Abstract: A method of applying curved leg elastics to absorbent garments involves stretching and wrapping an elastic ribbon about a curved side of a puck. A portion of the elastic ribbon is simultaneously folded onto a top surface of the puck. The puck is attached to a rotating device that rotates the puck into alignment with a substrate. The substrate is then bonded to the portion of the elastic ribbon in its stretched position on the puck, thereby forming a finished seam. The resulting absorbent garments have gasket-like leg openings with improved comfort and aesthetic appeal.

Abstract: A method of applying curved leg elastics to absorbent garments involves stretching and wrapping a pair of elastic ribbons about a first curved surface of a pair of pucks. A portion of each of the elastic ribbons is simultaneously folded onto a second surface of each of the pucks. The pucks are attached to a rotating device that rotates the pucks into alignment with a substrate. As the pucks are rotated toward the substrate, the pucks are also oscillated individually toward the substrate. Once the second surfaces of the pucks are aligned parallel to the substrate, the substrate is bonded to the second surface portion of each of the elastic ribbons in their stretched positions on the pucks, thereby forming finished seams. The resulting absorbent garments have gasket-like leg openings with improved comfort and aesthetic appeal.

Abstract: A pant-like, disposable absorbent article includes an absorbent chassis, a pair of opposed side panels, at least one line of weakness and at least one fastener. The absorbent chassis defines a pair of laterally opposed side edges and a pair of longitudinally opposed waist edges. The side panels extend between 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 front permanent joint. The opposed side panels further define a second side margin opposite the first side margin which is permanently attached to the side edge of the absorbent chassis in the other waist region of the absorbent article to provide a back permanent joint.

Abstract: An absorbent article having a flap and a spacer wherein the flap is positioned in the rear waist portion of the article and forms a pocket. The spacer is positioned proximate the pocket opening and biases the pocket into an open position. The flap may be a laterally extending liquid impermeable flap which is fixedly secured to the article along a seam. The seam, which may be substantially U-shaped, extends between first and second terminal ends. The flap has a free edge which extends between the first and second terminal ends of the seam. The seam and free edge of the flap define the boundaries of a pocket which is formed between the flap and a topsheet of the absorbent article. The pocket has an opening extending between the first and second terminal ends of the seam. The spacer affixed to the article whereby it is disposed between the flap and the topsheet proximate, and optionally extending through, the pocket opening to bias the free edge of the flap away from the topsheet.

Abstract: The invention relates to prefastened absorbent articles (20) including one or more of several improvement features. The articles can be made to be prefastened by having a singular fastening mechanism that includes an oversized fastener (60). The articles of the invention can include a multiple property fastener (60) that has at least one engagement zone (65) and at least one non-abrasive zone (67).

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 method of making a prefolded diaper or other undergarment includes the steps of forming a web of diaper material, placing a fastening system divided between front and back waist sections onto each diaper section of the web and cutting the web to define individual diapers. The diapers are then folded in half at the crotch section and are then microwaved in a high power resonant cavity microwave device to activate the latent elastic portions which are buried within the folded diaper. Where desired, the refastenable fastening system of the diaper, or the front and back waist sections or the diaper, may be registered in a fastening alignment and fastened together when the diaper is folded to create diapers which are useful upon removal from the point of sale container as pull on training pants.

Abstract: A method of applying curved leg elastics to absorbent garments involves stretching and wrapping a pair of elastic ribbons about a first curved surface of a pair of disks. A portion of each of the elastic ribbons folds onto a second surface of each of the disks. The disks are rotated about a point off-center from a center point of the disks. The portions of the elastic ribbons on the second surfaces of the disks are rotated onto a substrate and bonded to the substrate in their stretched positions on the disks, thereby forming finished seams. The resulting absorbent garments have gasket-like leg openings with improved comfort and aesthetic appeal.

Abstract: The invention relates to methods of fabricating absorbent articles. In a method of the invention, a bodyside liner, an absorbent core, and an outer cover are joined to form an absorbent article web sausage. Leg cut-outs are cut on opposing sides of the web sausage, and a waist opening is cut in a central region of the web sausage. Adhesive is applied to one of (i) a waist piece material and (ii) the web sausage about the waist opening; and also to one of (iii) extensible leg cuff material and (iv) the web sausage adjacent the leg cut-outs. A waist piece is severed from waist piece material, and is placed. over the waist opening and secured to the web sausage. Leg cuffs are severed from the leg cuff material, and are placed over the leg cutouts and secured to the web sausage. The waist piece and leg cut-outs are preferably stretched to a dimension representing about 5% to about 95% of stretch-to-stop dimensions when bonded to the web sausage.

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: Disclosed is an improved process for attaching and protecting a mechanical fastener on a disposable absorbent article and a disposable absorbent article produced by the same. The process comprises the following steps: (1) providing a disposable absorbent article which includes an outer cover, a bodyside liner, and an absorbent core disposed between the outer cover and the bodyside liner; (2) providing a mechanical fastener which includes a first fastening element; (3) attaching the first fastening element of the mechanical fastener to the disposable absorbent article; (4) releasably engaging the first fastening element with the disposable absorbent article to protect the first fastening element; and (5) subsequently packaging the disposable absorbent article for commercial sale. The first fastening element and a portion of the disposable absorbent article may be releasably engaged by constrictively passing them between a pair of rotatable nip rolls.

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 of applying curved leg elastics to absorbent garments involves stretching and wrapping a pair of elastic ribbons about a first curved surface of a pair of pucks. A portion of each of the elastic ribbons is simultaneously folded onto a second surface of each of the pucks. The pucks are attached to a rotating device that rotates the pucks into alignment with a substrate. As the pucks are rotated toward the substrate, the pucks are also oscillated individually toward the substrate. Once the second surfaces of the pucks are aligned parallel to the substrate, the substrate is bonded to the second surface portion of each of the elastic ribbons in their stretched positions on the pucks, thereby forming finished seams. The resulting absorbent garments have gasket-like leg openings with improved comfort and aesthetic appeal.

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: 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 method of applying curved leg elastics to absorbent garments involves stretching and wrapping a pair of elastic ribbons about a first curved surface of a pair of pucks. A portion of each of the elastic ribbons is simultaneously folded onto a second surface of each of the pucks. The pucks are attached to a rotating device that rotates the pucks into alignment with a substrate. As the pucks are rotated toward the substrate, the pucks are also oscillated individually toward the substrate. Once the second surfaces of the pucks are aligned parallel to the substrate, the substrate is bonded to the second surface portion of each of the elastic ribbons in their stretched positions on the pucks, thereby forming finished seams. The resulting absorbent garments have gasket-like leg openings with improved comfort and aesthetic appeal.

Abstract: Methods and apparatus for applying elastic material in a curvilinear pattern on a continuously moving substrate. The method moves a substrate along a substrate path, supplies the elastic material to an oscillation unit first roll mounted for pivoting and rolling engagement with a transfer roll, oscillates the oscillation unit in a path generally transverse to the substrate path, applies the elastic material from the first roll to the transfer roll in the desired curvilinear path configuration, then applies the elastic material from the transfer roll to the substrate and bonds the elastic material to the substrate. Optionally the first roll may apply the elastic material directly to the substrate.

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: Methods and apparatus for applying elastic material in a curvilinear pattern on a continuously moving substrate. The method moves a substrate along a substrate path, supplies the elastic material to an oscillation unit first roll mounted for pivoting and rolling engagement with a transfer roll, oscillates the oscillation unit in a path generally transverse to the substrate path, applies the elastic material from the first roll to the transfer roll in the desired curvilinear path configuration, then applies the elastic material from the transfer roll to the substrate and bonds the elastic material to the substrate. Optionally the first roll may apply the elastic material directly to the substrate.

Abstract: An absorbent article includes an absorbent pad and an extensible outer cover. The absorbent pad comprises an absorbent core surrounded by a first folded layer and optionally a second folded barrier layer. Folds of the first and second folded layers unfold and thereby open when an extensible bodyside liner and/or outer cover of the absorbent article are extended. The folds, when opened, extend the respective folded layers in a respective cross-direction or longitudinal direction. Extension of the folds of the first and second folded layers prevents tearing of the absorbent pad and damage to, or release of superabsorbent material from the absorbent pad during extension of the absorbent article. The folds can comprise T-folds, C-folds, pleated arrangements, corrugations, or the like.