroscopic cementitious material. The buffer treatment 46 may contain a very small amount of particulate gelling material to help obtain the initial flash-up liquid, but should not contain too much particulate material. However, when the target zone contains an excess of particulate hygroscopic gelling material, the binder can cause the absorbent structure to retain an undesirably large amount of liquid. In addition, this fluid may be prevented from being transported from the target area to other portions of the absorbent structure 32. As described above, the cushioning treatment portion 46 may be a separately formed layer, located adjacent to the outward facing surface of the topsheet 28 between the retention portion and the topsheet. The treated cushioning portion 46 need not include the entire thickness of the absorbent structure 32. The retention portion may, but need not, include a recessed area that completely or partially surrounds the buffer treatment 46, or the retention portion may be located completely below the buffer treatment. The configuration of the recesses in the retention portion 48 can facilitate an increased contact area between the retention portion 46 and the treatment 48 and improved liquid communication therebetween. It should be recognized, however, that the treated buffer 46 may, but need not, be configured to extend through the entire thickness of the absorbent structure 32 such that capillary flow of liquid into the retention portion 48 occurs primarily in a generally lateral (x-y) direction.

The treated cushioning portion may take any desired shape consistent with the absorbent requirements of the absorbent structure 32. Suitable shapes are, for example, circular, rectangular, triangular, trapezoidal, oblong, dog-bone jiv-shaped, hourglass-shaped or oval. The optimal shape of the buffer treatment portion is to increase the liquid communication surface area between the buffer treatment portion 46 and the holding portion 48 so as to fully realize the relative capillary force difference between the two portions. In some embodiments, the buffer processing portion may be substantially rectangular, for example.

In various configurations of the present invention, the buffer treatment 46 may extend the entire length of the retention portion 48 or only a portion thereof. When the cushioning treatment extends only partially along the length of the retention portion, it can be selectively positioned anywhere along the absorbent structure 32. For example, the treated cushioning portion 46 can function more effectively when it is offset toward the front waistband of the diaper and centered in the front portion of the absorbent structure 32 in the transverse direction. In this way, the treated cushioning portion 46 is similarly centered with respect to the longitudinal centerline of the absorbent structure 32 and is located primarily in the central region of the front portion of the absorbent structure 32.

In other configurations of the present invention, the end edge of the buffer-treated portion may be separated from the end edge of the retention portion 48 from the inside in the longitudinal direction. In a particular configuration of the present invention, the more adjacent front end edge to which the cushion-treated portion 46 corresponds may be separated from the front waistband end edge of the retention portion 48 by a predetermined distance.

It has been found that the effective fabric used to construct the cushioning treatment portion can be unambiguously characterized by specific parameters. Examples of these parameters are basis weight, permeability, porosity, surface area per void volume (SA/VV), compression resilience and saturation capacity. Other parameters may also include an adhesive matrix that helps stabilize the pore size structure and hydrophobicity. Such a bonding matrix with mixed fiber denier can help provide and substantially maintain a desired pore size structure.

Additional details regarding the materials used for the cushioning portion and methods suitable for determining the above parameters are set forth in U.S. patent application serial No.206,986 (attorney docket No. 11256) and U.S. patent application serial No.206,069, entitled "modified, cushioned fibrous nonwoven webs for personal care absorbent articles and the like", c.ellis and d.bishop, 1994, 3, 4 entitled "fibrous nonwoven web cushioning layer for personal care absorbent articles and the like", attorney docket, 1994, 3, 4; the contents of these two patent applications are incorporated herein by reference in a manner consistent with the present application.

In a desirable configuration of the present invention, the material for the buffer treatment portion may include natural fibers, synthetic fibers such as synthetic polymer fibers, and a combination thereof. The corresponding fabric may be composed, for example, of polyolefin fibers, which in a particular configuration may comprise bicomponent fibers. For example, polypropylene/polyethylene bicomponent fibers may be employed to form any bicomponent fiber portion of the fabric. In addition, the bicomponent fibers may be flat crimped or spiral crimped.

In the illustrated article configuration, two side panels 56 are independently provided and are operatively attached to the transversely opposite ends of the back waist portion of the back sheet 30. Specifically, each side panel is mounted to extend from a corresponding end edge of the back panel 30. Such side panels may be constructed from substantially inelastic materials such as polymeric films, woven fibers, nonwoven fibers, and the like, as well as combinations thereof. In some particular configurations of the invention, the side panels are formed of an elastic material, such as stretch bonded laminate (SRL) material, Neck Bonded Laminate (NBL) material, elastic film, elastic foam material, or the like. For example, suitable meltblown elastic fiber webs are described in U.S. patent 4663220 to t.wisheskl et al, 1987, 5, the disclosure of which is incorporated herein by reference. An example of a composite fabric comprising at least one layer secured to a fibrous elastic layer and a nonwoven fabric is described in european patent application No. EP0110010 published by 1987.4.8, which is EP 0217032a2 by inventor j. Examples of NBL materials are described in 1993, 7, 13 in m.mormon, U.S. patent No.5226992, the contents of which are incorporated herein by reference.

An example of an article comprising elastic side panels and fastening tabs of a selected configuration is described in U.S. patent application serial No.168615 (attorney docket No. 10961) entitled "dynamic fit diaper," filed by t.roess/er et al 1993, 12, 16. Various techniques for forming the desired fastening system are described in: 1995, 3, 21 to t.roesler et al, U.S. patent No.5399219 entitled "method of making a fastening system for a dynamically fitted diaper (attorney docket No. 11186); U.S. patent application Ser. No.286086 entitled "method of assembling elastic ears" filed by DFries, 1994, 8, 3 (attorney docket No. 11169); fries in 1995, 4, 3, U.S. patent application serial No.08/415383 entitled "assembly method for laminated belts" (attorney docket No. 111950), and d fries in 1995, 4, 3, U.S. patent application serial No.08/415382 entitled "absorbent article with laminated belts" (attorney docket No. 11990). The disclosures in each of the foregoing documents are hereby incorporated by reference in their entirety in a manner consistent with this application without undue conflict.

The fastening system may include a separately disposed reinforcing strip 88 of reinforcing and/or stiffening material laminated to the designated first surface of each side panel 56 at the outboard region 58 of the side panel. The illustrated reinforcing tape extends along substantially the entire length of the outboard end of the side panel 56. Furthermore, such a reinforcing strip has a length that is the length dimension of the fastening means 44 on the user engaging portion 38 of the fastening tab 36. The reinforcing strip 88 may, for example, be comprised of a release tape which may include a substrate comprised of a polymer film such as a polypropylene film. Suitable release tape materials are available from Avery corporation, having a trade name of Painesville, ohio.

The release strip of the reinforcing strip 88 may be configured or have a designated release surface and an opposing bonding surface. Suitable release materials having limited, low strength adhesion to typical pressure sensitive adhesives are disposed and distributed on the release side, while suitable bonding means, such as structural adhesive layers, are distributed over the bonding side. This structural adhesive layer is used to secure the reinforcing tape 88 to the designated portion of the final article. In particular, such a release tape may be operatively bonded and laminated to the outer side region 58 of the side panel 56 along the first surface of the side panel 56. The release strip shown may be configured to be substantially contiguously coextensive with its terminal outer side edge with the outer side edge of the side panel 56. Further, the width of the release tape in the lateral direction is preferably equal to or greater than the width of the fastening means provided on the user engagement area 38 of the fastening tab 36.

The illustrated fastening system includes a complementary opposing pair of fastening tabs 36 that provide a mechanism for retaining the article on the wearer. Each fastening tab includes a substrate 86 that may be composed of various substrate materials. For example, the illustrated embodiment of the fastening tab substrate may be comprised of a polymer film, such as a polypropylene film. Suitable film materials are available from Avery, commercially available from Painesville, ohio. Additionally, such fastening fabrics may include woven or nonwoven fabrics such as spunbond nonwoven fabrics.

The exemplary fastening tab substrate 86 shown includes a designated securing face and an opposite user face, as well as selected securing means located on the securing face. Such fastening means may be provided by adhesives, stickies, mating pieces of interconnected mechanical connectors, hook and loop fasteners, pins or belt fasteners, and the like, as well as combinations thereof. Such fastening means may comprise, for example, a hook (mushroom-head) or loop element of a hook-and-loop fastener. In the configuration shown, the fastening means is provided by an initial layer of adhesive distributed over the designated fastening surface, while the fastening system provides an adhesive fastening joint. The fastening tab can be configured to releasably adhere to a designated landing zone panel 92 that is attached to the front waist belt portion of the diaper to provide a refastenable adhesive fastening system.

With this adhesive fastening means, the above-mentioned initial adhesive layer can be used to effectively laminate and fasten the prescribed plain weave bond 39 of the fastening tab 36 along the prescribed second facing layer of the side sheet member 56 to the outer side region 58 of this side sheet member. Other types of attachment means, such as thermal bonding, sonic bonding, mechanical stitching, stapling, and the like, as well as combinations thereof, may be used to secure the fastening tabs to the side panels. Ultrasonic bonding may be used, for example, to provide a selected auxiliary bond.

Referring to fig. 1, the fastening tab 36 includes a plain weave bond 39 which overlaps the outer edge of the side panel 56 and extends beyond the side panel to form the consumer bonded region of the fastening tab. In certain configurations of the present invention, such a fastening tab may have a wider user bond to join with a narrower intermediate portion. This intermediate portion is located between the user bond and the greige scrim bond of the fastening tab. In another configuration of the invention, the fastening tab 36 may, but need not, include a finger pad region. This finger tab area may be essentially free of irregularities and may provide an area that can be quickly grasped by a user without contaminating or otherwise damaging the fastening device.

Various types and configurations of interconnected mechanical fastening devices may be used to provide an effective fastening system for the various configurations of the present invention. Typical examples of suitable mechanical fastener structures are described in U.S. patent application serial No.366080 entitled "high peel sheet fastener" filed by g.zehner et al 1994, 12, 28 (attorney docket No. 11571), and in U.S. patent application serial No.421640 entitled "multiple attachment fastening system" filed by p.van Gompel et al 1995, 4, 13 (attorney docket No. 11430), the entire disclosures of both of which are incorporated herein by reference in their entirety in a manner consistent with this application.

The following examples are provided to aid in a more detailed understanding of the invention. These examples are for illustrative purposes and are not intended to specifically limit the scope of the present invention.

Example (b)

Example 1: each sample was made from a 1.0mil (0.0254mm) thick polyurethane film (grade MP1882P, available from JPS Elastomerics, Northampton, Minn.). Such elastic films exhibit undesirably low stiffness, below the test scale of the test instrument.

Example 2: the sample was obtained from Procter commercially available from Cincinnati, Ohio under trade name&PAMPERS, marketed by Gamble corporation, as extended diapers. This diaper includes a waist cap, and a sample of the waist cap is used for the test. The size of each waist cover is so small that it is difficult to test as a separate piece of material. As a result, the test specimens of each side test included a waist cap material attached to the joined portion of the diaper liner and the diaper backsheet. Attaching the added liner and back sheet layers increased the overall stiffness of each test specimen. As a result, it is believed that the stiffness observed will be higher than that measured when the test is conducted on a test piece consisting of only waist cover material. The waist cap of each sample in this example 2 was composed of an elastic three-layer laminate. The laminate comprises a film of a polyethylene/polyvinyl acetate copolymer with TiO₂Filler) is sandwiched between two polypropylene nonwoven layers and then thermally bonded together. This sample exhibits too low a stiffness.

Example 3: the samples were taken from the company Molnlycke, having a trade name in Goteborg, sweden. The diaper includes an inner, body contacting layer in which there is a relatively large, elongate central through hole. Longitudinally extending elastic members are attached so as to gather the marginal region of the inner layer adjacent the side adjacent to the through-hole. It is observed that the inner layer material adjacent to the longitudinally opposite end edges of the through-hole forms a structure similar to a pair of waist flaps. The molnlucke diaper is provided with sufficient material to remove individual test specimens large enough for stiffness testing. The sample removed was similar to that removed from the stock blank and was 1 inch (2.54cm) long by 1/2 inches (1.27cm) wide. Each sample was a nonwoven fabric of polypropylene, bonded carded web. The test specimens show a stiffness which is too low.

Example 4: each sample was a Consolidated available from Chippewa Falls, Wisconsin under trade nameA laminate of 0.00035 inch (about 0.0089mm) thick polyethylene film (designation SF20) was purchased from thermoplasts. This laminate has 12 LYCRA, 470 dtex (dtex) elastic filaments laid out at about 260% elongation, 5 in the pocket 84 and 7 in the flap 82. The above film and elastic filaments were assembled and attached to a bicomponent polypropylene/polyethylene fiber spunbond fabric having 0.6osy (about 20.4 g/m)²) Basis weight of (a) was used as J available from Dawsonville, Georgia under trade name.&Melt-blown coating dots from laboratories Inc. coated with 6.5g/m²FINDLEY H2096 adhesive. These samples are typical waist pockets suitable for use in the present invention.

Example 5: each test specimen was a laminate of 0.00035 "(about 0.0089mm) thick polyethylene film (designation SF20) available from Cmolidated Thermoplastics. The laminate had 12 LYCRA elastic strands of 470 dtex applied at about 260% elongation, 7 in the pouch and 5 in the wing. The film and elastic filaments were bonded to a bicomponent polypropylene/polyethylene fiber spunbond fabric having 0.6osy (about 20.4 g/m)²) Basis weight of (1) from J&The melt-blown coater from M Laboratories corporation was coated at 6.5g/M²Findleh 2096 adhesive. This sample is a typical waist pocket to which the present invention is applied.

Example 6: each sample was a laminate of 0.0006 inch (about 0.015cm) thick polyethylene film (designation XEM 400.1.1) available from Consotidafed thermoplastics. The laminate had 6 360 denier flexible filaments of GLOSPAN S7, 2 in the pouch portion, applied at about 175% elongation, and 4 in the wing portion, applied at about 150% elongation. The film and elastic filaments were bonded to a bicomponent polypropylene/polyethylene fiber spunbond fabric having 0.6osy (about 20.4 g/m)²) Basis weight, 5g/m by coating with a vortex coater²FINDLEYH9214 adhesive. Such a sample is representative of a waist bag suitable for use in the present invention.

Example 7

Each test specimen was 0.0006 inch (about 0.015cm) thick as available from Consolidated thermoplasticA laminate of polyethylene films (No. XEM 400.1.1). The laminate had 6 GLOSPANS7 elastic filaments of 360 denier, 2 in the pocket portion, applied at about 175% elongation, and 4 in the wing portion, applied at about 150% elongation, the film and elastic filaments bonded to a polypropylene spunbond fabric having 0.6osy (about 20.4 g/m)²) Basis weight of (2) was coated with 5g/m by a vortex coater²FINDLEY Hg214 binder. This sample is a typical waist bag suitable for use in the present invention.

Example 8

Each sample was a laminate consisting of an 0,00035 inch (about 0.0089mm) thick polypropylene film (trade name XSF184) available from Consolidafed thermoplasfics. The laminate had 6, 490 denier GLOSDANS7 elastic filaments, 2 applied at about 200% elongation in the pouch and 4 applied at about 15% elongation in the wing. This film and elastic filament binder bicomponent polypropylene/polyethylene fiber spunbond fabric having 0.6osy (about 20.4 g/m)²) Coated with findley h2096 adhesive using a silk coating process. This sample is a typical waist bag suitable for use in the present invention.

The Garley stiffness 12 points of examples 1 to 8 are given in table 1.

TABLE 1 Garley stiffness

Garley stiffness (Standard Garley units-milligrams force) example 12345678

	Film	P&G	Molnlycke	12 filaments	12 filaments	6 pieces of silk	6 pieces of silk	6 pieces of silk
										Polyurethane	(waist cover)	(waist cover)	5 in the bag part	7 in the bag part	2 root in the bag part	2 root in the bag part	2 root in the bag part
Test specimen
									1	-	2.22	1.95	61.05	49.95	44.40	82.14	25.53
2	-	2.78	0.83	56.61	46.62	46.62	57.72	55.50
									3	-	3.61	0.56	75.48	48.84	57.72	55.50	26.64
4	-	3.06	0.83	62.16	51.06	88.80	66.60	18.87
									5	-	1.95	0.83	82.14	42.18	44.40	95.46	38.85
6	-	2.78	0.83	83.25	58.83	77.70	117.66	39.98
									7	-	0.56	1.67	74.37	45.51	53.28	91.02	51.06
8	-	1.95	0.56	75.48	48.84	51.06	86.58	31.08

9	-	3.61	1.11	63.27	51.06	-	93.24	-
									Ave	0.00	2.50	1.02	71.60	49.21	58.00	82.88	35.94

Average value of Ave

Measurement unit: standard Garley units, equivalent to milligram force (mf)

When tested, the laboratory was at standard conditions of 73 ° F (about 23 ℃) and 50% relative temperature. A suitable apparatus for performing the test is a Gurley digital stiffness tester, model 4171-D, available from Teledhee Gurley, Inc., having a trade designation of Troy, N.Y.; or by equivalent means. Examples 1 and 4 through 8 have Gurley stiffnesses obtained from test specimens taken from the raw material source of the film or laminate.

Although the invention has been described in considerable detail, it should be apparent that variations and modifications can be made without departing from the spirit of the invention. All such changes and modifications are intended to be included within the scope of the present invention as set forth in the appended claims.

Claims (21)

1. An absorbent article having a longitudinal dimension, a lateral width dimension, a front waistband portion, a back waistband portion, an intermediate portion connecting the front and back waistband portions, and a pair of laterally opposing elastic side edges, the article comprising:

a back sheet which is provided with a back cover,

a liquid pervious topsheet joined in superposed relation to said backsheet;

an absorbent body sandwiched between the topsheet and the backsheet; and

an elastic waist pocket connected to at least one of said back sheet and top sheet along at least one end edge of said article, said waist pocket comprising an extended wing portion and an extended pocket portion,

the pocket portion of the waist pocket comprises a substantially fixed edge portion provided on the article,

the movable edge of the elastic gather,

a substantially liquid-tight barrier layer of the bag,

a bag fabric layer connected in facing relation to the bag barrier layer,

and an array of individual, laterally extending bag elastics sandwiched between the bag barrier layer and the bag fabric layer to provide a substantially cross-directionally gathered, elastic waist bag composite.

2. The article of claim 1, wherein the wing portion of the waist pocket comprises:

a substantially liquid-impermeable flap barrier;

a wing fabric layer connected in facing relationship with the wing barrier layer; and

an array of individual, laterally extending flap elastics sandwiched between the flap barrier layer and the flap fabric layer to provide an elastic flap composite that is substantially transversely gathered to the flap elastics.

3. The article of claim 2 wherein the pocket portion of the waist pocket is integrally formed with the wing portion of the waist pocket; the pocket barrier layer is integrally formed with the wing barrier layer to form a wing-pocket barrier layer, while the pocket fabric layer is integrally formed with the wing fabric layer to form a wing-pocket fabric layer.

4. The article of claim 3 wherein said wing-bag barrier layer is substantially coextensive with said wing-bag fabric layer.

5. The article of claim 3, wherein the elastic in the wing portion is separated from the elastic in the pocket portion by a boundary gap that provides a separation distance of at least about 2 mm.

6. An article according to claim 3 wherein at least one of the elastic members in the pocket is located between the substantially fixed and movable side portions of the pocket and is separated from the substantially fixed side portion of the pocket by an adjacent gap distance of no more than about 20 mm.

7. The article of claim 5, wherein the pocket portion of the waist pocket is secured to the topsheet by a bonded region substantially confined to at least a portion of the boundary gap in the laterally intermediate portion of the article.

8. The article of claim 5 wherein the pocket portion of the waist pocket has laterally opposite ends which are secured generally flat against the topsheet.

9. The article of claim 5, wherein the pocket portion of the waist pocket is secured to the topsheet by a generally U-shaped bonding means.

10. The article of claim 5, wherein said backsheet includes a terminal waistband portion having an inwardly extending notch area formed thereon, and said waist pouch flap portion is configured to span across said notch area.

11. The article of claim 2 wherein said flap elastic member is configured to provide a flap contractive force and said bag elastic is configured to provide a bag contractive force, and said flap contractive force is greater than said bag contractive force.

12. The article of claim 1 wherein the split elastic member is spaced from the end edge of the movable edge portion of the bag portion by a distance of no more than about 13 mm.

13. The article of claim 1 wherein the bag elastic is spaced from the end edge of the actuated side portion of the bag portion by a distance of no more than about 7 mm.

14. An article as recited in claim 1, wherein one of said bag elastics is adjacent to and spaced from said end edge of said movable edge portion by a distance of no more than about 1 mm.

15. The article of claim 1, wherein the end edge is substantially unfolded.

16. The article of claim 1, wherein the pouch portion has a stiffness of at least about 5 mg.

17. The article of claim 1, wherein the pouch portion has a stiffness of at least about 15 mg.

18. The article of claim 1, wherein the pouch portion has a stiffness of at least about 30 mg.

19. The article of claim 1, wherein the pouch portion has a stiffness of no more than about 250 mg.

20. The article of claim 1, wherein the pouch portion has a stiffness of no more than about 200 mg.

21. The article of claim 1, wherein the pouch portion has a stiffness of no more than about 170 mg.