Abstract: Absorbent structures are disclosed which may be incorporated into liquid absorbent products, such as diapers, adult incontinence products, feminine hygiene products, and the like. The absorbent structures are made from a fibrous material and include a pair of opposing lateral flaps. The lateral flaps are folded onto the fibrous web. By folding the lateral flaps onto the fibrous web, greater basis weight areas may be formed on the absorbent structure. By varying the width of the lateral flaps, the basis weight differential may be increased and decreased. The lateral flaps also form the widest portion of the web material for facilitating folding during a continuous process.

Abstract: Prefastened absorbent articles (20) may include a singular fastening mechanism that includes an oversized fastener (60), to provide stability between the front waist region and the back waist region and to maintain the prefastened configuration. The prefastened absorbent articles can include a multiple property fastener (60) that has at least one engagement zone (65) and at least one non-abrasive zone (67).

Abstract: An absorbent garment, such as a diaper, folded in a manner that prevents leg elastics from remaining folded inward in a crotch region during product application. Each of two transversely opposed distal edges in a back waist region and each of two transversely opposed distal edges in a front waist region are folded onto a surface of the garment along respective longitudinal fold lines. The garment is also folded along at least one transverse fold line. A distance between the longitudinal fold lines in the back waist region may be greater than a distance between transversely opposed leg elastics in a crotch region of the garment. A distance between the longitudinal fold lines in the back waist region may be less than a combined distance between each of the transversely opposed distal edges of the back waist region and the respective longitudinal fold line.

Abstract: A method and apparatus for bonding and aperturing one or more fibrous webs including bonding at least one fibrous web in a bonding nip created by a rotatable bonding roll and a rotatable anvil roll and aperturing the at least one fibrous web in an aperturing nip created by a rotatable aperture roll and an anvil roll. The bonding roll has a plurality of protuberances extending from the peripheral bonding surface that define a bonding pattern and result in highly bonded regions within the fibrous web. The aperture roll has a plurality of projections extending from the peripheral aperture surface that define an aperturing pattern. The aperturing pattern substantially aligns with the bonding pattern thereby creating apertures within the highly bonded regions.

Abstract: A pant-like, refastenable, disposable absorbent article includes an absorbent chassis, a pair of opposed side panels, a pair of releasable joints and a pair of proportional fasteners. The absorbent chassis defines a pair of laterally opposed side edges and a pair of longitudinally opposed waist edges. The side panels extend between and connect the side edges of the absorbent chassis to define a waist opening and a pair of leg openings in the pant-like disposable absorbent article. Each of the opposed side panels defines a first side margin which is permanently attached to the side edge of the absorbent chassis in one waist region of the absorbent article to provide a permanent joint. Each of the opposed side panels further defines a second side margin opposite the first side margin which is releasably attached to the side edges of the absorbent chassis in the other waist region of the absorbent article to provide the releasable joints.

Abstract: A method for forming a stabilized airlaid layer (86) can include an airforming of a substantially unbonded fibrous layer (66) which includes absorbent fibers and binder-fibers. The fibrous layer (66) is exposed to high-frequency electromagnetic energy during a distinctively short activation period to activate the binder-fibers to provide the stabilized, airlaid layer (86). In a particular aspect the activation period can be not more than about 3 sec.

Abstract: Methods are disclosed for producing absorbent articles comprising molded airlaid webs and other molded fibrous webs. The molded webs can offer improved body fit and/or improved fluid handling. Molded airlaid webs, for example, can be formed having a central longitudinal hump and flexure zones longitudinally removed from the central hump to provide good contact with the body and improved fit when the article is squeezed from the sides. Molding can be achieved when a binder material is activated by an energy source and the web is held against a molding substrate. Energy sources can include microwaves, heated air, heated metal surfaces, ultraviolet radiation, ultrasonic energy, and the like.

Abstract: Methods are disclosed for producing absorbent articles comprising molded airlaid webs and other molded fibrous webs. The molded webs can offer improved body fit and/or improved fluid handling. Molded airlaid webs, for example, can be formed having a central longitudinal hump and flexure zones longitudinally removed from the central hump to provide good contact with the body and improved fit when the article is squeezed from the sides. Molding can be achieved when a binder material is activated by an energy source and the web is held against a molding substrate. Energy sources can include microwaves, heated air, heated metal surfaces, ultraviolet radiation, ultrasonic energy, and the like.

Abstract: A pant-like absorbent garment adapted to the non-symmetrical nature and leakage demands of the anatomy of the human body has variable spacing and curvature among the elastic members bonded around the leg openings such that the spacing and/or curvature is asymmetrical with respect to the wearer's anterior and posterior sides. The spacing and curvature profiles of the elastic members are designed to accommodate various pressure demands around a wearer's legs during different activities. The resulting garment has optimized comfort, fit and containment about the leg openings.

Abstract: A method of making a prefastened refastenable diaper or other undergarment includes the steps of forming a web of diaper material, cutting holes in the center of the web as precursor leg cutouts and, placing a fastening system divided between front and back waist sections onto each diaper section of the web to prepare inchoate diapers having their long axes in the cross machine direction of the web. Then the web is cut to define the web into individual diapers. The diapers are then folded in half at the crotch section, placing the fastening system section in lapping alignment and fastening the system together. The diapers are then removed by the leg holes to bundle and place the diapers in point of sale containers. The method lends itself to simple in-line process machinery for accomplishing the manufacture of the diapers.

Abstract: The invention relates to methods of fabricating an absorbent article. In one method of the invention, combination containment flaps and leg cuffs are formed on a common substrate. A plurality of elastomeric elements are included in the combination article to assist in forming containment flaps. Discrete leg cuff pieces are applied to the substrate at longitudinally spaced locations. In some embodiments, a cutting device slits the substrate substantially along a center line extending the length of the substrate, forming two continuous substrate portions. A glue gun applies adhesive to the substrate portion. The substrate portions are folded lengthwise, using the adhesive to form integral containment flaps and leg cuffs in a composite substrate. The composite substrate is secured to an absorbent article web sausage in forming absorbent articles. In another embodiment, the substrate is a first substrate which supports elastomeric elements used in forming leg cuffs and containment flaps.

Abstract: A pant-like absorbent garment adapted to the non-symmetrical nature and leakage demands of the anatomy of the human body has asymmetrical pressure around the leg openings with respect to the wearer's anterior and posterior sides. Elastic members are bonded about the leg openings with either higher tension on the posterior side and lower tension on the anterior side or higher tension on the anterior side and lower tension on the posterior side, depending on the intended wearer's level of activity. The resulting garments have optimized comfort, fit and containment about the leg openings.

Abstract: Disclosed is an improved fastening tape for use on a disposable absorbent garment. The fastening tape comprises a first substrate and an interlocking material attached to said first substrate. The interlocking material extends the entire width of the fastening tape, and the interlocking material is longitudinally spaced from both transverse edges of the fastening tape. Also disclosed is a process for manufacturing the fastening tape. The process involves providing a continuous length of an interlocking material having a width and traveling in a first direction. The interlocking material is attached to a first substrate to form a composite. The composite is then cut along a second direction to form fastening tapes suitable for attachment on a disposable absorbent garment. The second direction is substantially perpendicular to the first direction.

Abstract: A pant-like absorbent garment having curved leg cuffs has a gasket-like fit. A chassis of the absorbent garment defines first and second leg openings with curved cut-outs in the chassis. A bonded portion is located between a first portion and a second portion of each of two elastic strands. The bonded portions are bonded to the first and second leg openings about a periphery of the curved cut-outs, thereby forming finished seams. Second portions of the elastic strands can form rolled edges. The resulting absorbent garment has a comfortable, gasket-like fit and an aesthetically pleasing, finished look about the leg openings.

Abstract: A personal care article for preventing exudates from contacting the body of a user comprises a substrate including an extensible bodyside liner layer, and an aperture support structure limiting extensibility of the bodyside liner layer along the length of the aperture support structure. One support band of an aperture support structure runs through the gluteal fold between the buttocks of a user. The aperture support structure positions an aperture in the bodyside liner layer in the gluteal fold of a user, in alignment with the anus, so that fecal material enters a containment receptacle upon leaving the anus. In another embodiment, the personal care article can include a comfort stretch layer comprising an elastomeric, hot melt, pressure-sensitive adhesive located between a bodyside liner layer and an outer layer.

Abstract: A process and apparatus for making a three-dimensional garment. The process is carried out by loading an insert onto an expandable/retractable process loop fixture. A waist elastic member can be bonded to a waist area of the insert. A garment shell can be applied over the insert and the waist elastic member. A waist area of the garment shell can be attached to the waist elastic member and to the waist area of the insert.

Abstract: A method for forming a stabilized airlaid layer (86) can include an airforming of a substantially unbonded fibrous layer (66) which includes absorbent fibers and binder-fibers. The fibrous layer (66) is exposed to high-frequency electromagnetic energy during a distinctively short activation period to activate the binder-fibers to provide the stabilized, airlaid layer (86). In a particular aspect the activation period can be not more than about 3 sec.

Abstract: A method of making an undergarment having refastenable side seams (12, 14). The method includes a step of preconditioning a substantially two-dimension web (57) to include at least four refastening surfaces (82-85). The refastenable side seams (12, 14) can be incorporated into undergarments formed from a continuous web (57) in which the pre-forms (21) (that will ultimately result in individual undergarments) are oriented in either the machine direction or the cross-direction. The web (57) can be preconditioned to include refastening surfaces (82-85) on both of what becomes the exterior surface (30) and the body-contacting surface (28) of the undergarments.

Abstract: A personal care article comprising a front portion, first and second lateral sections having inner edges releasably fastened to the front portion and first and second outer portions attached to the front portion, a back portion, and a crotch portion between the front portion and the back portion, Outer edges of the first and second lateral sections are secured to third and fourth side edges of the back portion to form a pant-like article having a waist opening, and first and second leg openings. Strength of the attachment of the outer portions of the lateral sections to the front portion is less than strength of securement of the outer edges of the lateral sections to the back portion, whereby the attachments of the outer portions of the lateral sections to the front portion can be separated from the front portion without separating securement of the first and second lateral sections from the side edges of the back portion.

Abstract: A method and apparatus (20) for changing the speed of discrete components (22) can include a first rotatable drive member (32), and at least a second rotatable drive member (42) which is substantially coaxial with the first drive member (32). A first servo motor (34) is connected to rotate the first drive member (32), and at least a second servo motor (34) is connected to rotate the second drive member (42). A first transfer puck (36) is driven by the first rotatable drive member (32), and at least a second transfer puck (46) is driven by the second rotatable drive member (42). A first electronic drive (38) is connected to the first servo motor (34), and is configured to selectively move the first transfer puck (36) at a first, pick up speed (V1) and at least a second, deposit speed (V2). At least a second electronic drive (48) is connected to the second servo motor (44), and is configured to selectively move the second transfer puck (46) at the first pick up speed and at the second deposit speed (V2).