Abstract: In accordance with the present invention, a sanitary napkin having flaps and a stress relief means for relieving the stresses that develop in the flaps when the flaps are folded down along the edges of the wearer's panties in the crotch, is provided. The flaps are associated with an absorbent means along a line of juncture. The stress relief means can be provided along the line of juncture or in the flaps. Two preferred stress relief means are a notch and a slit.

Abstract: A disposable absorbent article for absorbing liquids, particularly body fluids such as urine. An absorbent core is encased in an outer covering layer to which flaps are connected along the longitudinal sides at a proximal edge. The flaps also have a distal edge which is displaced from the absorbent core means. The flaps are elasticized to render the distal edge elastically contractible so that the flap is gathered.

Abstract: An integral disposable absorbent garment, such as a disposable diaper or incontinent brief, having an integral belt segment on each side of the garment. The integral belt segments, in association with a receiving or attachment means, are intended to hold or suspend the garment about the lower torso of the wearer.

Abstract: Apparatus for and methods of forming, from a single column of fibers, an airlaid fibrous web having a multiplicity of components.

Abstract: Apparatus for and methods of forming airlaid fibrous webs having a multiplicity of layers and/or discrete particles of absorbent gelling material dispersed through at least a portion of the web. The apparatus is of the type which includes a laydown drum having a foraminous forming element, a primary vacuum chamber, and a dusting layer vacuum chamber; a primary hood; and a dusting layer hood. The dusting layer of fibers formed on the laydown drum acts to block the passage of particles or fibers entrained in a first fiber stream which is airlaid over the dusting layer so as to minimize equipment plugging problems and the loss of particles or fibers through the foraminous forming element. The primary vacuum chamber of the laydown drum preferably spans the primary hood and a portion of the dusting layer hood so that the dusting layer is not sheared off, damaged, or destroyed as the laydown drum rotates to the position where the first fiber stream is deposited over the dusting layer.

Abstract: Disposable diapers provided with breathable leg cuffs. Disposable diapers comprise a topsheet, an absorbent element, and a backsheet. The leg cuff of a disposable diaper is that part of the diaper which fits about the wearer's leg. Extensions of the backsheet can be used to form cuffs which are frequently elasticized. In the present invention the cuffs are formed of a material which allows passage of vapor ("breathes") while tending to retard the passage of liquid. Apertured thermoplastic films are examples of such materials. Certain advantages accrue in cuffs which are permeable to vapor in their distal portions and impermeable in the portions adjacent the absorbent element. If the disposable diaper has a breathable backsheet, the cuffs are constructed to be more permeable to vapor per unit area in their breathable portions than is the backsheet.

Abstract: Individualized, stiffened, twisted cellulosic fibers and absorbent structures made from such fibers. The fibers have an average dry fiber twist count of at least about 4.5 twist nodes per millimeter, an average wet fiber twist count of at least about 0.5 twist nodes per millimeter less than the dry fiber twist count, and a water retention value of between about 28% and about 50%. Preferably the fibers have an average wet fiber twist count of at least about 3.0 twist nodes per millimeter and an isopropyl alcohol retention value of less than about 30%.

Abstract: A process for making individualized, crosslinked fibers having low levels of residual crosslinking agent. The fibers are made by contacting the fibers with a crosslinking agent; reacting the crosslinking agent with the fibers to form intrafiber crosslink bonds in the substantial absence of interfiber bonds; and washing the fibers with an alkaline solution.

Abstract: A process for making wet-laid structures containing individualized, stiffened fibers. The wet-laid structures are obtained by: providing a slurry containing individualized, crosslinked fibers; depositing the slurry of fibers on a foraminous forming wire; directing at least one stream of fluid upon the fibers such that the fluid disperses flocculations of fibers and also inhibits the formation of additional flocculations of the fibers; and setting the fibers into a sheeted form while the fibers are in a substantially unflocculated condition. The step of setting the fibers into sheeted form may be performed by pressing the fibers against the forming wire with a screened roll, such as a cylindrical Dandy Roll. Preferably, a plurality of streams of fluid having sequentially decreasing volumetric flow rates are directed upon the fibers. The individualized, stiffened fibers may also be mixed with conventional, stiffened fibers or highly refined, stiffened fibers while in slurry form.

Abstract: Airlaid fibrous webs having a primary layer having discrete particles of absorbent gelling material dispersed through at least a portion of the web airlaid over a dusting layer of essentially hydrophilic fiber material. The dusting layer acts to block the passage of particles injected in the stream of fibers forming the primary layer so as to minimize equipment plugging problems and the loss of particles or fibers through the foraminous forming element and to provide a more efficient absorbent core.

Abstract: Individualized, crosslinked fiber, and process for making such fibers. The individualized, crosslinked fibers have between about 0.5 mole % and about 3.5 mole % crosslinking agent, calculated on a cellulose anhydroglucose molar basis, reacted with fibers in the form of intrafiber crosslink bonds, wherein the crosslinking agent is selected from the group consisting of C.sub.2 -C.sub.8 dialdehydes, C.sub.2 -C.sub.8 dialdehyde acid analogues having at least one aldehyde functionality, and oligomers of such C.sub.2 -C.sub.8 dialdehydes, and dialdehyde acid analogues. Preferably, the crosslinking agent is glutaraldehyde, and between about 0.75 mole % and about 2.5 mole % crosslinking agent react to form the intrafiber crosslink bonds. The individualized crosslinked fibers are useful in a variety of absorbent structure applications.

Abstract: A compact, low shipping volume paper product comprising a compression loaded, core-wound roll of paper and a compression constraining element; and concomitant method of making such a paper product. The roll comprises a length of paper which is wound on a tubular core, and which roll may have an obround or parallelopipedal shape due to being unidirectionally compressively loaded after winding; and then constrained against expanding by a suitable constraining element. Preferably, the roll is sufficiently compressively loaded to completely flatten the core. In another aspect of the invention, the roll may be further compressed by applying a compressive loading that is substantially greater than that needed to cause the core to become flat; and, some of that high compressive loading may be relieved before the constraining element is applied or secured.

Abstract: A disposable absorbent article with a mechanical fastening system having adhesive tape disposal means so as to provide convenient disposal of the absorbent article. The mechanical fastening system preferably comprises a first tape tab having a first fastening element, a landing member comprising a second fastening element engageable with the first fastening element, and disposal means comprising one or a number of separate adhesive tape tabs positioned on the body portion of the absorbent article. The adhesive tape tabs secure the absorbent article in a disposal configuration so as to prevent the contents of the soiled absorbent article from spilling or leaking out during disposal.

Abstract: An improved, continuous airlaying apparatus for making airlaid articles such as discrete absorbent fibrous cores for catamenial napkins and disposable diapers and the like having high structural integrity, and good edge definition. The articles are airlaid in discrete cavities as they pass through a deposition zone of the apparatus, and are compacted a predetermined amount prior to their being removed from their respective deposition cavities. An exemplary mechanism for effecting the compacting comprises a lugged cylinder having circumferentially spaced lugs which are configured and pitched to mesh in a quasi gear-like manner with the deposition cavities.

Abstract: A method of and apparatus for dynamically mechanically bonding together a plurality of laminae, at least one of which comprises thermoplastic material: for example, polyethylene. In one aspect of the invention the laminae are forwarded in face to face relation through a pressure biased nip between a patterned nip defining member and an opposing nip defining member (e.g., a relief patterned cylinder and an anvil cylinder) which members are independently driven to maintain a predetermined surface velocity differential between them. In another aspect of the invention which is particularly useful at intermediate and higher line velocities--preferably for line velocities of about 300 feet or more per minute and, more preferably, for line speeds of about 450 feet or more per minute--the nip defining members may be operated with equal surface velocities.

Abstract: A disposable diaper comprising an absorbent core that is encased between a liquid pervious topsheet and a liquid impervious backsheet, elasticized leg openings, and a fastening device for securing the diaper on a wearer. The fastening device comprises a first member having a plurality of fiber elements and a second member having a plurality of engaging elements that are mechanically engageable with the fiber elements of the first member. The engaging elements are disposed and manufactured so as to provide a fastening device that is capable of resisting the peel forces and shear stress that are encountered during use and that is comfortable and skin friendly for the wearer. Each of the engaging elements thus preferably comprises a stem and an enlarged head positioned on one end of the stem; the head having a smooth, generally convex top surface that provides a skin friendly second member and a bottom surface that extends radially outwardly from the stem to engage the fiber elements of the first member.

Abstract: An absorbent article wherein the deposition region of its absorbent member comprises a storage zone and an acquistion zone having a lower average density and a lower average basis weight per unit area than the storage zone. The acquisition zone is positioned toward the front of either the absorbent member or the absorbent article so that the acquistion zone may most effectively and efficiently rapidly acquire discharged liquids. The absorbent member also comprises a mixture of hydrophilic fibrous material and discrete particles of absorbent gelling material to enhance the absorbent capacity of the absorbent member.

Abstract: A disposable diaper having an improved leg cuff. The disposable diaper is provided with an elastic member which is affixed to the diaper at its ends and unaffixed in its central portion. The elastic member is contained between seams having bond portions and hinge portions.

Abstract: An integral disposable absorbent article such as a diaper provided with an absorbent core; a liquid impervious backsheet; a first barrier cuff disposed adjacent each longitudinal edge of the absorbent article and each having a first proximal edge and a first distal edge; a spacing means for spacing the first distal edge of each of the first barrier cuffs away from the liquid-receiving surface of the absorbent article; and a second barrier cuff disposed adjacent at least one and preferably adjacent each of the end edges of the absorbent article and having a second proximal edge and a second distal edge, the distal edges of the barrier cuffs overlapping at corner points to form a containment pocket. The spacing means preferably comprises a spacing elastic member that extends longitudinally along the first distal edge beyond the second distal edges.

Abstract: Disposable diapers having elasticized waistbands which are shaped to conform to the wearers' waists and method of making them. The shaped disposable diapers are made by affixing an elastomeric material having a heat unstable state and a heat stable and elastic state to the diaper while the elastomeric material is in its heat unstable state and then heating the elastomeric material while the diaper is restrained in a folded configuration.