Laminate(S) Comprising Beamed Elastics and Absorbent Article(S) Comprising Said Laminate(S)
The present disclosure relates to one or a combination of an absorbent article's chassis, inner leg cuffs, outer leg cuffs, ear panels, side panels, waistbands, and belts that may comprise one or more pluralities of tightly spaced (less than 4 mm, less than 3 mm, less than 2 mm, and less than 1 mm) and/or very fine (less than 300, less than 200, less than 100 dtex) and/or low strain (less than 300%, less than 200%, less than 100%) elastics to deliver low pressure less than 1 psi (according to the conditions defined by the Pressure-Under-Strand method below) under the elastics, while providing adequate modulus of (between about 2 gf/mm and 15 gf/mm) to make the article easy to apply and to comfortably maintain the article in place on the wearer, even with a loaded core (holding at least 50 mls of liquid), to provide for the advantages described above.
This application claims the benefit, under 35 USC 119(e), to U.S. Provisional Patent Application No. 62/436,589, filed on Dec. 20, 2016 (P&G 14618P); U.S. Provisional Patent Application No. 62/483,965, filed on Apr. 11, 2017 (P&G 14778P); U.S. Provisional Patent Application No. 62/553,149, filed on Sep. 1, 2017 (P&G 14917P); U.S. Provisional Patent Application No. 62/553,171, filed on Sep. 1, 2017 (P&G 14918P); U.S. Provisional Patent Application No. 62/553,538, filed on Sep. 1, 2017 (P&G 14921P); and U.S. Provisional Patent Application No. 62/581,278, filed on Nov. 3, 2017 (P&G 15007P); each of which are herein incorporated by reference in their entirety.
FIELD OF THE INVENTIONThe present disclosure relates to absorbent articles, more particularly, to disposable absorbent articles comprising elastic laminates configured to perform in various components of the disposable absorbent articles.
BACKGROUND OF THE INVENTIONThe present disclosure details elastomeric laminates comprising a greater number of elastic strands having a greater fineness and a closer spacing than has been previously disclosed or practiced in disposable absorbent articles. Further, the present disclosure details combinations of these elastic elements in groupings, including groupings with traditional elastics (e.g., strands, films, extruded strands, scrims, elastomeric nonwovens, etc.) that have not been previously disclosed.
These improved elastomeric laminates can be used as disposable absorbent article (for, example, taped diapers, pants, pads, and liners) components for fit and gasketing at the waist, legs, crotch and sides of the wearer to generally provide the greatest level of extensibility, the most comfortable wearing conditions, improved leakage protection and a better fit.
More particularly, these improved elastomeric laminates offer several advantages, including improved textures and less pressure of the elastic elements on the wearer's skin at a given modulus versus traditional elastomeric laminates known today. These improvements result in enhancing application (e.g., making pant articles easier to open for donning), fit, comfort, and reduced marking of the wearer's skin. The inventive elastomeric laminates disclosed in this application perform better than traditional stranded and film versions of laminates known today.
Elastic laminates of the prior art have a number of consumer negatives that vary based on the laminate structure. For example, traditional stranded laminates used in absorbent articles known today typically comprise elastic elements of relatively high decitex (also referred to herein as “dtex”) and relatively large elastic spacing, which when combined result in high pressure imparted by each elastic on the skin and large uncontrolled rugosities in the laminate both of which leads to increased skin marking, reduced comfort and a non-garment like appearance. Traditional stranded laminates typically comprise elements spaced at least 4 mm apart primarily due to manufacturing limitations and handling of individual strands of elastics via separate material infeeds. With regard to extruded strands and/or extruded scrim materials, they are similar to many elastomeric films in that they typically comprise thermoplastic materials that undergo significant stress relaxation over time and thus do not maintain the proper forces at the waist and legs to provide proper initial and sustained fit and gasketing over the entire wearing time.
Regarding elastic film laminates, they are significantly more occlusive (i.e., less breathable, very low or no air permeability), resulting in greater hydration of the skin and as a result significantly reduced comfort and increased marking associated with the susceptibility of the hydrated skin to marking. Also, film based elastic laminates in general tend to have a higher modulus versus stranded elastic laminates, therefore being more difficult to apply to a wearer (making it difficult to open for donning), therefore requiring more sizes to cover a given fit range of wearers. It is also very difficult to create a force profile across the elastic film laminate or scrim based elastic laminate as they are typically formed via webs with relatively uniform properties.
There has therefore been a long standing unmet consumer need which is to create a product that delivers very low pressure on the skin, high level of breathability, adequate force for sustained fit, low modulus, high extensibility and a smooth uniform texture. Such an absorbent article would provide improved skin condition, skin marking, skin hydration, ease of application, ease of removal, improved sustained fit, improved gasketing, as well as improved body conformity and wearer comfort.
To deliver against all of the unmet consumer needs requires a complete structural redesign of the elastomeric laminates used in the absorbent article. The balance of elastic decitex, elastic strand spacing, number of elastics and elastic pre-strain required to deliver such a unique blend of properties requires elastic decitex that are very low, well below that of the prior art, disposed at elastic to elastic spacing that are also very low, also well below the prior art, which in turn requires a larger number of elastics well above that known in the prior art, and elastic strains that are also low and well below nearly all of the known prior art. In addition to the very specific combinations of decitex, spacing, number of elastics and pre-strain required to deliver against the range of unmet consumer needs an additional factor of nonwoven choice, basis weight, composition, etc. is also critical to creating the overall desired structure.
Elastomeric laminates of the present disclosure have higher body contact and improved textures versus the prior art as demonstrate by the Surface Topography Method and less pressure of the elastic elements on the wearer's skin at a given modulus and reduced marking of the wearer's skin versus traditional elastic laminates known today as demonstrated by the Pressure-Under-Strand method. These improvements result in enhancing application (e.g., making pant articles easier to open for donning), fit, comfort as evidenced by the Product Measurement Test. These inventive elastomeric laminates also provide a very high level of breathability as evidenced by the WVTR Method and by the Air Permeability method. The inventive elastomeric laminates disclosed in this application perform better than traditional stranded and film versions of laminates known today.
The specific set of criteria required to deliver against all of the aforementioned unmet consumer needs with a single product not only requires unique elastomeric laminate structures but it requires a new process, beamed elastic (a plurality of elastics formed on and delivered from a beam or spool), for delivery of such a large number of low decitex elastics, at low pre-strain and low spacing in order to achieve the right balance of laminate properties. Such an approach to the best of our knowledge has never before been disclosed or attempted in the field of absorbent articles; hygiene articles, taped diapers, diaper pants, adult incontinence articles, menstrual products, etc.
SUMMARY OF THE INVENTIONIn one disclosed example, an absorbent article may comprise a chassis and a first elastomeric laminate. The chassis may comprise a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The first elastomeric laminate may comprise a first plurality of elastics between inner and outer nonwovens. The first plurality of elastics may have an Average-Strand-Spacing from about 0.25 mm to about 4 mm. The Average-Dtex of the first plurality of elastics may be from about 10 to about 500. The Pressure-Under-Strand of the first plurality of elastics may be from about 0.1 to about 1 psi.
The first elastomeric laminate may form at least a portion of at least one of a belt, a chassis, a side panel, a topsheet, a backsheet, an ear panel, and combinations thereof, and the first plurality of elastics may comprise from about 40 to about 1000 elastic strands.
The first elastomeric laminate may form at least a portion of at least one of a waistband, a waistcap, an inner leg cuff, an outer leg cuff, a transverse barrier, and combinations thereof, and where the first plurality of elastics may comprise from about 10 to about 400 elastic strands.
The first plurality of elastics may have an Open Area from about 80% to about 90%.
The first plurality of elastics may have a Pressure-Under-Strand from about 0.3 to about 0.8 psi.
The article further may comprise a back belt formed by at least a portion of the first elastomeric laminate, where the back belt may be divided into 4 equal sections, where Section 4 may comprise a proximal end edge of the belt, Section 1 may comprise a distal end edge of the back belt, Section 2 is proximate to Section 1 and Section 3 is proximate to Section 4, where at least two of the sections each have greater than 10 elastic strands, where the back belt is disposed in the back waist region, and where the back belt may comprise one or more sections having a Section-Modulus of between about 4 gf/mm and 10 gf/mm.
The article further may comprise a first panel formed by at least a portion of the first elastomeric laminate, and the article further may comprise a second panel formed by at least a portion of a second elastomeric laminate may comprise a second plurality of elastics between inner and outer nonwovens. The second plurality of elastics may have an Average-Strand-Spacing from about 0.25 mm to about 4 mm, an Average-Dtex from about 10 to about 500, and a Pressure-Under-Strand from about 0.1 to about 1 psi. And, each of the first and second panels may comprise greater than about 25 elastic strands. And, the first and second panels may be laterally opposed and disposed in the back waist region.
The article further may comprise a waistband formed by at least a portion of the first elastomeric laminate, where the waistband may comprise greater than 20 elastic strands, and where the waistband may be disposed in the back waist region.
The article further may comprise an inner leg cuff formed by at least a portion of the first elastomeric laminate, where the inner leg cuff may comprise greater than 15 elastic strands.
The first plurality of elastics may have a Percent Contact Area of at least one of: a) greater than about 11% at 100 um, b) greater than about 28% at 200 um, and c) greater than about 51% at 300 um, and where the first plurality of elastics may have a 2%-98% Height Value of <1.6 mm.
The first plurality of elastics may have an Air Permeability of at least one of: a) greater than about 40 cubic meters/square meter/minute Air Permeability at 0 gf/mm (no extension); b) greater than about 60 cubic meters/square meter/minute Air Permeability at 3 gf/mm (slight extension); and c) greater than about 80 cubic meters/square meter/minute Air Permeability at 7 gf/mm (moderate extension).
The first plurality of elastics may have a Water Vapor Transmission Rate of greater than 4000 g/m2/24 hrs.
The first plurality of elastics may have a Caliper of from about 0.5 mm to about 4 mm at 0 gf/mm (no extension); and a Caliper Retention Value from about 60% to about 95% at 3 gf/mm (slight extension); and/or a Caliper Retention Value from about 40% to about 90% at 7 gf/mm (moderate extension).
The first plurality of elastics may have a Rugosity Frequency of from about 0.2 mm−1 to about 1 mm−1, and a Rugosity Wavelength of from about 0.5 mm to about 5 mm.
The first plurality of elastics may have a Cantilever Bending of less than about 40 mm.
In another disclosed example, a package may comprise absorbent articles, may comprise a package material containing a plurality of absorbent articles and may comprise an indicia indicating sizing information used to calculate an Average Targeted Weight, a Donning-Ratio, and a Target Body Length-to-Waist Silhouette. Each absorbent article of the plurality absorbent articles, may comprise a chassis, a back belt, a front belt, a longitudinal axis, and a lateral axis. The chassis may comprise a topsheet, a backsheet and an absorbent core disposed between the topsheet and the backsheet, where the chassis may comprise a front end edge and a back end edge. The back belt may be disposed in the back waist region overlapping and extending longitudinally outboard of the back waist region of the chassis. The front belt may be disposed in the front waist region overlapping and extending longitudinally outboard of the front waist region of the chassis. The first plurality of elastics may have an Average-Strand-Spacing of less than 4 mm, and the second plurality of elastics may have an Average-Strand-Spacing of less than 4 mm. The back belt may be divided into 4 equal sections, where Section 4 may comprise a proximal end edge of the back belt, Section 1 may comprise a distal end edge of the back belt, and Section 2 is proximate to Section 1 and Section 3 is proximate to Section 4.
The front belt may be divided into 4 equal sections, where Section 4 may comprise a proximal end edge of the front belt, Section 1 may comprise a distal end edge of the front belt, and Section 2 is proximate to Section 1 and Section 3 is proximate to Section 4. The absorbent article may have the Donning-Ratio from about 1.0 and about 1.5.
The difference between the Target Body Length-to-Waist Silhouette and a Product Length-to-Waist Silhouette may be from about −0.3 to about 0.3.
The Product Hip-to-Waist Silhouette may be from about 0.8 to about 1.1.
One or more of the sections of the back belt may have a Section-Modulus of from about 2 gf/mm to about 15 gf/mm, and one or more of the sections of the front belt may have a Section-Modulus of from about 2 gf/mm to about 15 gf/mm.
In another disclosed example, an extensible article, may comprise a front waist edge, a back waist edge, a longitudinal axis extending from the midpoint of the front waist edge to the midpoint of the back waist edge, a lateral axis extending perpendicular to the longitudinal centerline through the midpoint of the longitudinal centerline, a first elastomeric laminate forming at least a portion of a belt, a side panel, or an ear panel in a first waist region, a second elastomeric laminate forming at least a portion of a belt, a side panel, or an ear panel in a second waist region, and a third elastomeric laminate formed by two substrate layers forming at least a portion of the chassis in a crotch region. Each of the first plurality of elastics, second plurality of elastics, and third plurality of elastics may have an Average-Strand-Spacing from about 0.25 mm to about 4 mm. The Average-Pre-Strain of each of the first plurality of elastics, second plurality of elastics and third plurality of elastics may be from about 50% to about 400%. The Average-Dtex of each of the first plurality of elastics, second plurality of elastics, and third plurality of elastics may be from about 10 to about 500. The third plurality of elastics may have one or more of: a) an Average-Strand-Spacing that is greater than one or both of the first and second plurality of elastics, b) an Average-Dtex that is lower than one or both of the first and second plurality of elastics, c) an Average-Pre-Strain that is lower than one or both of the first and second plurality of elastics, and d) a number of elastics that is lower than one or both of the first and second plurality of elastics. The elastic strands of each of the first plurality of elastics and second plurality of elastics may be disposed substantially parallel to the lateral axis. The elastic strands of the third plurality of elastics may be disposed substantially parallel to the longitudinal axis or substantially parallel to the lateral axis.
The following term explanations may be useful in understanding the present disclosure:
“Disposable,” in reference to absorbent articles, means that the absorbent articles, are generally not intended to be laundered or otherwise restored or reused as absorbent articles (i.e., they are intended to be discarded after a single use and, preferably, to be recycled, composted or otherwise discarded in an environmentally compatible manner). Disposable absorbent articles often comprise adhesive between the layers and/or elements to hold the article together (e.g., ear panels, side panels, and belts are joined to the chassis via adhesive and the layers of the ear panels, side panels, belts, and chassis are joined together using adhesive). Alternatively, heat and/or pressure bonding are used with the adhesive or in place of the adhesive. In such instances portions of the material layers may become partially melted and pressed together such that once cooled they are physically bonded together. Nonwovens (including, for example, polypropylene, polyethylene, etc.) adhesives (including, for example, styrenic block copolymers (e.g., SIS, SBS)), and absorbent gelling material (AGM 51—see
“Absorbent article” refers to devices, which absorb and contain body exudates and, more specifically, refers to devices, which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. Exemplary absorbent articles include diapers, training pants, pull-on pant-type diapers (i.e., a diaper having a pre-formed waist opening and leg openings such as illustrated in U.S. Pat. No. 6,120,487), refastenable diapers or pant-type diapers, incontinence briefs and undergarments, diaper holders and liners, feminine hygiene garments such as panty liners, absorbent inserts, menstrual pads and the like.
“Proximal” and “Distal” refer respectively to the location of an element relatively near to or far from the longitudinal or lateral centerline of a structure (e.g., the proximal edge of a longitudinally extending element is located nearer to the longitudinal axis than the distal edge of the same element is located relative to the same longitudinal axis).
“Body-facing” and “garment-facing” refer respectively to the relative location of an element or a surface of an element or group of elements. “Body-facing” implies the element or surface is nearer to the wearer during wear than some other element or surface. “Garment-facing” implies the element or surface is more remote from the wearer during wear than some other element or surface (i.e., element or surface is proximate to the wearer's garments that may be worn over the disposable absorbent article).
“Longitudinal” refers to a direction running substantially perpendicular from a waist edge to an opposing waist edge of the article and generally parallel to the maximum linear dimension of the article. Directions within 45 degrees of the longitudinal direction are considered to be “longitudinal.”
“Lateral” refers to a direction running from a longitudinally extending side edge to an opposing longitudinally extending side edge of the article and generally at a right angle to the longitudinal direction. Directions within 45 degrees of the lateral direction are considered to be “lateral.”
“Disposed” refers to an element being located in a particular place or position.
“Joined” encompasses configurations whereby an element is directly secured to another element by affixing the element directly to the other element, and configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s), which, in turn are affixed to the other element.
“Water-permeable” and “water-impermeable” refer to the penetrability of materials in the context of the intended usage of disposable absorbent articles. Specifically, the term “water-permeable” refers to a layer or a layered structure having pores, openings, and/or interconnected void spaces that permit liquid water, urine, or synthetic urine to pass through its thickness in the absence of a forcing pressure. Conversely, the term “water-impermeable” refers to a layer or a layered structure through the thickness of which liquid water, urine, or synthetic urine cannot pass in the absence of a forcing pressure (aside from natural forces such as gravity). A layer or a layered structure that is water-impermeable according to this definition may be permeable to water vapor, i.e., may be “vapor-permeable.”
“Elastic,” “elastomer,” or “elastomeric” refers to materials exhibiting elastic properties, which include any material that upon application of a force to its relaxed, initial length can stretch or elongate to an elongated length more than 10% greater than its initial length and will substantially recover back to about its initial length upon release of the applied force. Elastomeric materials may include elastomeric films, scrims, nonwovens, ribbons, strands and other sheet-like structures.
“Pre-strain” refers to the strain imposed on an elastic or elastomeric material prior to combining it with another element of the elastomeric laminate or the absorbent article. Pre-strain is determined by the following equation Pre-strain=((extended length of the elastic-relaxed length of the elastic)/relaxed length of the elastic)*100.
“Decitex” also known as Dtex is a measurement used in the textile industry used for measuring yarns or filaments. 1 Decitex=1 gram per 10,000 meters. In other words, if 10,000 linear meters of a yarn or filament weights 500 grams that yarn or filament would have a decitex of 500.
“Substrate” is used herein to describe a material which is primarily two-dimensional (i.e. in an XY plane) and whose thickness (in a Z direction) is relatively small (i.e. 1/10 or less) in comparison to its length (in an X direction) and width (in a Y direction). Non-limiting examples of substrates include a web, layer or layers of fibrous materials, nonwovens, films and foils such as polymeric films or metallic foils. These materials may be used alone or may comprise two or more layers laminated together. As such, a web is a substrate.
“Nonwoven” refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. Nonwovens do not have a woven or knitted filament pattern.
“Machine direction” (MD) is used herein to refer to the direction of material flow through a process. In addition, relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.
“Cross direction” (CD) is used herein to refer to a direction that is generally perpendicular to the machine direction.
“Taped diaper” (also referred to as “open diaper”) refers to disposable absorbent articles having an initial front waist region and an initial back waist region that are not fastened, pre-fastened, or connected to each other as packaged, prior to being applied to the wearer. A taped diaper may be folded about the lateral centerline with the interior of one waist region in surface to surface contact with the interior of the opposing waist region without fastening or joining the waist regions together. Example taped diapers are disclosed in various suitable configurations U.S. Patent Nos. 5,167,897, 5,360,420, 5,599,335, 5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537, 6,118,041, 6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787, 6,617,016, 6,825,393, and 6,861,571; and U.S. Patent Publication Nos. 2013/0072887 A1; 2013/0211356 A1; and 2013/0306226 A1.
“Pant” (also referred to as “training pant”, “pre-closed diaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refers herein to disposable absorbent articles having a continuous perimeter waist opening and continuous perimeter leg openings designed for infant or adult wearers. A pant can be configured with a continuous or closed waist opening and at least one continuous, closed, leg opening prior to the article being applied to the wearer. A pant can be pre-formed or pre-fastened by various techniques including, but not limited to, joining together portions of the article using any refastenable and/or permanent closure member (e.g., seams, heat bonds, pressure welds, adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can be pre-formed anywhere along the circumference of the article in the waist region (e.g., side fastened or seamed, front waist fastened or seamed, rear waist fastened or seamed). Example diaper pants in various configurations are disclosed in U.S. Pat. Nos. 4,940,464; 5,092,861; 5,246,433; 5,569,234; 5,897,545; 5,957,908; 6,120,487; 6,120,489; 7,569,039 and U.S. Patent Publication Nos. 2003/0233082 A1; 2005/0107764 A1, 2012/0061016 A1, 2012/0061015 A1; 2013/0255861 A1; 2013/0255862 A1; 2013/0255863 A1; 2013/0255864 A1; and 2013/0255865 A1, all of which are incorporated by reference herein.
“Closed-form” means opposing waist regions are joined, as packaged, either permanently or refastenably to form a continuous waist opening and leg openings.
“Open-form” means opposing waist regions are not initially joined to form a continuous waist opening and leg openings but comprise a closure means such as a fastening system to join the waist regions to form the waist and leg openings before or during application to a wearer of the article.
“Channel,” as used herein, is a region or zone in an absorbent material layer that has a substantially lower basis weight (e.g., less than 50%, less than 70%, less than 90%) than the surrounding material in the material layer. The channel may be a region in a material layer that is substantially absorbent material-free (e.g., 90% absorbent material-free, 95% absorbent material-free, or 99% absorbent material-free, or completely absorbent material-free). A channel may extend through one or more absorbent material layers. The channel generally has a lower bending modulus than the surrounding regions of the absorbent material layer, enabling the material layer to bend more easily and/or rapidly distribute more bodily exudates within the channel than in the surrounding areas of the absorbent material layer. Thus, a channel is not merely an indentation in the material layer that does not create a reduced basis weight in the material layer in the area of the channel.
Absorbent ArticlesProducts comprising elastomeric laminates 302 of the present disclosure may comprise absorbent articles 100 of differing structure and/or form that are generally designed and configured to manage bodily exudates such as urine, menses and/or feces, such as disposable taped diapers and pants, including baby and adult disposable absorbent articles and menstrual pads.
As shown in
Referring further to
Referring to
Referring to
Referring to
Particularly regarding belts 430, as illustrated in
Still regarding an elasticized chassis 200,
A portion or the entirety of the absorbent article 100 may be made to be laterally elastically extensible. The extensibility of the absorbent article 100 may be desirable in order to allow the absorbent article 100 to conform to a body of a wearer during movement by the wearer. The extensibility may also be desirable, for example, in order to allow the caregiver to extend the front waist region 36, the back waist region 38, the crotch region 37, and/or the chassis 200 to provide additional body coverage for wearers of differing size, i.e., to tailor the fit of the absorbent article 100 to the individual wearer and to aide in ease of application. Such extension may provide the absorbent article 100 with a generally hourglass shape, so long as the crotch region 37 is extended to a relatively lesser degree than the waist regions 36 and/or 38. This extension may also impart a tailored appearance to the absorbent article 100 during use.
The chassis 200 may be substantially rectangular and may have discrete side panels 330, extensible ear panels 530 and/or non-extensible ear panels 540 joined to the chassis 200 at or adjacent the chassis side edges 237 in one or both of the front waist region 36 and back waist region 38. As shown in
As shown in
A wearable article of the present disclosure may comprise one or more elastomeric laminates 302 having a plurality of laterally extending elastic elements wherein the one or more elastomeric laminates 302 may be present in a first waist region, the crotch region 37 and/or in the opposing second waist region and wherein the elastomeric laminate 302 disposed in one or both of the first and second waist regions may comprise a first plurality of elastics 316 having one or more of a higher Average-Dtex, higher Average-Pre-Strain and smaller Average-Strand-Spacing than a second plurality of elastics 316 of the elastomeric laminate 302 disposed in the crotch region 37. Such a wearable article may comprise one or more elastomeric laminates 302 having a first plurality of elastics 316, the first plurality of elastics 316 of the elastomeric laminate 302 comprising from about 100 to about 1500 elastic strands with an Average-Strand-Spacing from about 0.25 mm to about 4 mm, a Average-Dtex from about 10 to about 500, an Average-Pre-Strain from about 50% to about 400% and a first substrate 306 and/or second substrate 308 wherein one or both of the first and second substrate have a basis weight from about 6 grams per square meter to about 30 grams per square meter.
An absorbent article of the present disclosure may have an elastomeric laminate 302 forming at least a portion of one or more of a belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124 and backsheet 125. The elastomeric laminate 302 may comprise a plurality of elastics 316 having a specific Average-Dtex, nonwoven type, nonwoven basis weight, Average-Strand-Spacing and Average-Pre-Strain and the article further comprising an inner leg cuff 150 and/or an outer leg cuff 140 comprising an elastomeric laminate 302 having one or more identical or substantially identical laminate elements, e.g. Average-Dtex, nonwoven type, nonwoven basis weight, Average-Strand-Spacing and Average-Pre-Strain as one or more of a belt 430, side panel 630, elastomeric ear 530, chassis 200, topsheet 124 and backsheet 125.
When the elastomeric laminate 302 forms at least a portion of one or more of the group of article components consisting of a belt 430, a side panel 330, a chassis 200, a topsheet 124, a backsheet 125, and an ear panel 530 and comprises a first plurality of elastics 316, the first plurality of elastics 316 of the elastomeric laminate 302 may comprise from about 40 to about 1000 elastic strands with an Average-Strand-Spacing from about 0.25 mm to about 4 mm, an Average-Dtex from about 10 to about 500, an Average-Pre-Strain from about 50% to about 400% and a first substrate layer 306 and/or second substrate layer 308 wherein one or both of the first and second substrate layers have a basis weight from about 6 grams per square meter to about 30 grams per square meter.
It is also to be appreciated that one or more of the absorbent article components including a belt 430, side panel 330, ear panel 530, waistband 122, chassis 200, topsheet 124 and backsheet 125 may comprise an elastomeric laminate 302 formed from multiple beams of elastic. For example, one beam may form a first portion of one or more absorbent article components including a belt 430, side panel 330, ear panel 530, waistband 122, chassis 200, topsheet 124 and backsheet 125, and a second beam may form a second portion of one or more of an absorbent article component including a belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124 and backsheet 125 wherein the separate beams may comprise a different number of elastics 316, the beams may have elastics having different Average-Dtex, the elastics 316 of the two beams may be disposed at different Average-Strand-Spacing and/or the separate beams may deliver elastics 316 having different Average-Pre-Strain and/or the different beams may deliver elastics having different orientations in the product, e.g. liner, arcuate, angled, etc. The resultant portions of belt 430, side panel 630, elastomeric ear 530, chassis 200, topsheet 124 and/or backsheet 125 created from such a multi-beam approach may have different texture, garment-like appearance, breathability, Section-Modulus and/or different force.
Alternatively, the elastomeric laminate 302 comprising a first plurality of elastics 316 forming one or more of a belt 430, side panel 330, elastomeric ear 530, chassis 200, topsheet 124 and/or backsheet 125 may comprise from about 50 to about 825 elastic strands. In another embodiment, the first plurality of elastics 316 or the elastomeric laminate 302 may comprise from about 100 to about 650 elastic strands. In yet another embodiment, the first plurality of elastics 316 of the elastomeric laminate 302 may comprise from about 150 to about 475 elastic strands.
In certain embodiments, the elastomeric laminate 302 comprising a first plurality of elastics 316 forming one or more of a belt 430, side panel 330, elastomeric ear 530, chassis 200, topsheet 124 and/or backsheet 125 may have an Average-Strand-Spacing from about 0.5 mm to about 3.5 mm. In alternative embodiments, the first plurality of elastics of the elastomeric laminate 302 may have an Average-Strand-Spacing from about 0.75 mm to about 2.5 mm.
In one embodiment, the elastomeric laminate 302 forming one or more of a belt 430, side panel 330, elastomeric ear 530, chassis 200, topsheet 124 and/or backsheet 125 may have an Average-Dtex of the first plurality of elastics 316 from about 30 to about 400. Alternatively, the elastomeric laminate 302 may have an Average-Dtex of the first plurality of elastics 316 from about 50 to about 250.
In some embodiments of the elastomeric laminate 302 forming one or more of a belt 430, side panel 330, elastomeric ear 530, chassis 200, topsheet 124 and/or backsheet 125 may comprise elastics 316 having an Average-Pre-Strain which may be from about 75% to about 300%. Alternatively, the elastomeric laminate 302 may comprise elastics 316 with an Average-Pre-Strain from about 100% to about 250%.
When the elastomeric laminate 302 forms at least a portion of one or more of the group of article components consisting of a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and a transverse barrier 165 and comprises a first plurality of elastics 316, the first plurality of elastics 316 may comprise from about 10 to about 400 elastic strands with an Average-Strand-Spacing from about 0.25 mm to about 4 mm, a Average-Dtex from about 10 to about 500, an Average-Pre-Strain from about 50% to about 400% and a first substrate layer 306 and/or second substrate layer 308 each of the first and second substrate layers having a basis weight from about 6 grams per square meter to about 30 grams per square meter.
It is also to be appreciated that one or more of a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and/or a transverse barrier 165 may be formed from multiple beams of elastic, for example one beam may form a first portion of one or more of a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and/or a transverse barrier 165 and a second beam may form a second portion of one or more of a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and/or a transverse barrier 165 wherein the separate beams may comprise a different number of elastics, the beams may have elastics having different decitex, the elastics of the two beams may be disposed at different spacing and/or the separate beams may deliver elastics having different pre-strain and/or the different beams may deliver elastics having different orientations in the product, e.g. liner, arcuate, angled, etc. The resultant portions of the waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and/or transverse barrier 165 created from such a multi-beam approach may have different texture, garment-like appearance, Section-Modulus and/or different force.
Alternatively, the elastomeric laminate 302 comprising a first plurality of elastics 316 forming one or more of a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and/or a transverse barrier 165 may comprise from about 15 to about 300 elastic strands. In another embodiment, the first plurality of elastics 316 of the elastomeric laminate 302 may comprise from about 20 to about 225 elastic strands. In yet another embodiment, the first plurality of elastics 316 or the elastomeric laminate 302 may comprise from about 25 to about 150 elastic strands.
In certain embodiments, the elastomeric laminate 302 comprising a first plurality of elastics 316 forming one or more of a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and/or a transverse barrier 165 may have an Average-Strand-Spacing from about 0.5 mm to about 3.0 mm. In alternative embodiments, the first plurality of elastics 316 or the elastomeric laminate 302 may have an Average-Strand-Spacing from about 0.75 mm to about 2.5 mm.
In one embodiment, the elastomeric laminate 302 forming one or more of a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and/or a transverse barrier 165 may have an Average-Dtex of the first plurality of elastics 316 from about 30 to about 400. Alternatively, the elastomeric laminate 302 may have an Average-Dtex of the first plurality of elastics 316 from about 50 to about 250.
In some embodiments of the elastomeric laminate 302 forming one or more of a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and/or a transverse barrier 165 may comprise elastics having an Average-Pre-Strain from about 75% to about 300%. Alternatively, the elastomeric laminate may comprise elastic elements with an Average-Pre-Strain of between 100% and 250%.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate 302 comprising a plurality of elastics 316 having a Pressure-Under-Strand from about 0.1 psi to about 1 psi, or from about 0.2 psi to about 0.8 psi.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising an Air Permeability at 0 gf/mm (no extension) of greater than about 40 cubic meters/square meter/minute and/or a level of Air Permeability at 3 gf/mm (slight extension) of greater than about 60 cubic meters/square meter/minute and/or a level of Air Permeability at 7 gf/mm (moderate extension) of greater than about 80 cubic meters/square meter/minute.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Water Vapor Transmission Rate of greater than 2000 g/m2/24 hrs, greater than 4000 g/m2/24 hrs or greater than 6000 g/m2/24 hrs.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate having a Caliper at 0 gf/mm (no extension) of from about 0.5 mm to about 4 mm and/or a Caliper Retention value at 3 gf/mm (slight extension) of from about 60% to about 95% and/or a Caliper Retention at 7 gf/mm (moderate extension) of from about 40% to about 90%
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Cantilever Bending of less than about 40 mm, alternatively less than about 35 mm.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Percent Contact Area of greater than about 13% at 100 um and/or greater than about 27% at 200 um and/or greater than about 39% at 300 um and/or a 2%-98% Height Value of <1.6 mm. Alternatively, any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Percent Contact Area of greater than about 10% at 100 um and/or greater than about 20% at 200 um and/or greater than about 30% at 300 um and/or a 2%-98% Height Value of <2.2 mm.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Rugosity Frequency of from about 0.2 mm−1 to about 1 mm−1 and a Rugosity Wavelength of from about 0.5 mm to about 5 mm.
It is also to be appreciated that any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising one or more of the parametric values and ranges cited herein above.
The elastomeric laminate 302 may comprise an apertured elastomeric film material, elastic strands, elastomeric scrim materials, elastomeric nonwovens, elastic ribbons, foams and combinations thereof. The elastomeric laminate 302 may comprise a plurality of elastics 316 that may be the same color as one or both of the first substrate layer 306 and second substrate layer 308 so the elastic material may be more hidden, i.e. masked or may be of a different color so the elastic material is visible in the elastomeric laminate 302. Furthermore, the elastic 316 may be transparent or translucent such that it is virtually invisible. Transparency or translucency combined with the very low decitex of the elastic 316 may render the elastic 316 visibly and tactilely unnoticeable by users of absorbent articles comprising elastomeric laminate 302 comprising such elastics 316.
The elastomeric laminate 302 may comprise a plurality of elastics 316 and may be formed from a single beam. The plurality of elastics 316 may have a uniform elastic strand spacing or alternatively may have variable elastic strand spacing throughout the elastomeric laminate 302. The plurality of elastics 316 of the elastomeric laminate may also comprise larger gaps between one or more pairs of elastics wherein the gaps are 2× the Average-Strand-Spacing of the plurality of elastics 316. The gaps may be 4×, 10× or even 20× the Average-Strand-Spacing of the plurality of elastics 316. The elastomeric laminate 302 may comprise a plurality of elastics 316 and may be formed from multiple beams of elastic. A first beam comprising a first plurality of elastics 316a and a second beam comprising a second plurality of elastics 316b may both be disposed between first substrate layer 306 and second substrate layer 308 of the elastomeric laminate 302. One or both of the first plurality of elastics 316a and second plurality of elastics 316b may have a uniform elastic strand spacing or alternatively may have variable elastic strand spacing throughout. One or both of the first plurality of elastics 316a and second plurality of elastics 316b may comprise larger gaps between one or more pairs of elastics wherein the gaps in the first plurality of elastics 316a are 2× the Average-Strand-Spacing of the first plurality of elastics 316a. The gaps may be 4×, 10× or even 20× the Average-Strand-Spacing of the first plurality of elastics 316a. Furthermore, the second plurality of elastics 316b of may comprise larger gaps between one or more pairs of elastics wherein the gaps in the second plurality of elastics 316b are 2× the Average-Strand-Spacing of the second plurality of elastics 316b. The gaps may be 4×, 10×or even 20× the Average-Strand-Spacing of the first plurality of elastics 316b. The elastomeric laminate 302 comprising a plurality of elastics 316 formed from multiple beams of elastic may have a first plurality of elastics 316a of a first beam disposed in a partially overlapping orientation with a second plurality of elastics 316b of a second beam. The elastomeric laminate 302 comprising a plurality of elastics 316 formed from multiple beams of elastic may have a first plurality of elastics 316a of a first beam disposed in an offset orientation from a second plurality of elastics 316b of a second beam wherein the offset creates a gap between the first plurality of elastics 316a and second plurality of elastics 316b. The gap between the first plurality of elastics 316a and second plurality of elastics 316b may be 5×, 10× or even 20× the Average-Strand-Spacing of one of the first plurality of elastics 316a or second plurality of elastics 316b.
Any or all portions of the absorbent article 100 may comprise a bacteriophage composition as described in U.S. Ser. No. 61/931,229, titled Disposable Absorbent Articles Comprising Bacteriophages and Related Methods, and filed on Jan. 24, 2014.
Closed-Form Pant ArticleClosed-form, pant-style, absorbent articles are generally disclosed in
The pant comprising side panels 300 may be formed into a pant in a number of ways. The discrete elastomeric side panels 330 may be disposed in one or both of the waist regions. Observe that side panels 330 (see, for example
The refastenable seams 174 may comprise a fastening system 179 comprising a primary fastener 175, for example a mechanical fastener, velcro-like fasteners, hooks, etc., or mating fastener 178, for example a nonwoven or loop material intended to mate with a hook fastener, disposed on one or more of the discrete elastomeric side panels 330, for example a first portion of a fastening system 179 may be disposed on a first discrete elastomeric side panel 330 and a second portion of a fastening system 179 may be disposed on a second discrete elastomeric side panel 330. Several options for refastenable seams are illustrated in
As illustrated in
As disclosed in U.S. Ser. No. 11/999,229 the pant may comprise graphics. For instance, one or both of the elastomeric belts 430 may comprise one or more of an arrangement of belt graphics covering greater than about 30% of the surface area of the belt 430 and/or an arrangement of belt graphics when viewed from the outside appear to comprise at least three colors and/or an arrangement of belt graphics being disposed within 30 mm of a waist edge 438 of the belt 430 and/or an arrangement of belt graphics being disposed within about 10 mm of a leg edge 436 (front leg edge 436F or back leg edge 436B) of the belt 430 as illustrated in
As shown in
The belt pant 400 may comprise belts 430 having apertured nonwovens (comprising apertures 160—see
It is understood that when the fastening elements 175 and 178 mate interior surface to interior surface of the absorbent article 100, a flange seam is formed. But, when the fastening elements 175 and 178 mate interior surface to exterior surface of the absorbent article 100, an overlap seam is formed, as illustrated in
Referring to
Elastic members forming the elastomeric laminate 302, may be in the form of film (e.g., 317) or sections or strips thereof, strips, ribbons, bands, scrims, elastic nonwovens, elastic fibers or strands of circular or any other cross-section, or combinations thereof formed in any configuration of any elastomeric material such as described in, for example, co-pending U.S. applications Ser. Nos. 11/478,386 and 13/331,695, and U.S. Pat. No. 6,626,879. A suitable example is LYCRA HYFIT strands, a product of Invista, Wichita, Kans. Some strands for example the aforementioned LYCRA HYFIT may comprise a number of individual fibers wound together to form the strand. With regard to elastic strands formed of a number of individual fibers it has been discovered that the individual fibers can move relative to each other changing the cross sectional shape of the strand as well as becoming unraveled which can lead to poor control of the strands as well as poor bonding/adhering/joining of the elastic strands to one or both of the first substrate layer 306 and second substrate layer 308 of the elastomeric laminate 302. In order to minimize the negatives with regard to strands comprising a plurality of fibers it would be advantageous to minimize the number of fibers in a given strand. It would therefore be desirable to have less than about 40 fibers per strand, less than about 30 fibers per strand, less than about 20 fibers per strand, less than about 10 fibers per strand, less than about 5 fibers per strand and 1 fiber forming the strand. In the case of a single fiber forming the strand which can deliver comparable performance to the multi-fiber strands of the prior art it would be desirable for the fiber to have a fiber decitex from about 22 to about 300 and a fiber diameter from about 50 micrometers to about 185 micrometers.
Still referring to
As suggested in
It should be understood that the elastomeric laminates 302 may be formed in part in accordance with
One or more of the absorbent articles described above may comprise texture zones 318 disposed on the chassis 200, as well as on one or each of the side panels 330, elastomeric ear panels 530, belts 430, inner leg cuffs 150, outer leg cuffs 140, waistbands 122, waistcaps 123, chassis 200, topsheet 124 and backsheet 125 such that the texture zones are substantially aligned with each other or they collectively form a large textured zone or unified textural appearance. An overall textural appearance is desired to deliver a holistic garment-like look and feel. It is therefore beneficial if two or more of the aforementioned absorbent article structures (chassis 200, side panels 330, elastomeric ear panels 530, non-elastomeric ear panel 540, belts 430, inner leg cuffs 150, outer leg cuffs 140, waistbands 122, waistcaps 123, topsheet 124 and backsheet 125) comprise materials having one or more identical or substantially identical structural elements selected from the group of Average-Dtex between 10 decitex and 500 decitex (within a +/−50 decitex range), Average-Strand-Spacing from about 0.25 mm to about 5.0 mm (within a +/−1 mm range), Average-Pre-Strain from about 50% to about 400% (within a +/−50% range), a substrate basis weight from about 6 grams per square meter to about 30 grams per square meter (within a +/−5 grams per square meter range) and substrate, e.g. nonwoven layer, texture.
One or more of the absorbent articles described above may comprise a chassis 200 comprising one or more chassis graphics 299 (see
The donning benefit of the present disclosure is enabled by elastomeric laminates comprising a greater number of elastic strands having a greater fineness (e.g., a smaller decitex) and a closer spacing than has been previously disclosed or practiced in disposable absorbent articles. These improved laminates can be used as disposable absorbent article (for example, baby and adult taped diapers, baby and adult pants, feminine pads, and feminine liners) components to achieve a variety of benefits in conjunction with and beyond donning, including fit and gasketing at the waist, legs, crotch and sides of the wearer to generally provide the greatest level of extensibility, the most comfortable wearing conditions, improved skin condition (i.e., reduced skin marking), improved leakage protection and a better fit.
Donning-RatioDonning ease can be assessed by a Donning-Ratio, as illustrated in
The Donning-Ratio is calculated as:
Donning-Ratio=Target-Hip/[2*Relaxed-Product-Waist-Width]
The Donning-Ratio is unitless. Both the Target-Hip and Relaxed-Product-Waist-Width are in mm.
A product's size range is conveyed to consumers by a weight range and/or a waist range printed on the package. For products recommended by weight range, a Target-Weight is the average of the minimum and maximum recommended weights.
For many adult incontinence products, only a waist recommendation is provided. For these products, a Target-Weight can still be determined by calculating the Average Weight at the minimum and maximum recommended waists.
Average Weight (kg)=6.8142163*Waist (mm)̂0.5−130.72567
Once the Target-Weight for a product is determined, its corresponding Target-Hip is determined as shown on
Target-Hip (mm)=102.48574+108.62219*Weight (kg)̂0.5
The tables below show examples of currently marketed stranded closed-form products. The Donning-Ratio's for all are greater than 1.5, with some being as high as 3.0. The tables below illustrate some inventive examples utilizing elastomeric laminates of the present disclosure. The Donning-Ratio's as disclosed herein will make the donning of each easier for consumers and care givers.
Examples of Donning-Ratio for Existing Stranded Products
Open-form, taped-style, absorbent articles are generally disclosed in
As shown in
In addition to a pair of laterally opposing elastomeric ear panels 530 in a first waist region the tape diaper 500 may comprise a pair of laterally opposing discrete non-elastomeric ear panels 540 disposed in a second waist region, wherein one or both of the ear panels 530 and the ear panels 540 are non-rectangular as shown in
The taped diaper 500 may comprise first and second non-elastomeric ear panels 540 disposed in a first waist region and an elastomeric waistband 122 disposed in a first waist region as illustrated in
The elastomeric waistband 122 may have a lateral width that is >60% of a lateral width of the center chassis 200 and the center chassis may comprise a pair of laterally opposing fasteners 175 disposed in the same waist region as the waistband 122. The taped diaper 500 may have a waistband 122 that may overlap portions of two or more of an absorbent core 128 and/or a topsheet 124 and/or the inner leg cuffs 150 as illustrated in
The taped diaper 500 may comprise a pair of laterally opposing front ear panels 540 joined to the chassis 200 in the front waist region 36 and a pair of laterally opposing elastomeric ear panels 530 joined to the chassis 200 in the back waist region 38. The chassis 200 of the taped diaper 500 may be substantially rectangular as shown in
In an alternative embodiment illustrated in
The absorbent articles 100 of the present disclosure may comprise a topsheet 124. The topsheet 124 is the part of the absorbent article 100 that is in contact with the wearer's skin. The topsheet 124 may be joined to portions of the backsheet 125, the absorbent core 128, the leg cuffs 52, and/or any other layers as is known to those of ordinary skill in the art. The topsheet 124 may be compliant, soft-feeling, and non-irritating to the wearer's skin. Further, at least a portion of, or all of, the topsheet may be liquid permeable, permitting liquid bodily exudates to readily penetrate through its thickness. A suitable topsheet may be manufactured from a wide range of materials, such as porous foams, reticulated foams, apertured plastic films, woven materials, nonwoven materials, woven or nonwoven materials of natural fibers (e.g., wood or cotton fibers), synthetic fibers or filaments (e.g., polyester or polypropylene or bicomponent PE/PP fibers or mixtures thereof), or a combination of natural and synthetic fibers. The topsheet may have one or more layers. The topsheet may be apertured, may have any suitable three-dimensional features, and/or may have a plurality of embossments (e.g., a bond pattern). The topsheet may be apertured by overbonding a material and then rupturing the overbonds through ring rolling, such as disclosed in U.S. Pat. No. 5,628,097, to Benson et al., issued on May 13, 1997 and disclosed in U.S. Pat. Appl. Publication No. US 2016/0136014 to Arora et al. Any portion of the topsheet may be coated with a skin care composition, an antibacterial agent, a surfactant, and/or other beneficial agents. The topsheet may be hydrophilic or hydrophobic or may have hydrophilic and/or hydrophobic portions or layers. If the topsheet is hydrophobic, typically apertures will be present so that bodily exudates may pass through the topsheet.
Typical absorbent article topsheets have a basis weight of from about 5 gsm to about 50 gsm, from about 10 to about 35 gsm or from about 12 to about 30 gsm, but other basis weights are within the scope of the present disclosure.
Absorbent articles of the present disclosure may comprise three-dimensional, liquid permeable substrates forming a portion of or all of the topsheet 124 as described in U.S. Ser. Nos. 14/656,820; 14/680,394; and Ser. No. 14/680,426. These substrates may also comprise apertures. The texture of the three dimensional substrates forming the topsheet may be identical or substantially identical to substrates forming one or both surfaces of one or more of the chassis 200, side panels 330, elastomeric ear panels 530, non-elastomeric ear panel 540, belts 430, inner leg cuffs 150, outer leg cuffs 140, waistbands 122, waistcaps 123 and backsheet 125.
The topsheet 124 may also comprise topsheet graphics disposed on one or both surfaces of the topsheet 124. The topsheet graphics may be coordinated with graphics on other components of the article 100, e.g. chassis 200, side panel 330, ear panel 530, belt 430, waistband 122 and backsheet 125. In addition, graphics may be disposed on the exterior of the article 100 that coordinate with the topsheet graphics to make the absorbent article 100 have the appearance of underwear wherein the interior of the article has a similar pattern, color, etc. to the exterior of the article 100. The graphics may also highlight various structural elements within the article, e.g. the channels in the absorbent core.
A portion or the entirety of the topsheet may comprise a first substrate layer 306 and a second substrate layer 308 and may also comprise an elastic material, for example elastic strands 316, disposed between the first and second substrate layers 306 and 308. The first substrate layer 306 and the second substrate layer 308 may be separate and discrete layers or alternatively the first substrate layer 306 and second substrate layer 308 may be formed from a single web of material that is folded to form the first substrate layer 306 and second substrate layer 308 as described previously. In some configurations of the topsheet, the elastic material forming the topsheet may be an elastomeric laminate 302 and may comprise a plurality of elastic strands 316. The topsheet may further comprise one or more large apertures intended to allow bodily exudates to pass easily there through.
BacksheetsThe absorbent article 100 of the present disclosure may comprise a backsheet 125. The backsheet 125 is generally that portion of the absorbent article 100 positioned proximate to the garment-facing surface of the absorbent core 128. The backsheet 125 may be joined to portions of the topsheet 124, the absorbent core 128, and/or any other layers of the absorbent article by any attachment methods known to those of skill in the art. The backsheet film 126 prevents, or at least inhibits, the bodily exudates absorbed and contained in the absorbent core 128 from soiling articles such as bedsheets, undergarments, and/or clothing. The backsheet is typically liquid impermeable, or at least substantially liquid impermeable. The backsheet may, for example, be or comprise a thin plastic film, such as a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm. Other suitable backsheet materials may include breathable materials which permit vapors to escape from the absorbent article, while still preventing, or at least inhibiting, bodily exudates from passing through the backsheet.
A portion or the entirety of the backsheet 125 may be formed by an elastomeric laminate 302 comprising a first substrate layer 306 and a second substrate layer 308 and an elastic material, for example elastic strands 316, disposed between the first and second substrate layers 306 and 308. The first substrate layer 306 and the second substrate layer 308 may be separate and discrete layers or alternatively the first substrate layer 306 and second substrate layer 308 may be formed from a single web of material that is folded to form the first substrate layer 306 and second substrate layer 308 as described previously. In some configurations the backsheet film 126 of the backsheet 125, may form the first substrate layer 306 and the backsheet nonwoven 127 may form the second substrate layer 308 of the elastomeric laminate 302. In an alternative embodiment, one of the belt layers, inner belt layer 432 or outer belt layer 434 may form one of the first or second substrate layers 306 and 308 of the elastomeric laminate 302 overlaying and forming a portion of the backsheet 125 in the crotch region 37 of the absorbent article 100.
Leg CuffsThe absorbent articles 100 of the present disclosure may comprise leg cuffs 52, which include inner leg cuffs 150 and outer leg cuffs 140. The inner leg cuffs 150 may be positioned laterally proximal of outer leg cuffs 140. Each barrier leg cuff 32 may be formed by a piece of material which is bonded to the absorbent article 100 so it can extend upwards from a wearer-facing surface of the absorbent article 100 and provide improved containment of body exudates approximately at the junction of the torso and legs of the wearer. The inner leg cuffs 150 are delimited by a proximal edge joined directly or indirectly to the topsheet and/or the backsheet and a free terminal edge, which is intended to contact and form a seal with the wearer's skin. The inner leg cuffs 150 may extend at least partially between the front end edge 136 and the back end edge 138 of the absorbent article 100 on opposite sides of the longitudinal axis 42 and may be at least present in the crotch region 37. The inner leg cuffs 150 may each comprise one or more elastics 316 (e.g., elastic strands or strips) near or at the free terminal edge. These elastics 3316 cause the inner leg cuffs 150 to help form a seal around the legs and torso of a wearer. The outer leg cuffs 140 extend at least partially between the front end edge 136 and the back end edge 138. The outer leg cuffs 140 essentially cause portions of the absorbent article 100 proximate to the chassis side edges 237a and 237b to help form a seal around the legs of the wearer. The outer leg cuffs 140 may extend at least within the crotch region 37.
The absorbent article 100 may comprise an outer leg cuff 140 formed by a film, e.g. the backsheet film 126, a nonwoven, and an elastic material disposed between the backsheet film 126 and the nonwoven at or adjacent the side edge 237 of the chassis 200. Alternatively, as illustrated in
The web of material forming at least a portion of the inner and outer leg cuffs 150 and 140 may be folded laterally inward to form the outer cuff folded edge, i.e. distal cuff edge 142, first substrate layer 306 and/or second substrate layer 308 of the elastomeric laminate 302 forming the outer cuff and the web material may be folded laterally outward to form the inner cuff folded edge, i.e. proximal cuff edge 152, first substrate layer 306 and/or second substrate layer 308 of the elastomeric laminate 302 forming the inner cuff and the web of material may extend from the front waist end edge 136 to the back waist end edge 138 of the chassis 200 and may be joined to the topsheet 124 and/or backsheet 125 between the inner cuff folded edge, proximal cuff edge 152, and the outer cuff folded edge, distal cuff edge 142, in the crotch region 37. Elastic members, for example elastic strands 316, are disposed between the first and second substrate layers, 306 and 308, of the outer leg cuff 140 to form an elasticized outer leg cuff 140 and elastic members, for example elastic strands 316, are disposed between the first and second substrate layers 306 and 308 of the inner leg cuff 150 to form an elasticized inner leg cuff 150.
The elastic members forming the inner leg cuff 150 and the outer leg cuff 140 may be spaced apart from each other differently, i.e. one has greater spacing between the elastic elements than the other, such that the outer leg cuff 140 and the inner leg cuff 150 have differing tactile and aesthetic characteristics that create varying garment-like appearance, level of contraction and/or variation in amplitude and frequency of the texture formed in the first and second substrate layers 306 and 308. The elastic members forming the inner leg cuff 150 and/or the outer leg cuff 140 may be spaced evenly or irregularly to create contracted regions of uniform or changing amplitude and frequency in the outer leg cuff 140 and/or the inner leg cuff 150 such that a variety of garment-like appearances may be achieved.
As illustrated in
One or more of the Average-Dtex, Average-Strand-Spacing, Average-Pre-Strain, nonwoven basis weight and/or nonwoven texture of one or both of the inner leg cuff 150 and outer leg cuffs 140 may be identical or substantially identical to one or more of the chassis 200, side panels 330, elastomeric ear panels 530, non-elastomeric ear panels 540, belts 430, waistbands 122, topsheet 124 and backsheet 125.
One or both of the inner leg cuff 150 and the outer leg cuff 140 may be formed by an elastomeric laminate 302 comprising a first substrate layer 306 and a second substrate layer 308 and an elastic material, for example elastic strands 316, disposed between the first and second substrate layers 306 and 308. The first substrate layer 306 and the second substrate layer 308 may be separate and discrete layers or alternatively the first substrate layer 306 and second substrate layer 308 may be formed from a single web of material that is folded to form the first substrate layer 306 and second substrate layer 308 as described previously. In some configurations of the outer leg cuffs 140, the one or both of the first and second substrate layers 306 and 308 may be formed in part or whole by one or more of the backsheet nonwoven 127 and backsheet film 126.
The inner and/or outer leg cuffs 150 and 140 may be formed from multiple beams of elastic, for example one beam may form the inner leg cuff 150 and a second beam may form the outer leg cuff 140, wherein the separate beams may comprise a different number of elastics, the beams may have elastics having different decitex, the elastics of the two beams may be disposed at different spacing and/or the separate beams may deliver elastics having different pre-strain. The resultant inner and/or outer leg cuffs 150 and 140 created from such a multi-beam approach may have different texture, garment-like appearance, Section-Modulus and/or different force.
Waistbands/WaistcapsThe absorbent articles 100 of the present disclosure may comprise one or more elastic waistbands 122. The elastic waistbands 122 may be positioned on the garment-facing surface or the wearer-facing surface or may be formed therebetween. As an example, a first elastic waistband 122 may be present in the front waist region 36 near the front waist edge 136 and a second elastic waistband 122 may be present in the back waist region 38 near the back waist edge 138. The elastic waistbands 122 may aid in sealing the absorbent article 100 around a waist of a wearer and at least inhibiting bodily exudates from escaping the absorbent article 100 through the waist opening circumference. In some instances, an elastic waistband may fully surround the waist opening 190 of the absorbent article 100. A waist cap 123 may be formed by an extension of the waistband 122 and may remain unattached to the underlying structure in the central portion of the waist cap 123 to allow bodily exudates that flow along the topsheet 124 to be trapped between the topsheet 124 and the underside of the waist cap 123. In other words, the waist cap 123 may be joined to the underlying structure, e.g., center chassis 200 of the absorbent article 100 along the longitudinally distal edge of the waist cap 123 and/or along the laterally opposing side edges of the waist cap 123.
The elastomeric waistband 122 especially assists in maintaining the primary line of tension formed by the primary fastening system 179 and/or ear panels/flaps/panels allowing the article to conformably fit around the waist of the wearer where there is dynamic motion, and initially pre-tensioning the waist since the article typically is stretched at the waist when applying the article 100 on the wearer so that when the waistband 122 contracts and tension is transmitted from the waistband 122 along the waist opening 190. While some of the articles of the present disclosure may have the elastomeric waistband 122 disposed in the back waist region 38, alternatively, the articles 100 may be provided with elastomeric waistbands 122 disposed in the front waist region 36 or in both the front waist region 36 and the back waist region 38. In order for the waistband 122 to receive and maintain tension created by the fastening components, when present, it may be desirable that a portion of the waistband 122 is longitudinally aligned with at least a portion of the fastening system 179. In other words, a laterally extending line drawn through the fastener 175 and parallel to the lateral centerline will extend through at least a portion of the elastomeric waistband 122.
When the elastomeric waistband 122 is present in only one waist region, e.g. back waist region 38, it may be desirable that the waistband 122 be disposed laterally inward from the waist end edge, e.g. back waist end edge 138, of the article 100; alternatively, as shown in
The waistband 122 may be disposed between the topsheet 124 and backsheet 125 of the chassis 200 or may be disposed on the interior surface 202 of the chassis 200. The waistband 122 may be disposed in the same waist region as two elastomeric ear panels/panels or alternatively may be disposed in the same waist region as two non-elastomeric ear panels 540. When the absorbent article comprises an elastomeric waistband 122 and non-elastomeric ear panels 540, the waistband 122 may provide the primary tension along the waist region of the article. The waistband 122 may be disposed wholly between the non-elastomeric ear panels 540 of the article as illustrated in
A taped diaper may comprise a discrete waistband 122 disposed in at least one of the front and back waist regions 36 and 38, wherein the waistband 122 is spaced longitudinally inward from the respective front and back waist end edges 136 and 138 of the article 100 at least about 10 mm or at least about 20 mm. The distance the waistband 122 is spaced from the front and/or back waist edge 136 and 138 of the article 100 may be less than the longitudinal length of the waistband 122.
In either of the article forms above, a portion of the elastomeric waistband 122 may be disposed on an interior surface of one or more of the center chassis 200, the topsheet 124, the absorbent core 128 and the inner leg cuffs 150 in one or both of the waist regions of the absorbent article 100. Furthermore, a portion of the elastomeric waistband 122 may be disposed in an overlapping configuration with at least a portion of one or both of the laterally opposing panels/flaps/ears, e.g. elastomeric side panels 330, elastomeric ear panels 530 and non-elastomeric ear panels 540. Alternatively, a portion of the waistband 122 may be disposed between the topsheet 124 and the backsheet 125 in one or both of the waist regions.
The waistband 122 may be substantially rectangular. Alternatively, the waistband 122 may have one or more edges that are arcuate as shown in
The waistband 122 may be the same width as the center chassis 200 or may be wider or narrower than the center chassis 200. When the absorbent article comprises multiple waistbands, the waistband 122 in a first waist region, for example the front waist region 36, may have a different, shape, width, length, thickness, texture or elastic configuration than the waistband 122 in a second waist region, for example the back waist region 38.
The waistband 122 may extend longitudinally over one or both of the longitudinally opposing end edges 26 and 28 of the absorbent core 128 to form an elasticized waist cap 123. Such an elasticized waist cap 123 may be formed by an extension of the waistband 122 and may remain unattached to the underlying structure in the central portion of the waist cap 123 to allow bodily exudates that flow along the topsheet 124 to be trapped between the topsheet 124 and the underside of the waist cap 123. In other words, the waist cap 123 may be joined to the underlying structure, e.g. center chassis 200 of the absorbent article 100 along the longitudinally distal edge of the waist cap 123 and/or along the laterally opposing side edges of the waist cap 123.
The elasticized waistband 122 or waist cap 123 may be formed by an elastomeric laminate comprising a first substrate layer 306 and a second substrate layer 308 and may also comprise an elastic material, for example elastic strands 316, disposed between the first and second substrate layers 306 and 308. The first substrate layer 306 and the second substrate layer 308 may be separate and discrete layers or alternatively the first substrate layer 306 and second substrate layer 308 may be formed from a single web that is folded to form the first substrate layer 306 and the second substrate layer 308. In some configurations of the waist band 122 or waist cap 123 the elastic material disposed in the waistband 122 or waist cap 123 may comprise a plurality of elastic strands 316.
The absorbent article may comprise a waistband 122 disposed in both the front waist region 36 and the back waist region 38. In such embodiments, the waistband 122 in the front waist region 36 and the waistband 122 in the back waist region 38 may be formed from multiple beams of elastic, for example one beam may form the waistband 122 in the front waist region 36 and a second beam may form the waistband 122 in the back waist region 38, wherein the separate beams may comprise a different number of elastics, the beams may have elastics having different decitex, the elastics of the two beams may be disposed at different spacing and/or the separate beams may deliver elastics having different pre-strain. The resultant waistbands 122 in the front and back waist regions 36 and 38 created from such a multi-beam approach may have different texture, garment-like appearance, Section-Modulus and/or different force. It should also be appreciated that the two waistbands may be discrete from each other or may be made from a common web of material but have distinctly different physical properties.
One or more of the Average-Dtex, Average-Strand-Spacing, Average-Pre-Strain, nonwoven basis weight and/or nonwoven texture of one or both of the front and back waistbands may be identical or substantially identical to one or more of the chassis 200, side panels 330, elastomeric ear panels 530, non-elastomeric ear panel 540, belts 430, inner leg cuff 150, outer leg cuff 140, topsheet 124 and backsheet 125.
Side Panels The side panels 330 may be discrete from or integral with the chassis 200. A discrete side panel is formed as separate element, which is joined to the chassis 200. In some embodiments, this includes a plurality of side panels, e.g. 2 or 4 being joined to the side edges 237 of the chassis 200 in the front and/or rear waist regions 36 and 38. Discrete side panels may be formed of one or more layers. A waistband 122 may be placed across a portion of the chassis 200 and may overlap a portion of the side panels 330 to create a multi-piece continuous belt-like structure.
Alternatively, the absorbent article 100 may comprise a pair of discrete elastomeric side panels 330 disposed in a first waist region and a pair of discrete non-elastomeric ear panels 540 disposed in a second waist region.
Alternatively, the article may comprise a pair of discrete elastomeric side panels 330 disposed in a first waist region and a pair of integral non-elastomeric ear panels 540 in a second waist region wherein the integral non-elastomeric ear panels 540 may be formed in part by one or more of the backsheet nonwoven 127, backsheet film 126, cuff material, landing zone material and topsheet 124.
The discrete elastomeric side panels 330 may overlap the side edges 237 of the chassis 200 and may be disposed on the innermost surface 202 of the chassis 200 or alternatively to the outermost surface 204 of the chassis 200. Alternatively, the elastomeric side panels 330 may overlap a portion of the chassis 200 and may be disposed between layers of the chassis 200 for example between the backsheet 125 and the outer leg cuff 140, or between the backsheet 125 and the topsheet 124. The side panels 330 may be bonded to the chassis 200 adhesively, mechanically, thermally or by combinations thereof.
The elastomeric side panels 330 may comprise an apertured elastomeric film material, elastic strands, elastomeric scrim materials, elastomeric nonwovens, elastic ribbons, foams and combinations thereof. The elastomeric material of the side panel 330 may be the same color as the nonwoven of the side panel 330 or may be of a different color so the elastomeric material is visible in the elastomeric side panel 330.
The side panels 330 may be substantially rectangular or may have a shape, i.e. the side panels 330 are substantially non-rectangular. In addition to shape the side panels 330 may also comprise two or more visually distinct textural regions disposed on the side panel 330. Finally, one or more of the side panels 330 of the pant comprising side panels 300 may comprise a side panel graphic 399 and the chassis 200 may comprise a chassis graphic 299 wherein portions of the side panel graphic and portions of the chassis graphics are substantially aligned and/or when combined form a composite graphic element.
The side panels 330 may be discrete elements attached to the chassis 200 at or adjacent the side edges 237 of the chassis 200. Alternatively, the side panels 330 may be integral with the chassis 200, i.e. formed in part by one or more of the backsheet nonwoven 127, backsheet film 126, outer cuff material, topsheet 124 and core wrap.
The absorbent article may comprise side panels 330 disposed in both the front waist region 36 and the back waist region 38. In such embodiments, the side panels 330 in the front waist region 36 and the side panels 330 in the back waist region 38 may be formed from multiple beams of elastic, for example one beam may form at least a portion of the side panels 330 in the front waist region 36 and a second beam may form at least a portion of the side panels 330 in the back waist region 38, wherein the separate beams may comprise a different elastic composition, different number of elastics, the beams may have elastics having different decitex, the elastics of the two beams may be disposed at different spacing and/or the separate beams may deliver elastics having different pre-strain. The resultant side panels 330 in the front and back waist regions 36 and 38 created from such a multi-beam approach may have different texture, garment-like appearance, Section-Modulus and/or different force.
The side panel 330 may also be provided with differential extensibility along the longitudinal axis when stretched in the lateral direction. As used herein, the term “differential extensibility” refers to a non-uniform degree of elastic extension properties, as measured in the direction of stretching at various points along an axis oriented substantially perpendicular to the direction of stretching. The differential extensibility can be achieved in a number of different ways. The elasticized side panel 330 can comprise a variety of elastomeric materials, multiple configurations of the elastomeric materials (elastic spacing), or the extension properties (pre-strain) of the elastomeric material or other materials making up the elasticized belt, such as the first substrate layer 306 and/or second substrate layer 308 may be non-uniform. For example, differential extensibility can be achieved in selected adjacent portions of the elasticized side panel 330 by using elastomeric materials having varying extension or contractive forces, Section-Modulus, or other inherent properties such that more or less (varying) lateral extensibility is achieved in one portion of the elasticized side panel 330 than the adjacent portion. The elastomeric materials may also have varying lengths, sizes, and shapes that provide differential extensibility. Other ways of varying the properties of materials that form the elasticized side panel 330 as are known in the art may also be used. The differential extensibility may be achieved by leveraging multiple beams of elastic to deliver elastics having different material type, decitex, strain, spacing, etc.
The elasticized side panel 330 may be formed by an elastomeric laminate comprising a first substrate layer 306 and a second substrate layer 308 and may also comprise an elastic material, for example elastic strands 316, disposed between the first and second substrate layers 306 and 308. The first substrate layer 306 and the second substrate layer 308 may be separate and discrete layers or alternatively the first substrate layer 306 and second substrate layer 308 may be formed from a single web that is folded to form the first substrate layer 306 and the second substrate layer 308. In some configurations of the side panel 330 the elastic material disposed in the side panel 330 may comprise a plurality of elastic strands 316.
The absorbent article may comprise side panels 330 disposed in one or both of the front waist region 36 and the back waist region 38. In such embodiments, the side panels 330 in the front waist region 36 and the side panels 330 in the back waist region 38 may be formed from multiple beams of elastic, for example one beam may form the side panels 330 in the front waist region 36 and a second beam may form the side panels 330 in the back waist region 38, wherein the separate beams may comprise a different number of elastics, the beams may have elastics having different decitex, the elastics of the two beams may be disposed at different spacing and/or the separate beams may deliver elastics having different pre-strain. The resultant side panels 330 in the front and back waist regions 36 and 38 created from such a multi-beam approach may have different texture, garment-like appearance, Section-Modulus and/or different force.
One or more of the elastic Average-Dtex, Average-Strand-Spacing, Average-Pre-Strain, nonwoven basis weight and/or nonwoven texture of the side panels 330 may be identical or substantially identical to one or more of the chassis 200, waistbands 122, non-elastomeric ear panel 540, inner leg cuff, outer leg cuff, topsheet 124 and backsheet 125.
BeltsThe belts 430 (front belt 430F and back belt 430B) disposed on a belt pant 400 may comprise an inner belt layer 432 and an outer belt layer 434 layer and an elastomeric material disposed there between. The inner and outer nonwoven layers 432 and 434 may be joined using adhesives, thermal bonds, pressure bonds or thermoplastic bonds. Various suitable belt configurations can be found in U.S. Pub. No. 2013-0211363.
A belt pant 400 may comprise a first elastomeric belt 430 extending outwardly from a first end edge, e.g., back end edge 238, of the chassis 200 and a longitudinally opposing second elastomeric belt 430 extending outwardly from a longitudinally opposing second end edge, e.g. front end edge 236 of the chassis 200. The longitudinally distal edge of the first elastomeric belt and the longitudinally distal edge of the second elastomeric belt may form a portion of a waist opening 190 (e.g., 438 illustrated in
The absorbent article 100 may comprise a first belt 430 disposed in a first waist region, e.g. the front waist region 36, and a second belt 430 disposed in a longitudinally opposing second waist region, e.g. the back waist region 38, wherein one of the belts has a greater longitudinal length than the longitudinally opposing belt as measured along the side edge 437 of the belt 430 at or adjacent the side seam 170.
An absorbent belt pant 400 may comprise a first elastomeric belt 430 and a second elastomeric belt 430 that are discrete from one another. Each of the belts may comprise an inner belt layer 432 and an outer belt layer 434 wherein the inner belt layer 432 on the first belt 430 is separated by a gap from the inner belt layer 432 on the second belt 430 and the outer belt layer 434 on the first belt 430 is separated by a gap from the outer belt layer 434 on the second belt 430 (see
Alternatively, an absorbent belt pant 400 may comprise a first elastomeric belt 430 in a first waist region and a second elastomeric belt 430 in a second waist region, where each of the belts 430 may comprise an inner belt layer 432 and an outer belt layer 434 wherein one or both of the inner belt layer 432 and the outer belt layer 434 form a common belt layer extending from a first waist region to a second waist region forming a portion of the first belt 430 and a portion of the second belt 430 (see
The belt 430 may include slits, holes, slots or perforations providing increased breathability and air permeability, softness and garment like texture (see
One or both of the belts 430 on the belt pant 400 may comprise belt graphics 499. The belt graphics 499 may extend substantially around the entire circumference of the belt pant 400. The belt graphic 499 may extend around the circumference at least about 180 degrees or at least about 225 degrees or at least about 270 degrees. The belt graphics 499 (or color scheme) on the belt 430 may be substantially aligned with chassis graphics 299 disposed on the chassis 200 and/or may form a composite graphic element or graphical experience.
In some configurations, the absorbent article 100 may have a first elastic belt 430 and/or a second elastic belt 430 that may comprise curved contours. For example, the inner laterally extending edges, leg edge 436, of the first and/or second elastic belts 430 may include non-linear or curved portions (see
The elasticized belts 430 may comprise a first substrate layer 306 and a second substrate layer 308 and may also comprise an elastic material, for example elastic strands 316, disposed between the first and second substrate layers 306 and 308. The first substrate layer 306 and the second substrate layer 308 may be separate and discrete layers or alternatively the first substrate layer 306 and second substrate layer 308 may be formed from a single web that is folded to form the first substrate layer 306 and second substrate layer 308. In some configurations of the belts 430, the elastic material disposed in the belts 430 may comprise a plurality of elastic strands 316.
The absorbent article may comprise belts 430 disposed in both the front waist region 36 and the back waist region 38. In such embodiments, the belt 430 in the front waist region 36 and the belt 430 in the back waist region 38 may be formed from multiple beams of elastic, for example one beam may form at least a portion of the belt 430 in the front waist region 36 and a second beam may form at least a portion of the belt 430 in the back waist region 38, wherein the separate beams may comprise a different elastic composition, different number of elastics, the beams may have elastics having different decitex, the elastics of the two beams may be disposed at different spacing and/or the separate beams may deliver elastics having different pre-strain. The resultant belts 430 in the front and back waist regions 36 and 38 created from such a multi-beam approach may have different texture, garment-like appearance, Section-Modulus and/or different force.
The belts 430 may also be provided with differential extensibility along the longitudinal axis when stretched in the lateral direction. As used herein, the term “differential extensibility” refers to a non-uniform degree of elastic extension properties, as measured in the direction of stretching at various points along an axis oriented substantially perpendicular to the direction of stretching. This may, for example, include varying the elastic type, elastic spacing, elastic modulus or pre-strain of the elastomeric material(s). The differential extensibility is preferably designed into the elasticized belts 430 so that the lateral extensibility varies longitudinally through at least a portion of the elasticized belt 430. It is believed that differential extensibility along the longitudinal axis when stretched in the lateral direction allows the elasticized belt 430 to differentially stretch and conform to the wearer's waist during use while providing a secure anchor (illustrated by areas or zones of front anchoring force 61A and back anchoring force 61B in
The differential extensibility can be achieved in a number of different ways. The elasticized belt 430 can comprise a variety of elastomeric materials, multiple configurations of the elastomeric materials (elastic spacing), or the extension properties (pre-strain) of the elastomeric material or other materials making up the elasticized belt, such as the first substrate layer 306 and/or second substrate layer 308 may be non-uniform. For example, differential extensibility can be achieved in selected adjacent portions of the elasticized belt 430 by using elastomeric materials having varying extension or contractive forces, Section-Modulus, or other inherent properties such that more or less (varying) lateral extensibility is achieved in one portion of the elasticized belt 430 than the adjacent portion. The elastomeric materials may also have varying lengths, sizes, and shapes that provide differential extensibility. Other ways of varying the properties of materials that form the elasticized belt 430 as are known in the art may also be used. The differential extensibility may be achieved by leveraging multiple beams of elastic to deliver elastics having different material type, decitex, strain, spacing, etc.
One or more of the Average-Dtex, Average-Strand-Spacing, Average-Pre-Strain, nonwoven basis weight and/or nonwoven texture of the belts 430 may be identical or substantially identical to one or more of the chassis 200, waistbands 122, inner leg cuff 150, outer leg cuff 140, topsheet 124 and backsheet 125.
As shown in
Taped diaper absorbent articles 500 may comprise a first elastomeric ear panel 530 extending outwardly from a first side edge 237 of the chassis 200 and a laterally opposing second elastomeric ear panel 530 extending outwardly from a laterally opposing second side edge 237 of the chassis 200. The taped diaper 500 may comprise a chassis 200 having a longitudinally distal edge, e.g. back end edge 238, disposed in a first waist region, e.g. back waist region 38. The longitudinally distal edge of the chassis 200 and the longitudinally distal end edges 538 of the laterally opposing first elastomeric ear panel 530 and the second elastomeric ear panel 530 form a portion of a waist edge, e.g. back waist edge 138, of the taped diaper 500. The longitudinally proximal end edges 536 of the laterally opposing elastomeric ear panels 530 will form portions of the leg openings when the article is fastened around a wearer.
The taped diaper 500 may also comprise non-elastomeric ear panels 540 that may be combined with an elastomeric waistband 122 to create an elasticized waist opening 190. The non-elastomeric ear panels 540 may be rectangular or may be shaped, substantially non-rectangular. The ear panels may be in one or both of the waist regions and may be discrete and attached to the chassis 200 along the side edges 237 or alternatively they may be integral and formed in part by a portion of one or more of the backsheet 125, topsheet 124, leg cuff 140, or landing zone. In certain executions, the elastomeric ear panels 530 or non-elastomeric ear panels 540 of the taped diaper 500 may comprise one or more visually distinct textured zones.
One or more of the elastomeric ear panels 530 of the taped diaper 500 may comprise an ear graphic 599 disposed thereon. One or more of the elastomeric ear panels 530 comprise an ear graphic 599 and the chassis 200 comprises a chassis graphic 299. In certain executions, the ear graphic 599 disposed on the elastomeric ear panel 530 and the chassis graphic 299 disposed on the chassis 200 may be substantially aligned and/or may form a composite graphic element.
The elastomeric ear panels 530 may overlap a portion of the chassis 200 and may be disposed between layers of the chassis 200 for example between the backsheet 125 and the outer leg cuff 140, or between the backsheet 125 and the topsheet 124 or may be disposed on either the interior surface 202 or exterior surface 204 of the chassis 200. The elastomeric ear panels 530 may be bonded to the chassis 200 adhesively, mechanically, thermally or by combinations thereof.
The elastomeric ear panels 530 may be discrete elements attached to the chassis 200 at or adjacent the side edges 237 of the chassis 200. Alternatively, the elastomeric ear panels 530 may be integral with the chassis 200, i.e. formed in part by one or more of the backsheet nonwoven, backsheet film, outer cuff material, topsheet and core wrap. The ear panels may be elastomeric or may be non-elastomeric.
The elasticized ear panels 530 may comprise a first substrate layer 306 and a second substrate layer 308 and may also comprise an elastic material, for example elastic strands 316 disposed between the first and second substrate layers 306 and 308. The first substrate layer 306 and the second substrate layer 308 may be separate and discrete layers or alternatively the first substrate layer 306 and second substrate layer 308 may be formed from a single web of material that is folded to form the first substrate layer 306 and second substrate layer 308. In some configurations of the elastomeric ear panels 530 the elastic material disposed in the ear panels 530 may comprise a plurality of elastic strands 316.
The elasticized ear panels 530 may also be provided with differential extensibility along the longitudinal axis 42 when stretched in the lateral direction. As used herein, the term “differential extensibility” refers to a non-uniform degree of elastic extension properties, as measured in the direction of stretching at various points along an axis oriented substantially perpendicular to the direction of stretching. This may, for example, include varying the elastic type, elastic spacing, elastic modulus or pre-strain of the elastomeric material(s). The differential extensibility is preferably designed into the elasticized ear panel 530 so that the lateral extensibility varies longitudinally through at least a portion of the elasticized ear.
The differential extensibility can be achieved in a number of different ways. The elasticized ear panel 530 can comprise a variety of elastomeric materials, multiple configurations of the elastomeric materials (elastic spacing), or the extension properties (pre-strain) of the elastomeric material or other materials making up the elasticized ear panel 530, such as the first substrate layer 306 and/or second substrate layer 308 may be non-uniform. For example, differential extensibility can be achieved in selected adjacent portions of the elasticized ear panel 530 by using elastomeric materials having varying extension or contractive forces, Section-Modulus, or other inherent properties such that more or less (varying) lateral extensibility is achieved in one portion of the elasticized ear panel 530 than the adjacent portion. The elastomeric materials may also have varying lengths, sizes, and shapes that provide differential extensibility. Other ways of varying the properties of materials that form the elasticized ear panels 530 as are known in the art may also be used. The differential extensibility may be achieved by leveraging multiple beams of elastic to deliver elastics having different material type, decitex, strain, spacing, etc.
One or more of the elastic Average-Dtex, Average-Strand-Spacing, Average-Pre-Strain, nonwoven basis weight and/or nonwoven texture of the elasticized ear panels 530 may be identical or substantially identical to one or more of the chassis 200, waistbands 122, non-elastomeric ear panels 540, inner leg cuff 150, outer leg cuff 140, topsheet 124 and backsheet 125.
As illustrated in
The chassis 200 is generally referred to above. It should be further understood that the chassis 200 may be elasticized such that the chassis 200 comprises a first substrate layer 306 and a second substrate layer 308 and may also comprise an elastic material, for example elastic strands 316, disposed between the first and second substrate layers 306 and 308. For example, a plurality of elastics 316 may be disposed on the chassis 200 outwardly of the backsheet film 126, longitudinally and/or laterally as illustrated in
More specifically, the chassis 200 may comprise elastics 316 that do not overlap elastics 316 of the ear panels 530, side panels 330, or belts 430 (see
The laterally oriented chassis elastics (316″) illustrated in
The chassis may be shaped or non-rectangular, in one waist region and substantially rectangular in the opposing waist region. Alternatively, the chassis may be substantially rectangular in one or both of the waist regions and non-rectangular in the crotch region.
As shown in
A wearable article of the present disclosure may comprise one or more elastomeric laminates 302 having a plurality of laterally extending elastic elements wherein the one or more elastomeric laminates 302 may be present in a first waist region, the crotch region 37 and/or in the opposing second waist region and wherein the elastomeric laminate 302 disposed in one or both of the first and second waist regions may comprise a first plurality of elastics 316 having one or more of a higher Average-Dtex, higher Average-Pre-Strain and smaller Average-Strand-Spacing than a second plurality of elastics 316 of the elastomeric laminate 302 disposed in the crotch region 37. Such a wearable article may comprise one or more elastomeric laminates 302 having a first plurality of elastics 316, the first plurality of elastics 316 of the elastomeric laminate 302 comprising from about 100 to about 1500 elastic strands with an Average-Strand-Spacing from about 0.25 mm to about 4 mm, an Average-Dtex from about 10 to about 500, an Average-Pre-Strain from about 50% to about 400% and a first substrate 306 and/or second substrate 308 wherein one or both of the first and second substrate have a basis weight from about 6 grams per square meter to about 30 grams per square meter.
In an alternative embodiment, an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 wherein the backsheet 125 comprises a backsheet film 126 and a backsheet nonwoven 127. The backsheet being formed at least in part by an elastomeric laminate 302 comprising a first plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308. The first plurality of elastics 316 comprises greater than about 10 elastic strands having an Average-Strand-Spacing of from about 0.5 about 5 mm, an Average-Dtex of from about 10 about 500 and an Average-Pre-Strain of from 75% to about 350% and being disposed substantially parallel with the longitudinal axis 42. The backsheet film 126 and backsheet nonwoven 127 may form one or both of the first substrate layer 306 and second substrate layer 308. In other words, the first plurality of elastics 316 may be disposed between the backsheet film 126 and the backsheet nonwoven 127. The absorbent article 100 also comprises at least one from the group consisting of a belt 430, an ear panel 530, a side panel 330, a waistband 122, an inner leg cuff 150 and an outer leg cuff 140 joined to the chassis 200. The belt 430, ear panel 530, side panel 330 and waistband 122 when present may comprise an elastomeric laminate 302 comprising a second plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308 and being disposed substantially parallel with the lateral axis 44. The second plurality of elastics 316 may comprise greater than 40 elastics with an Average-Strand-Spacing of less than 4 mm and Average-Pre-Strain of from 75% to about 300%. In embodiments, wherein the chassis comprises laterally opposed inner leg cuffs 150 and/or outer leg cuffs 140, each of the cuffs may comprise at least 6 elastic strands disposed substantially parallel with the first plurality of elastics 316 and having an Average-Strand-Spacing of less than about 3 mm and Average-Pre-Strain of between about 75% and 300%. In certain embodiments, a portion of the first plurality of elastics 316a may overlap with a portion of the second plurality of elastics 316b. The first plurality of elastics 316a may have one or more of: a) an Average-Strand-Spacing that is greater than the second plurality of elastics, b) an Average-Dtex that is lower than the second plurality of elastics 316b, c) an Average-Pre-Strain that is lower the second plurality of elastics 316b, and d) a number of elastics that is lower than the second plurality of elastics. A portion of the first plurality of elastics 316a may be disposed in an arcuate shape or may be disposed at an angle relative to one or both of the longitudinal axis 42 and lateral axis 44. A portion of the second plurality of elastics 316b may be disposed in an arcuate shape or may be disposed at an angle relative to one or both of the longitudinal axis 42 and lateral axis 44.
In yet another embodiment, an extensible article may comprise an elastomeric laminate 302 formed by a first substrate layer 306 and a second substrate layer 308 and a first plurality of elastics 316a, a second plurality of elastics 316b and a third plurality of elastics 316c disposed between the first substrate layer 306 and the second substrate layer 308. The first plurality of elastics 316a may be disposed in a first waist region, the second plurality of elastics 316b may be disposed in a second waist region and a third plurality of elastics 316c may be disposed in a crotch region. The first plurality of elastics 316a may comprise greater than about 40 elastic strands, the second plurality of elastics 316b may comprise greater than about 40 elastic strands and the third plurality of elastics 316c may comprise greater than about 10 elastic strands. One or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c may have an Average-Strand-Spacing from about 0.25 mm to about 5 mm. The Average-Dtex of one or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c is from about 10 to about 500. The Average-Pre-Strain of one or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c is from about 75% to about 300%. The elastic strands of each of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c are disposed substantially parallel to a lateral axis 44. The Pressure-Under-Strand of one or more of the first plurality of elastics 316a, the second plurality of elastics 316b and the third plurality of elastics 316c is from about 0.1 to about 1.0 psi. One or both of the first substrate layer 306 and second substrate layer 308 may have a basis weight of between about 6 grams per square meter to about 30 grams per square meter. The third plurality of elastics 316c may have one or more of: a) an Average-Strand-Spacing that is greater than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b, b) an Average-Dtex that is lower than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b, c) an Average-Pre-Strain that is lower than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b, and d) a number of elastics that is lower than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b.
In an alternative embodiment, an extensible article may comprise an elastomeric laminate 302 formed by a first substrate layer 306 and a second substrate layer 308 and a first plurality of elastics 316a, a second plurality of elastics 316b and a third plurality of elastics 316c disposed between the first substrate layer 306 and the second substrate layer 308. The first plurality of elastics 316a may be disposed in a first waist region, the second plurality of elastics 316b may be disposed in a second waist region and a third plurality of elastics 316c may be disposed in a crotch region. The first plurality of elastics 316a may comprise from about 100 to about 600 elastic strands, the second plurality of elastics 316b may comprise from about 100 to about 600 elastic strands and the third plurality of elastics 316c may comprise from about 20 to about 200 elastic strands. One or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c may have an Average-Strand-Spacing from about 0.5 mm to about 2.5 mm. The Average-Dtex of one or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c is from about 30 to about 250. The Average-Pre-Strain of one or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c is from about 75% to about 300%. The elastic strands of each of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c are disposed substantially parallel to a lateral axis 44. In an alternative embodiment, the third plurality of elastics 316c may be disposed substantially parallel to the longitudinal axis 42. The Pressure-Under-Strand of one or more of the first plurality of elastics 316a, the second plurality of elastics 316b and the third plurality of elastics 316c is from about 0.2 to about 0.8 psi. One or both of the first substrate layer 306 and second substrate layer 308 may have a basis weight of between about 6 grams per square meter to about 25 grams per square meter. The third plurality of elastics 316c may have one or more of: a) an Average-Strand-Spacing that is greater than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b, b) an Average-Dtex that is lower than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b, c) an Average-Pre-Strain that is lower than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b, and d) a number of elastics that is lower than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b.
In yet another embodiment, an extensible article may comprise one or more elastomeric laminate 302 formed by a first substrate layer 306 and a second substrate layer 308, and a first plurality of elastics 316a, a second plurality of elastics 316b, and a third plurality of elastics 316c disposed between the first substrate layer 306 and the second substrate layer 308. The first plurality of elastics 316a may be disposed in a first waist region, the second plurality of elastics 316b may be disposed in a second waist region and a third plurality of elastics 316c may be disposed in a crotch region. The first plurality of elastics forms a back belt 430B, the second plurality of elastics forms a front belt 430F and the third plurality of elastics forms an extensible crotch. The first plurality of elastics 316a may comprise greater than about 40 elastic strands, the second plurality of elastics 316b may comprise greater than about 40 elastic strands and the third plurality of elastics 316c may comprise greater than about 10 elastic strands. One or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c may have an Average-Strand-Spacing from about 0.25 mm to about 5 mm. The Average-Dtex of one or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c is from about 10 to about 500. The Average-Pre-Strain of one or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c is from about 75% to about 300%. The elastic strands of one or more of the first plurality of elastics 316a, second plurality of elastics 316b and third plurality of elastics 316c are disposed substantially parallel to a lateral axis 44. The Pressure-Under-Strand of one or more of the first plurality of elastics 316a, the second plurality of elastics 316b and the third plurality of elastics 316c is from about 0.1 to about 1.0 psi. One or both of the first substrate layer 306 and second substrate layer 308 may have a basis weight of between about 6 grams per square meter to about 30 grams per square meter. The third plurality of elastics 316c may have one or more of: a) an Average-Strand-Spacing that is greater than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b, b) an Average-Dtex that is lower than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b, c) an Average-Pre-Strain that is lower than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b, and d) a number of elastics that is lower than one or both of the first plurality of elastics 316a and the second plurality of elastics 316b.
Length-to-Waist SilhouetteA key benefit of having the Product Length-to-Waist Silhouette closer to that of the Body Length-to-Waist Silhouette and designed to change accordingly with body weight is that the product itself more closely matches the shape of the body. This results in the product being deformed to a significantly lesser degree during application than one that is generically designed to fit a bigger range as illustrated by the current marketed products. It also results in a product fit, which is more tailored to the body shape, providing more effective gasketing and less extraneous material in the crotch. Product designs which mimic the general shape of the body convey to consumers a better, more tailored fit as the Product Length-to-Waist Silhouettes are more similar to consumers' Body Length-to-Waist Silhouettes. The designs enabled by the present disclosure are more targeted by design and therefore provide a greater level of fit, gasketing, comfort and discretion.
Desirably, an absorbent article should be designed and sized to maintain contact with and conform as closely as possible to a wearer's body. Such a body-conforming design may increase the effectiveness of the absorbent article by reducing the possibility that urine, or the like, will spread or travel along the wearer's body and leak out of rather than be absorbed into the absorbent article. However, current stranded absorbent articles on the market do not adequately address body shape or product shape and therefore do not fit a broad range of users adequately or provide the desired level of close fit.
It may be desirable to link the Product Length-to-Waist Silhouette to that of the targeted consumers Body Length-to-Waist Silhouette in order to achieve a better fitting, better conforming, better gasketing product. This may increase the wearing comfort for each consumer while reducing leakage.
In order to deliver sufficient pressure on the body, which is necessary for good fit, closed-form pant products currently in the market which comprise of elastic strands for the waist belt tend to have a narrower Relaxed Product Waist Width. This is due to their strand spacing' s and strand decitex, which result is a relatively low modulus and therefore require more stretch to deliver the necessary pressure. They achieve this greater in-use stretch via greater pre-strain, which results in their relaxed waists being significantly smaller than the body of the user.
A key benefit of present disclosure is that the improved elastic laminates deliver sufficient wearing pressure, necessary for good fit, without the amount of pre-strain required in today's currently marketed stranded closed-form pant articles. This results in closed-form pant articles that have a Relaxed Product Waist Width closer to that of the Body Waist Width.
The table below illustrates inventive stranded products, whose Product Length-to-Waist Silhouettes match the trends of the consumers that they are targeted to fit and thereby provide better fit & comfort while reducing the chance of leakage. These inventive products are provided simply as non-limiting examples.
“Waist Width” is defined as the width of the body measured horizontally in the front of the body at the omphalion (center of navel). See
“Body Length” means the vertical distance from the navel to the maximum depth of the crotch, determined by the maximum depth of the crotch within the sagittal plane. See
“Body Length-to-Waist Silhouette” means the Body Length (mm) divided by the Waist Width (mm). See
“Relaxed Product Length” means the longitudinal distance between the longitudinally distal most point in the crotch region and the longitudinally distal most point along the front waist edge. The longitudinal distance is measured parallel to the longitudinal axis of the product. Refer to
“Relaxed Product Waist Width” means the lateral distance from the distal most point at the right side of the front waist edge to the distal most point at the left side of the front waist edge. The lateral distance is measured perpendicular to the longitudinal axis of the product. Refer to
“Product Length-to-Waist Silhouette” means Relaxed Product Length (600) (mm) divided by the Relaxed Product Hip Width (601) (mm). See
A product's size range is conveyed to consumers by a weight range and/or a waist range printed on the package. For products recommended by weight range, a Target-Weight is the average of the minimum and maximum recommended weights.
For many adult incontinence products, only a waist recommendation is provided. For these products, a Target-Weight can still be determined by calculating the Average Weight at the minimum and maximum recommended waists.
A Target Body Length-to-Waist Silhouette can be approximated, as shown on
Target Body Length-to-Waist Silhouette=a+b*w+c/w+d*ŵ2+e/ŵ2+f*ŵ3+g/ŵ3
Where:
w=weight in kg
a=1.401979E+00
b=−9.012608E−03
c=−1.086641E+01
d=7.314561E−06
e=5.678403E+01
f=6.589002E−08
g=−9.152613E+01
The closer the Product Length-to-Waist Silhouette is to the Target Body Length-to-Waist Silhouette, the better fitting, better gasketing that product will be.
Examples of Product Length-to-Waist Silhouette Existing Stranded Products
A key benefit of having the Relaxed Product Waist Width, the Relaxed Product Hip Width, and the Relaxed Product Crotch Width (each defined below) relatively equal to each other is that they combine to create a more rectangular, more uniform, and, hence, a more stable package. Absorbent articles are generally distributed to consumers in packages of multiple stacked articles, as illustrated in
In one embodiment, an absorbent article 100, comprises a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125. The absorbent article 100 also comprises a back belt 430B joined to the back waist region 38 of the chassis 200 and extending outboard of the back waist region 38 of the chassis 200. The article also comprising a front belt 430F joined to the front waist region 36 of the chassis 200 and extending outboard of the front waist region 36 of the chassis 200. The front belt 430F may be joined to the back belt 430B at or adjacent the laterally opposing belt side edges 437 to form leg openings 192 and a waist 190 opening to form a closed-form pant 400. The back belt 430B having a first plurality of elastics 316a comprising greater than about 40 elastic strands and the front belt 430F having a second plurality of elastics 316b comprising greater than about 40 elastics strands. The first plurality of elastics 316a having an Average-Strand-Spacing of less than about 4 mm. The second plurality of elastics 316b having an Average-Strand-Spacing of less than about 4 mm. One or both of the first plurality of elastics 316a and second plurality of elastics 316b having a portion that overlaps with the absorbent core 128. The absorbent article 100 having a Product Hip-to-Waist Silhouette from about 0.8 to about 1.1, alternatively from about 0.9 to about 1.0. The absorbent article 100 may have a Product Waist-to-Crotch Silhouette is from about 0.8 to about 2.0, alternatively from about 0.9 to about 1.5, in another embodiment the Product Waist-to-Crotch Silhouette may be from about 1.2 to about 1.35. The absorbent article may also have a Relaxed Product Waist Width from about 80 mm to about 270 mm, alternatively from about 170 mm to about 270 mm and in other embodiments from about 80 mm to about 180 mm. The absorbent article may also have a Relaxed Product Hip Width from about 80 mm to about 300 mm, alternatively from about 80 mm to about 200 mm. The absorbent article may also have a Relaxed Product length from about 200 mm to about 300 mm.
The back belt 430B may be divided into 4 equal sections, the first section, Section 1, including the distal most elastic, the fourth section, Section 4, including the proximal most elastic, the second section, Section 2, is disposed adjacent the first section and the third section, Section 3, is disposed between the second section and the fourth section, Section 4. The front belt 430F may also be divided into 4 equal sections, the first section, Section 1, including the distal most elastic, the fourth section, Section 4, including the proximal most elastic, the second section, Section 2, is disposed adjacent the first section and the third section, Section 3, is disposed between the second section and the fourth section, Section 4. One or more of the sections forming the front belt 430F may have a different Section-Modulus from the remaining sections of the front belt 430F. One or more of the sections forming the back belt 430B may have a different Section-Modulus from the remaining sections of the front belt 430B. Alternatively, one or more of the sections forming the front belt 430F may have a different Section-Modulus from one or more of the sections forming the back belt 430B
The back belt 430B and front belt 430F may both be formed at least in part by an elastomeric laminate 302 comprising a first substrate layer 306 and a second substrate layer 308 and a plurality of elastics disposed between the first and second substrate layers 306 and 308. One or both of the first and second substrate 306 and 308 forming at least a portion of the back belt 430B and one or both of the first and second substrate 306 and 308 forming at least a portion of the front belt 43F are separate and spaced apart from each other. Alternatively, one or both of the first and second substrate 306 and 308 forming at least a portion of the back belt 430B and one or both of the first and second substrate 306 and 308 forming at least a portion of the front belt 43F are continuous and extends from the first waist edge to the longitudinally opposing second waist edge. The elastomeric laminate may also comprise an adhesive joining the first substrate layer 306 and/or second substrate layer 308 to the plurality of elastics 316. The adhesive may be selected from the group consisting of Styrenic block copolymers, Polyolefins, Ethylene-vinyl Acetates, Polyurethanes, Ethylene-propylene copolymers, Propylene-ethylene copolymers, Polyolefin block polymers, Polyolefin homo-polymers, Polyesters, Polyamides, Silicones, Cyanoacrylics, Acrylics, butyl rubber, and combinations thereof.
In certain embodiments, one of the sections in the front belt 430F may comprise more elastics that one or more of the remaining sections of the front belt 430F and one of the sections in the back belt 430B may comprise more elastics that one or more of the remaining sections of the back belt 430B. The front belt 430F may have at least one section that comprises greater than 10 elastics and the back belt 430B may have at least two sections that comprise greater than 10 elastics. The front belt 430F may have at least two sections having an Average-Strand-Spacing of less than about 3 mm and the back belt 430B may have at least three sections having an Average-Strand-Spacing of less than about 3 mm.
In another example of an absorbent article 100, the absorbent article comprises a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125. The absorbent article 100 also comprises a back belt 430B joined to the back waist region 38 of the chassis 200 and extending outboard of the back waist region 38 of the chassis 200. The article also comprising a front belt 430F joined to the front waist region 36 of the chassis 200 and extending outboard of the front waist region 36 of the chassis 200. The front belt 430F may be joined to the back belt 430B at or adjacent the laterally opposing belt side edges 437 to form leg openings 192 and a waist 190 opening to form a closed-form pant 400. The back belt 430B having a first plurality of elastics 316a comprising greater than about 40 elastic strands and the front belt 430F having a second plurality of elastics 316b comprising greater than about 40 elastics strands. The first plurality of elastics 316a having an Average-Strand-Spacing of less than about 4 mm. The second plurality of elastics 316b having an Average-Strand-Spacing of less than about 4 mm. One or both of the first plurality of elastics 316a and second plurality of elastics 316b having a portion that overlaps with the absorbent core 128. The absorbent article 100 having a Product Hip-to-Waist Silhouette from about 0.8 to about 1.1, alternatively from about 0.9 to about 1.1. The absorbent article 100 may have a Product Waist-to-Crotch Silhouette is from about 0.8 to about 2.8, alternatively from about 0.8 to about 2.5, in another embodiment the Product Waist-to-Crotch Silhouette may be from about 0.8 to about 2.0. The absorbent article may also have a Relaxed Product Waist Width from about 200 mm to about 400 mm, alternatively from about 225 mm to about 375 mm and in other embodiments from about 250 mm to about 350 mm. The absorbent article may also have a Relaxed Product Hip Width from about 200 mm to about 450 mm, alternatively from about 225 mm to about 425 mm, in other embodiments the Relaxed Product Hip Width may be from about 250 mm to about 400 mm. The absorbent article may also have a Relaxed Product length from about 250 mm to about 450 mm, alternatively from about 275 to about 425, in yet another embodiment the Relaxed Product Length may be from about 300 mm to about 400 mm.
The back belt 430B may be divided into 4 equal sections, the first section, Section 1, including the distal most elastic, the fourth section, Section 4, including the proximal most elastic, the second section, Section 2, is disposed adjacent the first section and the third section, Section 3, is disposed between the second section and the fourth section, Section 4. The front belt 430F may also be divided into 4 equal sections, the first section, Section 1, including the distal most elastic, the fourth section, Section 4, including the proximal most elastic, the second section, Section 2, is disposed adjacent the first section and the third section, Section 3, is disposed between the second section and the fourth section, Section 4. One or more of the sections forming the front belt 430F may have a different Section-Modulus from the remaining sections of the front belt 430F. One or more of the sections forming the back belt 430B may have a different Section-Modulus from the remaining sections of the front belt 430B. Alternatively, one or more of the sections forming the front belt 430F may have a different Section-Modulus from one or more of the sections forming the back belt 430B
The back belt 430B and front belt 430F may both be formed at least in part by an elastomeric laminate 302 comprising a first substrate layer 306 and a second substrate layer 308 and a plurality of elastics disposed between the first and second substrate layers 306 and 308. One or both of the first and second substrate 306 and 308 forming at least a portion of the back belt 430B and one or both of the first and second substrate 306 and 308 forming at least a portion of the front belt 43F are separate and spaced apart from each other. Alternatively, one or both of the first and second substrate 306 and 308 forming at least a portion of the back belt 430B and one or both of the first and second substrate 306 and 308 forming at least a portion of the front belt 43F are continuous and extends from the first waist edge to the longitudinally opposing second waist edge. The elastomeric laminate may also comprise an adhesive joining the first substrate layer 306 and/or second substrate layer 308 to the plurality of elastics 316. The adhesive may be selected from the group consisting of Styrenic block copolymers, Polyolefins, Ethylene-vinyl Acetates, Polyurethanes, Ethylene-propylene copolymers, Propylene-ethylene copolymers, Polyolefin block polymers, Polyolefin homo-polymers, Polyesters, Polyamides, Silicones, Cyanoacrylics, Acrylics, butyl rubber, and combinations thereof.
In certain embodiments, one of the sections in the front belt 430F may comprise more elastics that one or more of the remaining sections of the front belt 430F and one of the sections in the back belt 430B may comprise more elastics that one or more of the remaining sections of the back belt 430B. The front belt 430F may have at least one section that comprises greater than 20 elastics, alternatively greater than 40 elastics and the back belt 430B may have at least two sections that comprise greater than 20 elastics, alternatively greater than 40 elastics. The front belt 430F may have at least two sections having an Average-Strand-Spacing of less than about 3 mm and the back belt 430B may have at least three sections having an Average-Strand-Spacing of less than about 3 mm.
Examples of Product Hip-to-Waist & Waist-to-Crotch Silhouette for Existing Stranded Products
The absorbent article 100 may also include a fastening system 179. When fastened, the fastening system 179 interconnects the front waist region 36 and the rear waist region 38 resulting in a waist circumference that may encircle the wearer during wear of the absorbent article 100. This may be accomplished by connecting the side panels 330 in one waist region with the side panels 330 in the longitudinally opposing waist region (e.g. a refastenable seam in a pant comprising side panels 300) or by connecting elastomeric ear panels 530 in one waist region with the chassis 200 in the longitudinally opposing waist region (e.g. a closure in a taped diaper 500). The fastening system 179 may comprises a fastener 175 such as tape tabs, hook and loop fastening components, interlocking fasteners such as tabs & slots, buckles, buttons, snaps, and/or hermaphroditic fastening components, although any other known fastening means are generally acceptable. Referring to
As shown in
In
In
In
In
In
For the belt refastenable executions, the references to front belt 430F and back belt 430B should be considered to be interchangeable such that a fastener 175 that is described above in the front waist region 36 may be disposed in the back waist region 38 in a similar structural configuration.
Identical or Substantially Identical ChassisAs disclosed in U.S. Pub. No. 2013/0211355, it may be desirable to offer an array of packages for fitting wearers having different needs, but comprising identical or substantially identical chassis 200. For instance, an array may comprise a first package comprising a first absorbent article 100 and a second package may comprise a second absorbent article 100, where the first and second packages comprise articles having identical or substantially identical chassis 200 as described in U.S. Pub. No. 2013/0211355. More particularly, the first package may comprise a first chassis 200 and the second package may comprise a second chassis 200, where each of the first and second chassis comprise the same dimensions of one or more of: core width at the lateral axis 44, core width at one of the front or rear core edge 26 and 28, a distance from a left outer cuff distal edge 142 to a right outer cuff distal edge 142, a distance from a left inner cuff proximal edge 152 to a left outer cuff distal edge 142, a distance from a left inner cuff proximal edge 152 to a right inner cuff proximal edge 152, a distance from a left inner cuff proximal edge 152 to a left outer cuff distal edge 142, a free height of the inner cuff, inner cuff hem fold width, inner cuff elastics length, outer cuff elastics length, core length, chassis length and backsheet width.
Further, each of the first and second chassis 200 may comprise identical chemical compositions of one or more of a topsheet 124, backsheet film 126, backsheet nonwoven 127, core super absorbent polymers, core pulp, core nonwoven, core tissue, leg cuff film, leg cuff nonwoven, super absorbent polymer adhesive, core nonwoven adhesive, leg cuff elastic adhesive, and backsheet nonwoven/film adhesive.
And, each of the first and second chassis 200 may comprise the same basis weight of one or more of the topsheet 124, backsheet film 126, backsheet nonwoven 127, core super absorbent polymers, core pulp, leg cuff nonwoven, leg cuff film, super absorbent polymer adhesive, leg cuff adhesive, and backsheet nonwoven/film adhesive.
And, each of the first and second chassis 200 may comprise compositionally identical core super absorbent polymers. The first and second chassis 200 may have identical component cross sectional order and disposition in at least one of the front waist region 36, back waist region 38, and crotch region 37. The inner leg cuffs 150 of the first and second chassis 200 may be composed of the compositionally identical materials.
Further, the inner leg cuffs 150 of the first and second chassis 200 may have identical component cross sectional order and disposition in at least one of the front waist region 36, back waist region 38, and crotch region 37. The distance from the left outer cuff distal edge 142 to a right outer cuff distal edge 142 may the same. The distance from the left inner cuff proximal edge 152 to left outer cuff distal edge 142 may be the same. The distance from the left inner cuff proximal edge 152 to the right inner cuff proximal edge 152 is the same. The lengths of the inner and outer cuffs 150 and 140 are the same.
Further one or more of the chassis 200, belt 430, side panel 330, ear panel 530, waistband 122, inner leg cuff 150, outer leg cuff 140, topsheet 124 and backsheet 125 of a first absorbent article and one or more of the chassis 200, belt 430, side panel 330, ear panel 530, waistband 122, inner leg cuff 150, outer leg cuff 140, topsheet 124 and backsheet 125 of a second absorbent article being identical or substantially identical to each other with regard to one or more of Average-Dtex, Average-Strand-Spacing, Average-Pre-Strain, nonwoven basis weight and/or nonwoven texture.
Different product offerings in an array may have identical or substantially identical chassis 200 as the side panels 330, ear panels 530 or belts 430 may be used to distinguish the absorbent article forms one from another. For example, first and second absorbent articles may have identical chassis (compositionally, dimensionally, cross-sectionally), but the first article 100 may have a different length due to disposition of the belts. As a second example, first and second absorbent articles 100 may have identical chassis (compositionally, dimensionally, cross-sectionally), but the first article may have a different length and/or width due to the size of the belts.
First and second absorbent articles 100 may have identical chassis compositionally, but not dimensionally, and not cross-sectionally. First and second absorbent articles 100 may have identical chassis dimensionally, but not compositionally, and not cross-sectionally. First and second absorbent articles 100 may have identical chassis cross-sectionally, but not dimensionally, and not compositionally. Alternatively, first and second absorbent articles 100 may have two, but not three of (1) compositionally, (2) dimensionally, and (3) cross-sectionally identical chassis.
It should be noted that for all of the above statements relating to identical or substantially identical chassis that a third package comprising a third article 100 may be added. It should also be noted that the structure and/or form of the first article 100, second article 100 and third article 100 when present can all be different in other words the first article 100 may be an open-form, taped diaper 500, the second article may be a closed-form, side panel refastenable pant 300, and the third article 100 may be a closed-form, belt pant 400.
GraphicsThere is a desire to make disposable absorbent articles 100 look more like underwear. This desire is driven by the desire to address the psychological and emotional development needs of the wearer, especially infants and children. There are several factors that can affect whether an absorbent article 100 is perceived as underwear-like. These factors include, but are not limited to, the noticeability of seams 170, the existence of graphics on a larger percentage of the viewable surfaces of the absorbent article 100, the appearance of waist and leg features and graphics flowing from or over two or more absorbent article components.
There are, however, many obstacles to designing and executing an absorbent article 100 that is underwear-like. One is that absorbent articles are a compilation of separate article components and as new disposable absorbent article technologies are developed, they may result in the need for incorporation of additional, separate, article components. Because of the manner in which absorbent article components are incorporated, even the viewable surfaces of the article may have seams or areas of overlap or connection. Thus, it is challenging to place graphics on these individual components and to line them up such that the multi-component construction appears to be an integrated structure wherein the seams are de-emphasized and process variations are masked.
Further, depending on the type of article construction, it is challenging to maintain the uniform appearance of graphics that may be printed on more than one component. For example, a component with a particular graphic printed on it may eventually be incorporated into the article at a different depth than an adjacent component that also has a graphic printed on it. Depending on whether particular portions of a graphic are printed on an outermost layer, for example, or, if not, how opaque the layers may be through which the various portions of the graphic may be viewed, can have an impact on an entire article graphic that is meant to look uniform and consistent in that the various portions may have measureable differences in appearance when printed on different components or at different depths relative to the outer surface. For these and other reasons, it is challenging to create an absorbent article that comprises mainstream technologies and also that comprises graphics on multiple absorbent article components, such that the graphics flow from one absorbent article component to another article component in a manner that deemphasizes transitions from one component to another and creates a holistic underwear-like appearance.
It is a desire of the present disclosure to provide absorbent articles 100 that look like underwear, while, at the same time, incorporating multiple absorbent article components that offer the benefits and functionality of the latest technologies (e.g., high stretch components integrated with low/no stretch components, highly breathable, high air permeability components, etc.). More specifically, it is a desire of the present disclosure to provide absorbent articles 100 comprising graphics disposed on or spanning multiple viewable absorbent article components while creating a uniform appearance.
Disposable absorbent articles 100 of the present disclosure can have 2 or 4 elastomeric ear panels 530 or side panels 330 that overlap with a portion of the chassis 200 or an elastomeric belt 430 disposed in one or both of the waist regions that overlap with a portion of the chassis 200. The ear panels 530 or side panels 330 may comprise a first graphic element and the chassis 200 may comprise a second graphic element wherein the graphic elements are designed to work in concert with each other to create a composite graphic element. A first elastomeric ear panel 530 or side panel 330 may comprise a first graphic extending from a side edge of the ear or side panel 537 and 337 respectively toward the longitudinal axis 42, a second elastomeric ear panel 530 or side panel 330 comprises a second graphic extending from a side edge of the ear or side panel 537 and 337 respectively toward the longitudinal axis 42 and the center chassis 200 comprises a third graphic extending from a first side edge 237 of the chassis to the opposing side edge 237 of the chassis wherein the first, second and third graphic are substantially aligned. In general, a composite graphic is formed when two or more separate graphics are substantially aligned to form a larger continuous graphic.
As disclosed in U.S. Ser. No. 15/479,407, disposable absorbent articles comprising one or more belts 430 a first graphic may be printed on a surface of one of the layers of one of the first belt or second belts 430, a second graphic may be printed on a surface of one of the group consisting of a nonwoven layer of the first belt 430 or second belt 430, a layer of the chassis 200, a backsheet 125, and an outer cover, e.g. backsheet nonwoven 127. Additional graphics may be printed on other layers of the article, for example, any of the layers of the belts 430, the elastomeric material, the chassis 200, or of the backsheet 125 or outer cover. A first elastomeric belt 430 may comprise a first graphic element and the chassis 200 comprises a second graphic element wherein the first and second graphic elements are substantially aligned.
When the absorbent article comprises a belt 430, it is desirable that the arrangement of graphic elements cover greater than about 30% of the surface area of the belt 430 or greater than about 40% or greater than about 50%. The graphic elements may cover greater than 75% of the surface area of the belt 430. Additionally, the arrangement of graphics may when viewed from the outside appear to comprise at least 3 colors or at least 5 colors or greater than 7 colors. To provide a very underwear-like appearance the arrangement of graphic elements may be disposed within 30 mm of the waist edge 136 and 138 in one or both of the waist regions, or within 20 mm or within 10 mm of the leg opening edge. The graphics elements may be disposed at or immediately adjacent the waist edge of one or both of the belts 430. In addition, it may be desirable that the arrangement of graphic elements may also be disposed within about 10 mm of a leg edge of the belt 430.
When the absorbent article comprises discrete side panels 330 or ear panels 530, it is desirable that the arrangement of graphic elements cover greater than about 10% of the surface area of the side panel 330 or ear panel 530 or greater than about 25% or greater than about 50%. The graphic elements may cover greater than 75% of the surface area of the discrete side panel 330 or ear panel 530. Additionally, the arrangement of graphics may when viewed from the outside appear to comprise at least 3 colors or at least 5 colors or greater than 7 colors. To provide a very underwear-like appearance the arrangement of graphic elements may be disposed within 30 mm of the waist edge in one or both of the waist regions or within 20 mm or within 10 mm of the leg opening edge. The graphics elements may be disposed at or immediately adjacent the waist edge of the side panels 330 or ear panels 530. In addition, it may be desirable that the arrangement of graphic elements may also be disposed within about 10 mm of a leg opening edge of the side panel 330 or ear panel 530.
For graphics meant to be viewed from the outside of the absorbent article, it may be desirable to print on a layer that is outboard of the elastic layer, including outboard (between the elastic layer and the exterior) of elastic strands as the elastic layer may occlude the visibility of any graphics printed inboard (between the elastic layer and the wearer). As such the interior surface of the most exterior nonwoven layer of the belt, elastomeric ear panels, side panels, and chassis, may be ideal for printing graphics when combined with elastic layers as disclosed herein.
For graphics meant to be viewed from the inside of the absorbent article, it may be desirable to print on a layer that is inboard of the elastic layer, including inboard (between the elastic layer and the wearer) of elastic strands as the elastic layer may occlude the visibility of any graphics printed outboard (between the elastic layer and the exterior). As such the exterior surface of the most interior nonwoven layer of the belt, elastomeric ear panels, side panels, and chassis, may be ideal for printing graphics when combined with elastic layers as disclosed herein.
Absorbent CoresAs used herein, the term “absorbent core” 128 refers to the component of the absorbent article 100 having the most absorbent capacity and that comprises an absorbent material. Referring to
Referring to
The core wrap may be made of a single substrate, material, or nonwoven folded around the absorbent material, or may comprise two (or more) substrates, materials, or nonwovens which are attached to another. Typical attachments are the so-called C-wrap and/or sandwich wrap. In a C-wrap, the longitudinal and/or transversal edges of one of the substrates may be folded over the other substrate to form flaps. These flaps are then bonded to the external surface of the other substrate, typically by gluing. Other techniques may be used to form a core wrap. For example, the longitudinal and/or transversal edges of the substrates may be bonded together and then folded underneath the absorbent core 128 and bonded in that position as illustrated in
The core wrap may be at least partially sealed adjacent all of the sides of the absorbent core 128 so that substantially no absorbent material leaks out of the core. By “substantially no absorbent material” it is meant that less than 5%, less than 2%, less than 1%, or about 0% by weight of absorbent material escape the core wrap. The term “seal” is to be understood in a broad sense. The seal does not need to be continuous along the whole periphery of the core wrap but may be discontinuous along part or the whole of it, such as formed by a series of seal points spaced on a line. A seal may be formed by gluing and/or thermal bonding.
The core wrap may also be formed by a single substrate which may enclose as in a parcel wrap the absorbent material and be sealed along the front side and rear side of the core and one longitudinal seal. The core wrap may comprise one or more nonwoven layers formed of a co-form material having a pulp fiber to synthetic fiber ratio of from 1:3 to 3:1, i.e. 25%:75% pulp fiber:synthetic fiber to 75%:25% pulp fiber:synthetic fiber.
ChannelsAs illustrated in
The absorbent core 128 may comprise more than two channels, for example, at least 3, at least 4, etc. Shorter channels may also be present, for example in the rear waist region or the front waist region of the core as represented by the pair of channels 129 towards the front of the absorbent article 100. The channels 129 may comprise one or more pairs of channels symmetrically arranged, or otherwise arranged relative to the longitudinal axis 42 or the lateral axis 44.
At least some or all of the channels 129 may be permanent channels, meaning their integrity is at least partially maintained both in the dry state and in the wet state. Permanent channels may be obtained by provision of one or more adhesive materials, for example, the fibrous layer of adhesive material or construction glue that helps adhere a substrate with an absorbent material within the walls of the channel. Permanent channels may also be formed by bonding the upper side and lower side of the core wrap and/or the topsheet 124 to the backsheet 125 together through the channels. Typically, an adhesive may be used to bond both sides of the core wrap or the topsheet and the backsheet through the channels, but it is possible to bond via other known processes, such as pressure bonding, ultrasonic bonding, heat bonding, or combinations thereof. The core wrap or the topsheet 124 and the backsheet 125 may be continuously bonded or intermittently bonded along the channels 129. The channels 129 may advantageously remain or become visible at least through the topsheet 124 and/or backsheet 125 when the absorbent article 100 is fully loaded with a fluid. This may be obtained by making the channels substantially free of SAP, so they will not swell, and sufficiently large so that they will not close when wet. Furthermore, bonding the core wrap to itself or the topsheet 124 to the backsheet 125 in the channel area may be advantageous.
Absorbent cores and/or liquid management systems without any channels are also within the scope of the present disclosure. These cores may include airfelt-free cores, SAP/pulp cores, pulp cores, or other cores known to those of skill in the art.
Acquisition LayersOne or more acquisition materials (e.g., 130) may be present at least partially intermediate the topsheet 124 and the absorbent core 128. The acquisition materials are typically hydrophilic materials that provide significant wicking of bodily exudates. These materials may dewater the topsheet 124 and quickly move bodily exudates into the absorbent core 128. The acquisition materials 38 may comprise one or more nonwoven materials, foams, cellulosic materials, cross-linked cellulosic materials, air laid cellulosic nonwoven materials, spunlace materials, or combinations thereof, for example. In some instances, portions of the acquisition materials may extend through portions of the topsheet 124, portions of the topsheet 124 may extend through portions of the acquisition materials, and/or the topsheet 124 may be nested with the acquisition materials. Typically, an acquisition material or layer may have a width and length that are smaller than the width and length of the topsheet 124. The acquisition material may be a secondary topsheet in the feminine pad context. The acquisition material may have one or more channels as described in the absorbent core 128 section (including the embossed version). The channels in the acquisition material may align or not align with channels in the absorbent core 128. In an example, a first acquisition material may comprise a nonwoven material and as second acquisition material may comprise a cross-linked cellulosic material.
Absorbent Article Packaging and Package IndiciaThe absorbent articles 100 of the present disclosure may be placed into packages 610 (shown in
Desirably, the package 610 has parallel sides and a package top that is parallel to the package bottom, making the package ideal for stacking on a shelf for storage or for display in a store for purchase by consumers. Typically packages 610 of absorbent articles 100 are labeled with a recommended wearer weight range (typically for babies, infants, and toddlers) and/or by waist circumference (typically for adult absorbent article products) that the packaged article is intended to fit. As a result, the weight and/or the waist circumference information is most often placed on the package 610 as part of the indicia 1000 to identify the appropriate size of the article needed by the consumer.
Further, the indicia 1000 may illustrate the wearer wearing the article and/or a separate indicia may illustrate the article component or feature. Regarding absorbent articles for babies, descriptions of suitable stages of development indicia and methods of displaying packages comprising absorbent articles may be found in U.S. Pat. No. 7,222,732 to Ronn, titled MERCHANDISE DISPLAY SYSTEM FOR IDENTIFYING DISPOSABLE ABSORBENT ARTICLE CONFIGURATIONS FOR WEARERS.
Chemistry (Spandex vs. Extruded Strands) and Structure
Beamed elastic uses Spandex fibers. One type of Spandex fiber is “PolyUrethane Urea” elastomer or the “high hard segment level PolyUrethane” elastomer, which must be formed into fibers using a solution (solvent) spinning process (as opposed to being processable in the molten state.) The Urea linkages in PolyUrethane Urea provides strong mutual chemical interactions crucial for providing “anchoring” that enables good stress relaxation performance at temperatures near body temperature on timescales corresponding to diaper wear, including overnight. This type of anchoring enables better force relaxation (i.e. little force decay with time when held in stretched condition at body temperature) over many thermoplastic polyurethane (PolyUrethane with hard segment melting below 200 deg. C) or thermoplastic Styrenic block copolymers.
In contrast, extruded strands and scrims are typically made of Styrenic block copolymers or thermoplastic elastomers that can be formed in the molten state by conventional extrusion processes. Thermoplastic elastomers include compositions like polyolefin, polyurethane (PolyUrethane with hard segment melting below 200 deg. C) elastomers, etc. Because these thermoplastic elastomers like Polyurethane (PolyUrethane with hard segment melting below 200 deg. C) can be melted/remelted, and extruded it makes them susceptible to higher stress relaxation in use, which is a major negative. The styrenic block copolymers used in extruded strands comprise a comparatively long rubbery midblock situated between comparatively short end blocks. End blocks sufficiently short to enable good flow conventional extrusion processes often have a greater propensity to stress relax and undergo force relaxation over time see
The Urea linkage present in Spandex requires it to be made by spinning process. Spandex can't be melted/remelted or extruded like Styrenic block copolymers. Spandex pre-polymer is combined with solvent and additives, and the solution is spun to make solid spandex fiber. Multiple fibers are then formed together to make one spandex strand. The Spandex strands may have surface finish to avoid blocking and wound onto spools. The one spandex fiber may have a decitex of about 15, so a 500 decitex strand may have nominally 33 fibers wound together to make one strand. Depending on the decitex we use for beam approach, we may have 15 fibers (or filaments), 8 fibers, 5 fibers, 3 fibers or even as low as 2 fibers. Spandex fiber can be mono-component or bi-component (as disclosed in WO201045637A2).
Further related to the chemistry of beamed elastics, it may be desirable to coat the beamed elastics with an oil, such as a silicone oil, including about 10%, about 7%, about 5%, about 3%, or about 1% silicone oil. Treating the beamed elastics with silicone oil helps to prevent blocking (cross-linking) when the strands are wound to a spool or a beam and it also lowers the COF for the strand in textile machinery (for weaving, knitting and warping processes).
Commercially available Spandex strands may also be known as Lycra, Creora, Roica, or Dorlastan. Spandex is often referred as Elastan fiber or Polyurethane fiber.
LYCRA HYFIT strands, a product of Invista, Wichita, Kans., are a suitable for making the strands that make up the plurality of elastics 316 that make up the elastomeric laminate 302. Some strands, for example, the aforementioned LYCRA HYFIT, may comprise a number of individual fibers wound together to form the strand. With regard to elastic strands formed of a number of individual fibers it has been discovered that the individual fibers can move relative to each other changing the cross sectional shape of the strand as well as becoming unraveled which can lead to poor control of the strands as well as poor bonding/adhering/joining of the elastic strands to one or both of the first substrate layer 306 and second substrate layer 308 of the elastomeric laminate 302. In order to minimize the negatives with regard to strands comprising a plurality of fibers it would be advantageous to minimize the number of fibers in a given strand. It would therefore be desirable to have less than about 40 fibers per strand, less than about 30 fibers per strand, less than about 20 fibers per strand, less than about 10 fibers per strand, less than about 5 fibers per strand and 1 fiber forming the strand. In the case of a single fiber forming the strand which can deliver comparable performance to the multi-fiber strands of the prior art it would be desirable for the fiber to have a fiber decitex from about 22 to about 300 and a fiber diameter from about 50 micrometers to about 185 micrometers.
SensorsThe absorbent articles of the present disclosure may comprise a sensor system for monitoring changes within the absorbent article 100. The sensor system may be discrete from or integral with the absorbent article 100. The absorbent article 100 may comprise sensors that can sense various aspects of the absorbent article 100 associated with insults of bodily exudates such as urine and/or BM (e.g., the sensor system may sense variations in temperature, humidity, presence of ammonia or urea, various vapor components of the exudates (urine and feces), changes in moisture vapor transmission through the absorbent articles garment-facing layer, changes in translucence of the garment-facing layer, color changes through the garment-facing layer, etc.). Additionally, the sensor system my sense components of urine, such as ammonia or urea and/or byproducts resulting from reactions of these components with the absorbent article 100. The sensor system may sense byproducts that are produced when urine mixes with other components of the absorbent article 100 (e.g., adhesives, AGM, etc.). The components or byproducts being sensed may be present as vapors that may pass through the garment-facing layer. It may also be desirable to place reactants in the diaper that change state (e.g. color, temperature, etc.) or create a measurable byproduct when mixed with urine or BM. The sensor system may also sense changes in pH, pressure, odor, the presence of gas, blood, a chemical marker or a biological marker or combinations thereof.
The sensor system or portions thereof may be integrated with the absorbent article 100 with hook and loops fasteners, adhesives, thermal bonds, mating fasteners like snaps or buttons, or may be disposed in pockets, recesses or void spaces built into the absorbent article 100, or combinations thereof. Many of these integration means enable removal of and/or attachment of the sensor system or portions thereof from or to the absorbent article 100. The absorbent article 100 may further comprise graphics for the purpose of properly locating the sensor system or portions thereof. In addition, in cases where an auxiliary article is present, the auxiliary article may be joined to the absorbent article 100 by similar integration means. Regarding pockets, it may be desirable to form a pocket within or adjacent to the wearer-facing layer or garment-facing layer of the article. A pocket may be formed by joining an additional material (e.g., a nonwoven strip) to the interior or exterior surface of the garment-facing layer. When joined to the interior surface of the garment-facing layer, it may be desirable to position an open edge (to be the pocket opening) of the sheet to be coterminous or adjacent to an edge of the waist opening 190 such that there is no need to make a cut in the garment-facing layer for inserting the sensor system 700 or portions thereof into the pocket opening.
As used in this application, the term “sensor system” refers not only to the elements responsible for detecting a stimulus and/or change in status of the article and signaling such detection, but also may include the housing or carrier layer or substrate around such element(s). A “sensor system” may include a carrier layer with multiple elements capable of detecting one or more stimuli; and, the multiple elements may create multiple locations capable of detecting one or more stimuli. The sensor systems of the present disclosure may be formed of multiple components capable of monitoring urine and/or fecal insults. The sensor system may take on a variety of configurations, which are determined by the means in which the presence of urine and/or feces is detected. After detection of urine and/or feces, the sensor system may inform a caregiver and/or a child by generating a notification. The notification may be an auditory signal, an olfactory signal, a tactile signal or a visual signal. It is understood that the sensor system may comprise a device for sending a wireless signal to a remote receiver which may in turn result in an auditory signal, a visual signal, a tactile signal or other sensory signal and/or combinations thereof.
Various sensors may be used as part of the sensor system, including inductive, capacitive, ultra-sonic, optical, moisture, humidity (e.g., MVTR), pH, biological, chemical, mechanical, temperature, electromagnetic and combinations thereof, as described and illustrated in U.S. Pub. Nos. 2012/0310190 and 2012/0310191.
The sensor system may include one or more transmitters. A transmitter is a device that sends electromagnetic waves carrying messages or signals, for instance, one or more of the sensor elements may comprise a transmitter. Alternatively, a transmitter may be removably fixed to the absorbent article 100 or to an auxiliary article such that it is in contact or in communication with the sensor elements.
Feminine Absorbent ArticleThe feminine absorbent article 801, shown in
Apertured film materials suitable for use as the topsheet 124 as shown in
Non-limiting examples of woven and nonwoven materials suitable for use as the topsheet 124 include fibrous materials made from natural fibers, modified natural fibers, synthetic fibers, or combinations thereof. These fibrous materials can be either hydrophilic or hydrophobic, but it is preferable that the topsheet be hydrophobic or rendered hydrophobic. As an option portions of the topsheet can be rendered hydrophilic, by the use of any known method for making topsheets containing hydrophilic components. One such method include treating an apertured film component of a nonwoven/apertured thermoplastic formed film topsheet with a surfactant as described in U.S. Pat. No. 4,950,264, issued to Osborn on Aug. 21, 1990. Other suitable methods describing a process for treating the topsheet with a surfactant are disclosed in U.S. Pat. Nos. 4,988,344 and 4,988,345, both issued to Reising et al. on Jan. 29, 1991. The topsheet 124 may have hydrophilic fibers, hydrophobic fibers, or combinations thereof.
When the topsheet 124 comprises a nonwoven fibrous material in the form of a nonwoven web, the nonwoven web may be produced by any known procedure for making nonwoven webs, nonlimiting examples of which include spunbonding, carding, wet-laid, air-laid, meltblown, needle-punching, mechanical entangling, thermo-mechanical entangling, and hydroentangling. A specific example of a suitable meltblown process is disclosed in U.S. Pat. No. 3,978,185, to Buntin et al., issued Aug. 31, 1976. The nonwoven may be compression resistant as described in U.S. Pat. No. 7,785,690 entitled “Compression Resistant Nonwovens” issued on Aug. 31, 2010. The nonwoven web may have loops as described in U.S. Pat. No. 7,838,099 entitled “Looped Nonwoven Web” issued on Nov. 23, 2010.
Other suitable nonwoven materials include low basis weight nonwovens, that is, nonwovens having a basis weight of from about 18 g/m2 to about 25 g/m2. An example of such a nonwoven material is commercially available under the tradename P-8 from Veratec, Incorporation, a division of the International Paper Company located in Walpole, Mass. Other nonwovens are described in U.S. Pat. No. 5,792,404 and U.S. Pat. No. 5,665,452.
The topsheet 124 may comprise tufts as described in U.S. Pat. No. 8,728,049 entitled “Absorbent Article Having a Tufted Topsheet” issued on May 20, 2014, U.S. Pat. No. 7,553,532 entitled “Tufted Fibrous Web” issued on Jun. 30, 2009, U.S. Pat. No. 7,172,801 entitled “Tufted Laminate Web” issued on Feb. 6, 2007, or U.S. Pat. No. 8,440,286 entitled “Capped Tufted Laminate Web” issued on May 14, 2013. The topsheet may have an inverse textured web as described in U.S. Pat. No. 7,648,752 entitled “Inverse Textured Web” issued on Jan. 19, 2010. Tufts are also described in U.S. Pat. No. 7,410,683 entitled “Tufted Laminate Web” issued on Aug. 12, 2008.
The topsheet 124 may comprise one or more structurally modified zones as described in U.S. Pat. No. 8,614,365 entitled “Absorbent Article” issued on Dec. 24, 2013. The topsheet may have one or more out of plane deformations as described in U.S. Pat. No. 8,704,036 entitled “Sanitary Napkin for Clean Body Benefit” issued on Apr. 22, 2014. The topsheet 124 may have a masking composition as described in U.S. Pat. No. 6,025,535 entitled “Topsheet For Absorbent Articles Exhibiting Improved Masking Properties” issued on Feb. 15, 2000.
The absorbent core 128 may be any absorbent means capable of absorbing or retaining liquids (e.g., menses and/or urine). The absorbent core 128 may be manufactured in a wide variety of sizes and shapes (e.g., rectangular, oval, hourglass, dog bone, asymmetric, etc.) and from a wide variety of liquid-absorbent materials commonly used in sanitary napkins and other absorbent articles such as comminuted wood pulp which is generally referred to as airfelt. Examples of other suitable absorbent materials include creped cellulose wadding; meltblown polymers including coform; chemically stiffened, modified or cross-linked cellulosic fibers; synthetic fibers such as crimped polyester or polyolefin fibers; peat moss; tissue including tissue wraps and tissue laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling materials; or any equivalent material or combinations of materials, or mixtures of these. The absorbent core 128 may have more than one layer wherein each layer may be identical or distinct in one or more property or composition from another layer. A particularly preferred absorbent core 128 is made of thermally bonded airlaid material having less than 50 percent synthetic fibers. Synthetic fibers are preferred due to the ease with which they fuse together to join the core and topsheet as described below. A particularly preferred synthetic fiber is a bi-component material having a polyethylene sheath and a polypropylene center.
The configuration and construction of the absorbent core 128 may also be varied (e.g., the absorbent core may have varying caliper zones (e.g., profiled so as to be thicker in the center), hydrophilic gradients, superabsorbent gradients, or lower density and lower average basis weight acquisition zones; or may comprise one or more layers or structures). The total absorbent capacity of the absorbent core should, however, be compatible with the design loading and the intended use of the sanitary napkin. Further, the size and absorbent capacity of the absorbent core 128 may be varied to accommodate different uses such as incontinence pads, panty liners, regular sanitary napkins, or overnight sanitary napkins.
The fluid absorbent material can be constructed from any of a variety of materials commonly used in disposable absorbent articles. Examples of suitable absorbent materials include creped cellulose wadding, cotton fluff, and citric acid cross-linked cellulose pulp disclosed in U.S. Pat. No. 5,190,563, issued Mar. 2, 1993, U.S. Pat. No. 5,183,707, issued Feb. 2, 1993; and U.S. Pat. No. 5,137,537, issued Aug. 11, 1992, all issued to Herron et al.; synthetic fibers disclosed in U.S. Pat. No. 4,578,414, Sawyer, issued Mar. 25, 1986; absorbent foams, absorbent sponges, superabsorbent composites, superabsorbent foam, and super absorbent polymers. A preferred fluid absorbent material is comminuted and airlaid wood pulp fibers commonly referred to as absorbent fluff. An absorbent fluff having a density of from about 0.05 g to about 0.175 g per cm3 is generally acceptable.
The absorbent core structure may comprise a substrate and superabsorbent polymer layer as those described in U.S. Pat. No. 8,124,827 filed on Dec. 2, 2008 (Tamburro); U.S. application Ser. No. 12/718,244 published on Sep. 9, 2010; U.S. application Ser. No. 12/754,935 published on Oct. 14, 2010; or U.S. Pat. No. 8,674,169 issued on Mar. 18, 2014.
The backsheet 125 acts as a barrier to any absorbed bodily fluids that may pass through the absorbent core to the garment surface thereof with a resulting reduction in risk of staining undergarments or other clothing. Further, the barrier properties of the backsheet 125 permit manual removal, if a wearer so desires, of the interlabial absorbent article with reduced risk of hand soiling. A preferred material is a soft, smooth, compliant, liquid and vapor pervious material that provides for softness and conformability for comfort, and is low noise producing so that movement does not cause unwanted sound.
The backsheet 125 may comprise a wet laid fibrous assembly having a temporary wet strength resin incorporated therein as described in U.S. Pat. No. 5,885,265 (Osborn, III.) issued Mar. 23, 1999. The backsheet 125 may further be coated with a water resistant resinous material that causes the backsheet 125 to become impervious to bodily fluids without impairing the spreading of adhesive materials thereon.
Another suitable backsheet material is a polyethylene film having a thickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils). The backsheet 125 may be embossed and/or matte finished to provide a more clothlike appearance. Further, the backsheet 125 may permit vapors to escape from the absorbent core 42 (i.e., the backsheet is breathable) while still preventing body fluids from passing through the backsheet 125. A preferred microporous polyethylene film which is available from Tredegar Corporation, Virginia, USA, under Code No. XBF-1 12W.
Suitable breathable backsheets for use herein include all breathable backsheets known in the art. In principle there are two types of breathable backsheets, single layer breathable backsheets which are breathable and impervious to liquids and backsheets having at least two layers, which in combination provide both breathability and liquid imperviousness. Suitable single layer breathable backsheets for use herein include those described for example in GB A 2184 389, GB A 2184 390, GB A 2184 391, U.S. Pat. No. 4,591,523, U.S. Pat. No. 3,989,867, U.S. Pat. No. 3,156,242 and WO 97/24097.
The backsheet 125 may have two layers: a first layer comprising a gas permeable aperture formed film layer and a second layer comprising a breathable microporous film layer as described in U.S. Pat. No. 6,462,251 (Cimini) issued Oct. 8, 2002. Suitable dual or multi layer breathable backsheets for use herein include those exemplified in U.S. Pat. No. 3,881,489, U.S. Pat. No. 4,341,216, U.S. Pat. No. 4,713,068, U.S. Pat. No. 4,818,600, EP 203 821, EP 710 471, EP 710 472, and EP 793 952.
The backsheet 125 may be vapor permeable as described in U.S. Pat. No. 6,623,464 (Bewick-Sonntag) issued Sep. 23, 2003 or U.S. Pat. No. 6,664439 (Arndt) issued Dec. 16, 2003.
The backsheet 125 can be formed from any vapor permeable material known in the art. Backsheet 125 can be a microporous film, an apertured formed film, or other polymer film that is vapor permeable, or rendered to be vapor permeable, as is known in the art.
The backsheet 125 can be typically positioned adjacent the outer-facing surface of the absorbent core and can be joined thereto by any suitable attachment device known in the art. For example, the backsheet 125 may be secured to the absorbent core by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines, spirals, or spots of adhesive.
The absorbent article may also include such other suitable features as are known in the art including, but not limited to, re-closeable fastening system, lotion, acquisition layers, distribution layers, wetness indicators, sensors, elasticized waist bands and other similar additional elastic elements and the like, belts and the like, waist cap features, containment and aesthetic characteristics and combinations thereof.
Wings/FlapsSanitary napkins may have flaps 802 as shown in
Sanitary napkins having flaps of the various types are disclosed in U.S. Pat. No. 4,687,478, entitled “Shaped Sanitary Napkin With Flaps,” which issued to Van Tilburg on Aug. 18, 1987, U.S. Pat. No. 4,589,876, entitled “Sanitary Napkin,” which issued to Van Tilburg on May 20, 1986 and U.S. Pat. No. 5,389,094 entitled “Absorbent Article Having Flaps and Zones of Differential Extensibility,” which issued to Lavash et al. on Feb. 14, 1995.
The flaps 802 extend laterally outward beyond the longitudinal side edges of the main body portion from their proximal edges to their distal edges (or “free ends”). The flaps 802 extend outward from at least the central region of the main body portion. The flap transverse centerline may coincide with the principal transverse centerline of the absorbent article, but this is not absolutely required.
The flaps 802 can be joined to the main body portion in any suitable manner. The term “joined”, as used herein, encompasses configurations in which an element is directly secured to another element by affixing the element directly to the other element; configurations in which the element is indirectly secured to the other element by affixing the element to intermediate member(s) which in turn are affixed to the other element; and configurations in which one element is integral with another element, i.e., one element is essentially part of the other element.
The flaps 802 can comprise one or more separate components that are joined to the garment-facing side of the main body portion. Preferably, in such a case, the flaps each comprise a separate component that is joined to the garment-facing side of the main body portion. In such alternative embodiments, the flaps are preferably otherwise unattached to the garment-facing side of the main body portion of the absorbent article between the points where they are attached to the main body portion and the longitudinal side edges of the main body portion. The flaps 802 in these latter embodiments can be joined to the garment-facing side of the main body portion by any suitable attachment mechanism. Suitable attachment mechanisms include, but are not limited to adhesives, and the like.
The places or regions on the absorbent article where the flaps 802 are joined to (or extend from) the main body portion, are referred to herein as “junctures”. These regions will typically be longitudinally-oriented (or “longitudinal”) junctures, such as lines of juncture. These regions can be any of various curved or straight lines, but they are not limited to lines. Thus, the junctures can comprise flanges, strips, intermittent lines, and the like.
Flaps 802 may have zones of extensibility (or “zones of differential extensibility”) in the front half and the back half of each flap. The zones of extensibility relieve stresses which are created in flaps by the folding of the flaps around the crotch of the wearer's undergarment. The zones of extensibility thereby help eliminate bunching of flaps caused by said stresses. The zones of extensibility may comprise pre-corrugated or “ring rolled” regions of the flaps in which the corrugations define ridges and valleys that are oriented at an angle to the principal longitudinal centerline. Suitable structures for providing the flaps with zones of extensibility are described in greater detail in U.S. Pat. No. 5,389,094 issued to Lavash, et al.
The flaps 802 may be transparent as described in U.S. Pat. No. 8,491,554, “Transparent Absorbent Article” issued on Jul. 23, 2013.
The flaps 802 may be spaced apart flaps associated with the main body portion as described in U.S. Pat. No. 8,178,748 entitled “Absorbent Article” filed in the name of John Lee Hammons, issued on May 15, 2012. The article may have more than one set of flaps extending from the main body as described in U.S. Pat. No. 6,375, 645 entitled “Absorbent Article Wrapper Comprising A Side Flap Fastener Cover, issued on Apr. 23, 2002.
Each flap 802 may have an adhesive patch. Preferentially, such adhesive is associated with the face of the flap which contacts the undergarment of the wearer. Also the central portion of the absorbent article intermediate the flaps may have adhesive associated with the area of the central portion of the absorbent article which contacts the undergarment of the wearer. Preferentially such adhesive is joined to the outwardly oriented face of the backsheet 125.
A feminine absorbent article 801 may comprise flaps 802 and/or cuffs 150 formed at least in part by an elastomeric laminate 302 comprising a first plurality of elastics 316 disposed between first and second substrate layers. Such an elastomeric laminate 302 may have first plurality of elastics 316 comprising from about 10 to about 400 elastic strands having an Average-Strand-Spacing from about 0.25 mm to about 5 mm and an Average-Dtex of the first plurality of elastics 316 from about 10 to about 600.
In alternative embodiments of the elastomeric laminate 302 the first plurality of elastics 316 may comprise from about 15 to about 300 elastic strands. In other embodiments, the first plurality of elastics 316 may comprise from about 20 to about 225 elastic strands. In yet other alternative embodiments, the first plurality of elastics 316 may comprise from about 25 to about 150 elastic strands.
In certain embodiments, the first plurality of elastics 316 may have an Average-Strand-Spacing from about 0.25 mm to about 3.0 mm. In other embodiments, the first plurality of elastics 316 has an Average-Strand-Spacing from about 0.5 mm to about 2.0 mm.
In some embodiments, the Average-Dtex of the first plurality of elastics 316 may be from about 30 to about 400 and in alternative embodiments, the Average-Dtex of the first plurality of elastics 316 may be from about 50 to about 250.
In certain embodiments, the feminine absorbent article 801 may comprise leg cuff like structures disposed at or adjacent the side edges of the article as shown in
The absorbent article may have one or more graphics as shown in
Referring to
The elastomeric laminates 302 made according to the processes and apparatuses 301 discussed herein may be used as to construct various types of components used in the manufacture of different types of absorbent articles 100, such as diaper pants and taped diapers. To help provide additional context to the subsequent discussion of the absorbent article embodiments, the following provides a general description of absorbent articles 100 in the form of diapers and/or pants that include components comprising the elastomeric laminates 302 disclosed herein.
In some assembly processes, stretched elastic strands 316 may be advanced in a machine direction and may be adhered between two advancing substrates, wherein the stretched elastic strands 316 are spaced apart from each other in a cross direction. Some assembly processes are also configured with several elastic strands 316 that are very closely spaced apart from each other in the cross direction. In some configurations, close cross directional spacing between elastic strands 316 can be achieved by drawing elastic strands 316 from windings that have been stacked in the cross direction on a beam 314 (e.g., a warp beam). For example, various textile manufacturers may utilize beam elastics and associated handling equipment, such as available from Karl Mayer Corporation. It may be desirable to treat the elastic strands of the beam(s) with silicone oil because it avoids blocking (cross-linking) when the strands are wound to a spool or a beam and because it also lowers the COF for the strand in textile machinery (for weaving, knitting and warping processes).
As illustrated herein, the apparatuses 301 and processes may be configured such that elastic strands 316 may be advanced from the beams 314 and directly to the assembly process without having to touch additional machine components, such as for example, guide rollers. It is also to be appreciated that in some configurations, elastic strands 316 may be advanced from the beams 314 and may be redirected and/or otherwise touched by and/or redirected before advancing to the assembly process. For example, the process may have a first beam 314a with a rotation axis in a first cross direction CD1. As the first beam 314a rotates, the first plurality of elastic strands 316a advance from the first beam 314a in a first machine direction MD1 with the first elastic strands 316a being spaced apart from each other in the first cross direction CD1. The elastic strands 316 may then be redirected by rollers from the first machine direction MD1 to a second machine direction MD2, wherein the elastic strands 316 may remain separated from each other in a second cross direction CD2. From the rollers, the elastic strands 316 may advance in the second machine direction MD2 to be combined with the first and second substrates, 306, 308 to form the elastomeric laminate 302. It is to be appreciated that for processes comprising multiple beams, the first and/or second beams 314a, 314b may be arranged and/or oriented such that the beam rotation axis 346 may be parallel, perpendicular, or otherwise angularly offset with respect to the machine direction advancement of the elastomeric laminate 302 and/or the first and/or second substrates 306, 308. It should also be appreciated that the elastomeric laminate 302 may comprise more than a first substrate 306 and a second substrate 308, i.e. a third substrate and/or a fourth substrate. In such embodiments, a first set of elastic strands 316a from a first beam 314a may be disposed between a first substrate 306 and a second substrate 308 and a second set of elastic strands 316b from a second beam 314b may be disposed between a second substrate 308 and a third substrate providing an elastomeric laminate 302 with elastic strands 316 disposed in multiple, separate, layers of the laminate.
It is to be appreciated that the apparatuses 301 herein may be configured in various ways with various features described herein to assemble elastomeric laminates 302 having various stretch characteristics. For example,
With continued reference to
As illustrated herein, the apparatuses and processes may be configured such that elastic strands may be advanced from the beams and directly to the assembly process without having to touch additional machine components, such as for example, guide rollers. It is also to be appreciated that in some configurations, elastic strands may be advanced from beams and may be redirected and/or otherwise touched by and/or redirected before advancing to the assembly process. For example,
As shown in
As shown in
As shown in
With continued reference to
As previously discussed, the apparatus 301 includes the second plurality of elastic strands 316b configured to replace the first plurality of elastics 316a once the first beam 314a is completely depleted or nearly depleted of first elastics 316a. As shown in
As previously mentioned, the elastomeric laminate 302 may also be subject to additional converting processes. Such additional converting processes may incorporate the elastomeric laminate 302 into discrete absorbent articles 100. As such, an inspection system may be configured to detect and/or track a defective length of the elastomeric laminate 302. A defective length of elastomeric laminate 302 may be defined by a length of elastomeric laminate 302 that includes both the first elastic strands 316a and the second elastics 316b positioned together between the first and second substrates 306, 308. A defective length of elastomeric laminate 302 may also be defined by a length of elastomeric laminate 302 that includes the splicer member 354, leading ends 356 of the second elastics 316b, and/or the trailing ends 358 of the first elastics 316a. The inspection system may also correlate inspection results and measurements from the defect length of the elastomeric laminate 302 with absorbent articles 100 made therefrom. In turn, the inspection system may be used to control a reject system on a converting process of absorbent articles, wherein absorbent articles manufactured with portions of the defective length of elastomeric laminate 302 are rejected. In some configurations, defective articles may be subject to the rejection system and removed from the assembly process. Absorbent articles 100 that are not deemed to be defective may be subject to further processing steps, such as folding and packaging. It is to be appreciated that such an inspection system may be configured in various ways, such as disclosed in U.S. Patent Publication No. 2013/0199696 A1.
As previously mentioned, absorbent articles according to the present disclosure may comprise elastomeric laminates that may be used to construct various components of taped and/or pant diapers, such as a pair of laterally opposing inner leg cuffs, a pair of laterally opposing outer leg cuffs, a back belt, a front belt, a pair of laterally opposing side panels, a pair of laterally opposing ear panels, a back waistband, a front waistband, front and/or back waist caps, and discrete expansion panels disposed in areas overlapping the center chassis and the like.
It is to be appreciated that different components may be used to construct the elastomeric laminates 302 in accordance with the methods and apparatuses herein. For example, the first and/or second substrates 306, 308 may include nonwovens and/or films. In addition, the first and/or second elastics 316a, 316b may be configured in various ways and having various decitex values. In some configurations, the first and/or second plurality of elastics 316a, 316b may be configured with decitex values ranging from about 10 decitex to about 500 decitex, specifically reciting all 1 decitex increments within the above-recited range and all ranges formed therein or thereby. It is also to be appreciated the first beam 314a and the second beam 314b may be configured in various ways and with various quantities of elastic strands, types of elastic strands and/or colors of elastic strands. Example beams, also referred to as warp beams, that may be used with the apparatus and methods herein are disclosed in U.S. Pat. Nos. 4,525,905; 5,060,881; and 5,775,308; and U.S. Patent Publication No. 2004/0219854 A1. Although
Furthermore, the plurality of elastics 316 may be joined to one or both of the first substrate 306 and second substrate 308 by means of adhesive bonding, mechanical bonding, thermal bonding, ultrasonic bonding or other lamination means known in the art, including elastics that have been treated with silicone oil. The first and second substrates 306 and 308 may be melted around the elastic strands (by, for example, ultrasonic bonding the first and second substrates)—see Attorney Docket No, 14918P (U.S. Ser. No. 62/553,171), filed on Sep. 1, 2017, first-named inventor Uwe Schneider, assigned to The Procter & Gamble Company. Melting the first and second substrates 306 and 308 together may be desirable for overcoming the anti-stick properties of the elastics of silicone oil placed on the strands. Alternatively, the first and second substrates 306 and 308 may be bonded in between elastic strands comprising silicone oil. Further, lines of adhesives may also be used between first and second substrates 306 and 308 as described in Attorney Docket No, 14917P (U.S. Ser. No. 62/553,149), filed on Sep. 1, 2017, first-named inventor Uwe Schneider, assigned to The Procter & Gamble Company. Still further, silicone oil may be removed from the elastic strands to allow for better bonding of the elastic strands to the first and second substrates 306 and 308 as disclosed in Attorney Docket No, 14778P (62/483,965), filed on Apr. 11, 2017, first-named inventor Uwe Schneider, assigned to The Procter & Gamble Company. One or more of the bonding methods described and referenced in this paragraph may be used with elastic strands comprising from about 10%, about 7%, about 5%, about 3%, or about 1% silicone oil.
In addition, the first substrate 306 and/or second substrate 308 may have a material basis weight of from about 6 grams per square meter to about 30 grams per square meter. It should also be understood that the elastomeric laminates 302 described herein may have a uniform elastic pattern, decitex, spacing and pre-strain or may alternatively have multiple zones that may be supplied via multiple beams 314 having comprising varying compositions of elastic type, decitex, spacing or pre-strain.
It is the process disclosed in this PROCESS section of the present application that forms the elastomeric laminate 302 of the present disclosure and that may be further incorporated into the various absorbent article components such as the belts, ear panels, side panels, transverse barriers, topsheets, backsheets, cuffs, waistbands, waistcaps, and/or chassis to offer the benefits described in this patent application. Further details of the process of creating beamed elastomeric laminate(s) for use in disposable absorbent articles are disclosed in U.S. Publication Number 62/436,589, titled “METHODS AND APPARATUSES FOR MAKING ELASTOMERIC LAMINATES WITH ELASTIC STRANDS UNWOUND FROM BEAMS,” first-named inventor being Schneider, filed on Dec. 20, 2016. The elastomeric laminate 302 may be produced as part of the absorbent article manufacturing line, or may be produced offline, and unwound as an elastomeric laminate that is fed into the absorbent article manufacturing line.
Elastomeric Laminate(s) of the Present DisclosureAn “elastomeric laminate 302” of the present disclosure may comprise a plurality of elastics 316 between a first substrate 306 and a second substrate layer 308, where the plurality of elastics 316 (often referred to as a “first plurality of elastics,” a “second plurality of elastics,” etc.) has an Average-Strand-Spacing from about 0.25 mm to about 4 mm, an Average-Dtex from about 10 to about 500, and a Pressure-Under-Strand from about 0.1 to about 1 psi. Ultimately, “plurality of elastics” is a term of context, where certain properties, arrangements, attributes, characteristics, etc. define what a certain “plurality of elastics” is. Said elastomeric laminate 302 may be used to form at least a portion of various absorbent article components. When the elastomeric laminate 302 forms at least a portion of at least one of the group consisting of a belt, a chassis, a side panel, a topsheet, a backsheet, an ear panel, and combinations thereof, the plurality of elastics 316 of the elastomeric laminate 302 may comprise from about 40 to about 1000 elastic strands. And, when the elastomeric laminate 302 forms at least a portion of at least one of the group consisting of a waistband, a waistcap, an inner leg cuff, an outer leg cuff, a transverse barrier, and combinations thereof, the first plurality of elastics 316 of the elastomeric laminate 302 may comprise from about 10 to about 400 elastic strands. Ultimately, “plurality of elastics” is a term of context, where certain properties (e.g., Average-Dtex, Average-Strand-Spacing, Pressure-Under-Strand, etc.), arrangements, attributes, characteristics, disposition, etc. of the elastics are referenced to define what a certain “plurality of elastics” is.
Further, the elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a belt 430, a side panel 330, chassis 200, a topsheet 124, backsheet 125, and an ear panel 530, the elastomeric laminate 302 may comprise a plurality of elastics 316 having from about 40 to about 1000 elastic strands with an Average-Strand-Spacing from about 0.25 mm to about 4 mm, Average-Dtex from about 10 to about 500, an Average-Pre-Strain from about 50% to about 400%; and a first substrate 306 and a second substrate 308 each having a basis weight from about 6 grams per square meter to about 30 grams per square meter.
When the elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a belt 430, a side panel 330, chassis 200, a topsheet 124, backsheet 125, and an ear panel 530, the elastomeric laminate 302 may comprise a plurality of elastics 316 having from about 50 to about 825 elastic strands. Further, the plurality of elastics 316 may comprise from about 100 to about 650 elastic strands. Still further, the plurality of elastics 316 may comprise from about 150 to about 475 elastic strands.
When the elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a belt 430, a side panel 330, chassis 200, a topsheet 124, backsheet 125, and an ear panel 530, the elastomeric laminate 302 may comprise a plurality of elastics 316 having an Average-Strand-Spacing from about 0.5 mm to about 3.5 mm. Further, the plurality of elastics 316 may have an Average-Strand-Spacing from about 1.0 mm to about 2.5 mm.
When the elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a belt 430, a side panel 330, chassis 200, a topsheet 124, backsheet 125, and an ear panel 530, the elastomeric laminate 302 may comprise a plurality of elastics 316 having an Average-Dtex from about 30 to about 400. Further, the elastomeric laminate 302 may have an Average-Dtex of the plurality of elastics 316 from about 50 to about 250.
When the elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a belt 430, a side panel 330, chassis 200, a topsheet 124, backsheet 125, and an ear panel 530, the elastomeric laminate 302 may comprise a plurality of elastics 316 having an Average-Pre-Strain which may be from about 75% to about 300%. Further, the elastomeric laminate may comprise a plurality of elastics 316 with an Average-Pre-Strain of from about 100% to about 250%
The elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and a transverse barrier 16, and may comprise a plurality of elastics 316 having from about 10 to about 400 elastic strands with an Average-Strand-Spacing from about 0.25 mm to about 4 mm, Average-Dtex from about 10 to about 500, an Average-Pre-Strain from about 50% to about 400% and a first substrate 306 and/or second substrate 308 each having a basis weight from about 6 grams per square meter to about 30 grams per square meter.
The elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and a transverse barrier 16, and may comprise a plurality of elastics 316 having from about 15 to about 300 elastic strands. Further, the plurality of elastics 316 may comprise from about 20 to about 225 elastic strands. Further, the plurality of elastics may 316 comprise from about 25 to about 150 elastic strands.
The elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and a transverse barrier 16, and may comprise a plurality of elastics 316 having an Average-Strand-Spacing from about 0.5 mm to about 3.0 mm. Further, the plurality of elastics 316 may have an Average-Strand-Spacing from about 0.75 mm to about 2.5 mm.
The elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and a transverse barrier 16, and may comprise a plurality of elastics 316 having an Average-Dtex from about 30 to about 400. Alternatively, the plurality of elastics 316 of the elastomeric laminate 302 may have an Average-Dtex from about 50 to about 250.
The elastomeric laminate 302 may form at least a portion of one or more of the group of article components including a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and a transverse barrier 16, and may comprise a plurality of elastics 316 having an Average-Pre-Strain from about 75% to about 300%. Alternatively, the elastomeric laminate may comprise elastic elements with an Average-Pre-Strain of from about 100% to about 250%.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate 302 comprising a plurality of elastics 316 having Pressure-Under-Strand from about 0.1 psi to about 1 psi, or from about 0.2 psi to about 0.8 psi.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising an Air Permeability at 0 gf/mm (no extension) of greater than about 40 cubic meters/square meter/minute and/or a level of Air Permeability at 3 gf/mm (slight extension) of greater than about 60 cubic meters/square meter/minute and/or a level of Air Permeability at 7 gf/mm (moderate extension) of greater than about 80 cubic meters/square meter/minute.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Water Vapor Transmission Rate of greater than 2000 g/m2/24 hrs, greater than 4000 g/m2/24 hrs or greater than 6000 g/m2/24 hrs.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising an Open Area greater than about 70%, greater than about 80%, greater than about 90%.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate having a Caliper at 0 gf/mm (no extension) of from about 0.5 mm to about 4 mm and/or a Caliper Retention Value at 3 gf/mm (slight extension) of from about 60% to about 95% and/or a Caliper Retention Value at 7 gf/mm (moderate extension) of from about 40% to about 90%
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Cantilever Bending of less than about 40 mm or alternatively less than about 35 mm in other embodiments the Cantilever Bending may be less than 30 mm or alternatively less than 25 mm. The elastomeric laminate 302 of the present disclosure may have Cantilever Bending of from about 15 mm to about 30 mm.
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Percent Contact Area of greater than about 13% at 100 um and/or greater than about 27% at 200 um and/or greater than about 39% at 300 um and/or a 2%-98% Height Value of <1.6 mm. Alternatively, any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Percent Contact Area of greater than about 10% at 100 um and/or greater than about 20% at 200 um and/or greater than about 30% at 300 um and/or a 2%-98% Height Value of <2.2 mm. Comparative difference in Percent Contact Area are show in
Any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising a Rugosity Frequency of from about 0.2 mm−1 to about 1 mm−1 and a Rugosity Wavelength of from about 0.5 mm to about 5 mm.
It is also to be appreciated that any one of the belt 430, side panel 330, ear panel 530, chassis 200, topsheet 124, backsheet 125, waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 or transverse barrier may comprise an elastomeric laminate comprising one or more of the parametric values and ranges cited herein above.
An absorbent article of the present disclosure may have an elastomeric laminate 302 forming at least a portion of one or more of a belt 430, side panel 330, ear panel 530, waistband 122, chassis 200, topsheet 124 and backsheet 125. The elastomeric laminate 302 may comprise a plurality of elastics 316 having a specific Average-Dtex, nonwoven type, nonwoven basis weight, Average-Strand-Spacing and Average-Pre-Strain. And, the article may comprise two or more absorbent article components (including a belt 430, side panel 330, ear panel 530, waistband 122, chassis 200, topsheet 124 and backsheet 125) comprising an elastomeric laminate 302 having one or more identical or substantially identical laminate elements (including Average-Dtex, nonwoven type, nonwoven basis weight, Average-Strand-Spacing and Average-Pre-Strain).
Beyond the beamed elastic strands 316 that may be used in each of the absorbent article components, other elastic components such as elastic nonwovens, elastomeric films, elastomeric foams, elastomeric scrims, and elastomeric ribbons, or combinations thereof, may be used with the beamed elastics 316.
In one embodiment, an absorbent article comprising an elastomeric laminate 302 and the elastomeric laminate may form at least a portion of one or more of the group of article components including a belt 430, a side panel 330, chassis 200, a topsheet 124, backsheet 125, and an ear panel 530. The elastomeric laminate 302 may comprise a plurality of elastics 316 having from about 40 to about 1000 elastic strands or from about 100 to about 650 elastic strands or from about 150 to about 475 elastic strands. The plurality of elastics 316 may have an Average-Strand-Spacing from about 0.25 mm to about 4 mm or from about 0.5 mm to about 3.5 mm or from about 0.75 mm to about 2.5 mm. The plurality of elastics 316 may comprise elastic having an Average-Dtex from about 10 to about 500 or from about 30 to about 400 or from about 50 to about 250. The plurality of elastic 316 may also have an Average-Pre-Strain from about 50% to about 400% or from about 75% to about 300% or from about 100% to about 250%. The elastomeric laminate may also comprise a first substrate layer 306 and/or a second substrate layer 308 wherein each may have a basis weight from about 6 grams per square meter to about 30 grams per square meter. The elastomeric laminate 302 comprising the plurality of elastics 316 may have Pressure-Under-Strand from about 0.1 psi to about 1 psi, or from about 0.2 psi to about 0.8 psi. The elastomeric laminate may comprise an Air Permeability at 0 gf/mm (no extension) of greater than about 40 cubic meters/square meter/minute and/or a level of Air Permeability at 3 gf/mm (slight extension) of greater than about 60 cubic meters/square meter/minute and/or a level of Air Permeability at 7 gf/mm (moderate extension) of greater than about 80 cubic meters/square meter/minute. The elastomeric laminate may comprise a Water Vapor Transmission Rate of greater than 2000 g/m2/24 hrs, greater than 4000 g/m2/24 hrs or greater than 6000 g/m2/24 hrs. The elastomeric laminate having a Caliper at 0 gf/mm (no extension) of from about 0.5 mm to about 4 mm and/or a Caliper Retention Value at 3 gf/mm (slight extension) of from about 60% to about 95% and/or a Caliper Retention Value at 7 gf/mm (moderate extension) of from about 40% to about 90%. The elastomeric laminate may comprise a Cantilever Bending of less than about 40 mm, alternatively less than about 35 mm. The elastomeric laminate may also comprise a Percent Contact Area of greater than about 10% at 100 um and/or greater than about 20% at 200 um and/or greater than about 28% at 300 um and/or a 2%-98% Height Value of <1.8 mm. Alternatively, the elastomeric laminate may comprise a Percent Contact Area of greater than about 11% at 100 um and/or greater than about 28% at 200 um and/or greater than about 51% at 300 um and/or a 2%-98% Height Value of <1.6 mm. The elastomeric laminate having a Rugosity Frequency of from about 0.2 mm−1 to about 1 mm−1 and a Rugosity Wavelength of from about 0.5 mm to about 5 mm. In alternative embodiments, the elastomeric laminate may comprise a Rugosity Frequency from about 0.2 mm−1 to about 0.85 mm−1 and Rugosity Wavelengths of from about 1.2 mm to about 5 mm. The elastomeric laminate may also have a Section-Modulus of from about 2 gf/mm to about 15 gf/mm, alternatively from about 3 gf/mm to about 12 gf/mm, in alternative embodiments from about 4 gf/mm to about 10 gf/mm. The elastomeric laminate may also have an Open Area of greater than about 60%, alternatively greater than about 75% or greater than about 90%.
In another embodiment, an absorbent article comprising an elastomeric laminate 302 and the elastomeric laminate may form at least a portion of one or more of the group of article components including a waistband 122, waistcap 123, inner leg cuff 150, outer leg cuff 140 and a transverse barrier 16. The elastomeric laminate 302 may comprise a plurality of elastics 316 having from about 10 to about 400 elastic strands or from about 15 to about 300 elastic strands or from about 20 to about 225 elastic strands or from about 25 to about 150 elastic strands. The plurality of elastics 316 may have an Average-Strand-Spacing from about 0.25 mm to about 4 mm or from about 0.5 mm to about 3.5 mm or from about 0.75 mm to about 2.5 mm. The plurality of elastics 316 may comprise elastic having an Average-Dtex from about 10 to about 500 or from about 30 to about 400 or from about 50 to about 250. The plurality of elastic 316 may also have an Average-Pre-Strain from about 50% to about 400% or from about 75% to about 300% or from about 100% to about 250%. The elastomeric laminate may also comprise a first substrate layer 306 and/or a second substrate layer 308 wherein each may have a basis weight from about 6 grams per square meter to about 30 grams per square meter. The elastomeric laminate 302 comprising the plurality of elastics 316 may have Pressure-Under-Strand from about 0.1 psi to about 1 psi, or from about 0.2 psi to about 0.8 psi. The elastomeric laminate may comprise an Air Permeability at 0 gf/mm (no extension) of greater than about 40 cubic meters/square meter/minute and/or a level of Air Permeability at 3 gf/mm (slight extension) of greater than about 60 cubic meters/square meter/minute and/or a level of Air Permeability at 7 gf/mm (moderate extension) of greater than about 80 cubic meters/square meter/minute. The elastomeric laminate may comprise a Water Vapor Transmission Rate of greater than 2000 g/m2/24 hrs, greater than 4000 g/m2/24 hrs or greater than 6000 g/m2/24 hrs. The elastomeric laminate having a Caliper at 0 gf/mm (no extension) of from about 0.5 mm to about 4 mm and/or a Caliper Retention Value at 3 gf/mm (slight extension) of from about 60% to about 95% and/or a Caliper Retention Value at 7 gf/mm (moderate extension) of from about 40% to about 90%. The elastomeric laminate may comprise a Cantilever Bending of less than about 40 mm, alternatively less than about 35 mm. The elastomeric laminate may also comprise a Percent Contact Area of greater than about 10% at 100 um and/or greater than about 20% at 200 um and/or greater than about 28% at 300 um and/or a 2%-98% Height Value of <1.8 mm. Alternatively, the elastomeric laminate may comprise a Percent Contact Area of greater than about 11% at 100 um and/or greater than about 28% at 200 um and/or greater than about 51% at 300 um and/or a 2%-98% Height Value of <1.6 mm. The elastomeric laminate having a Rugosity Frequency of from about 0.2 mm−1 to about 1 mm−1 and a Rugosity Wavelength of from about 0.5 mm to about 5 mm. In alternative embodiments, the elastomeric laminate may comprise a Rugosity Frequency from about 0.2 mm−1 to about 0.85 mm−1 and Rugosity Wavelengths of from about 1.2 mm to about 5 mm. The elastomeric laminate may also have a Section-Modulus of from about 2 gf/mm to about 15 gf/mm, alternatively from about 3 gf/mm to about 12 gf/mm, in alternative embodiments from about 4 gf/mm to about 10 gf/mm. The elastomeric laminate may also have an Open Area of greater than about 60%, alternatively greater than about 75% or greater than about 90%.
In another embodiment, an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and an elastomeric laminate 302 joined to the chassis 200 whereby the elastomeric laminate 302 comprises a first plurality of elastics 316 disposed between first and second substrate layers 306 and 308. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a chassis 200, belt 430, a side panel 330, topsheet 124, backsheet 125 and an ear panel 530. The first plurality of elastics 316 of the elastomeric laminate 302 may comprise from about 40 to about 1000 elastic strands disposed at an Average-Strand-Spacing from about 0.25 mm to about 4 mm having an Average-Dtex from about 10 to about 600 thereby providing an Pressure-Under-Strand from about 0.1 to about 1 psi. The elastomeric laminate 302 may also have an Air Permeability at 0 gf/mm of from about 40 to about 120 m3/m2/min.
In an alternative embodiment, the absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and an elastomeric laminate 302 joined to the chassis 200 whereby the elastomeric laminate 302 comprises a first plurality of elastics 316 disposed between first and second substrate layers 306 and 308. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a chassis 200, belt 430, a side panel 330, topsheet 124, backsheet 125 and an ear panel 530. The first plurality of elastics 316 of the elastomeric laminate 302 may comprise from about 100 to about 600 elastic strands disposed at an Average-Strand-Spacing from about 0.5 mm to about 2.5 mm having an Average-Dtex from about 25 to about 250 thereby providing an Pressure-Under-Strand from about 0.2 to about 0.8 psi. The elastomeric laminate 302 may also have an Air Permeability at 3 gf/mm of from about 50 to about 150 m3/m2/min.
In another embodiment, an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and an elastomeric laminate 302 joined to the chassis 200 whereby the elastomeric laminate 302 comprise a first plurality of elastics 316 disposed between first and second substrate layers 306 and 308. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a waistband 122, a waistcap 123, an inner leg cuff 150, an outer leg cuff 140, and a transverse barrier 165. The first plurality of elastics 316 of the elastomeric laminate 302 may comprise from about 10 to about 400 elastic strands disposed at an Average-Strand-Spacing from about 0.25 mm to about 5 mm having an Average-Dtex from about 10 to about 600 thereby providing a Pressure-Under-Strand from about 0.1 to about 1 psi. The elastomeric laminate 302 may also have an Air Permeability at 0 gf/mm of from about 40 to about 120 m3/m2/min.
In an alternative embodiment, the absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and an elastomeric laminate 302 joined to the chassis 200 whereby the elastomeric laminate 302 comprise a first plurality of elastics 316 disposed between first and second substrate layers 306 and 308. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a waistband 122, a waistcap 123, an inner leg cuff 150, an outer leg cuff 140, and a transverse barrier 165. The first plurality of elastics 316 of the elastomeric laminate 302 may comprise from about 20 to about 225 elastic strands disposed at an Average-Strand-Spacing from about 0.5 mm to about 2.0 mm having an Average-Dtex from about 50 to about 250 thereby providing an Pressure-Under-Strand from about 0.1 to about 1 psi. The elastomeric laminate 302 may also have an Air Permeability at 0 gf/mm of from about 50 to about 150 m3/m2/min.
In another embodiment, an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125, the chassis further comprises a front waist region and a back waist region. The absorbent article 100 may comprise a back belt 430 joined to the back waist region 38 of the chassis 200. The back belt 430 extending outboard of the back waist region 38 of the chassis 200. The back belt 430 is formed at least in part by an elastomeric laminate 302 comprising a first plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308 the first plurality of elastics 316 comprising greater than about 40 elastic strands having an Average-Strand-Spacing of less than 4 mm. The first plurality of elastics 316 of the belt is disposed between first and second substrate layers, wherein the substrate layers may have differences in composition, polymer type, fiber diameter, fiber shape, bond pattern, color, nonwoven type (e.g. spunbond, carded, etc.) and/or basis weight. The back belt 430 may be joined at or adjacent the side edges of the belt 437 to another portion of the absorbent article 100 to form a closed-form pant. Alternatively, the back belt 430 at or adjacent the end edges 437 may remain unattached, e.g. unfastened, to other parts of the absorbent article 100 and thus may be packaged in an open-form.
In another embodiment, an absorbent article 100 may comprise a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125, the chassis further comprising a front waist region and a back waist region. The absorbent article 100 may comprise a front belt 430F joined to the front waist region and a back belt 430B joined to the back waist region 38 of the chassis 200. The front belt 430F extending outboard of the front waist region 36 of the chassis 200 and the back belt 430B extending outboard of the back waist region 38 of the chassis 200. The back belt 430B may be formed at least in part by an elastomeric laminate 302 comprising a first plurality of elastics 316a disposed between a first substrate layer 306 and a second substrate layer 308 the first plurality of elastics 316a comprising greater than about 40 elastic strands having an Average-Strand-Spacing of less than 4 mm and Average-Pre-Strain from about 75% to about 300%. The first plurality of elastics 316a of the back belt 430B is disposed between first and second substrate layers 306 and 308, wherein the substrate layers may have differences in composition, polymer type, fiber diameter, fiber shape, bond pattern, color, nonwoven type (e.g. spunbond, carded, etc.) and/or basis weight. The front belt 430F may be formed at least in part by an elastomeric laminate 302 comprising a second plurality of elastics 316b disposed between a first substrate layer 306 and a second substrate layer 308 the second plurality of elastics 316b comprising greater than about 40 elastic strands having an Average-Strand-Spacing of less than 4 mm and Average-Pre-Strain from about 75% to about 300%. The second plurality of elastics 316b of the front belt 430F is disposed between first and second substrate layers 306 and 308, wherein the substrate layers may have differences in composition, polymer type, fiber diameter, fiber shape, bond pattern, color, nonwoven type (e.g. spunbond, carded, etc.) and/or basis weight. The front belt 430F and back belt 430B may be joined to each other at or adjacent the respective side edges of the belt 437 to form a closed-form pant. Alternatively, the front belt 430F and back belt 430B may remain unattached, e.g. unfastened, at or adjacent the end edges 437 and thus may be packaged in an open-form. The first plurality of elastics 316a and the second plurality of elastics 316b may have one or more of substantially the same number of elastics, substantially the same Average-Strand-Spacing, substantially the same Average-Pre-Strain and/or Average-Dtex. Alternatively, the first plurality of elastics 316a and the second plurality of elastics 316b may have one or more of a different number of elastics, different Average-Strand-Spacing, different Average-Pre-Strain and/or different Average-Dtex.
In another embodiment, an absorbent article 100, comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125. The absorbent article having first and second side panels 330 wherein the proximal side edges of the side panels 330 are joined to the chassis 200 at or adjacent the laterally opposing side edges 237 of the chassis 200 in the back waist region 38. The first and second side panels 330 may comprise an elastomeric laminate 302 having a first plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308. The first plurality of elastics 316 comprising greater than about 40 elastic strands and an Average-Strand-Spacing of less than 4 mm. The absorbent article 100 may also comprise a waistband 122 disposed in the back waist region 38 of the center chassis 200 between but not overlapping with the first and second side panels 330. Alternatively, the waistband 122 may overlap with a portion of the first and second side panels 330. The waistband 122 may comprise an elastomeric laminate 302 having a plurality of elastics 316 comprising greater than about 10 elastic strands having an Average-Strand-Spacing of less than 4 mm and an Average-Pre-Strain from about 75% to about 300%. 19. The first and second substrate layers 306 and 308 may each have a basis weight from about 6 grams per square meter to about 30 grams per square meter. The absorbent article 100 may also comprise a waistband 122 disposed in the back waist region 38 of the center chassis 200 between but not overlapping with the first and second side panels 330. Alternatively, the waistband 122 may overlap with a portion of the first and second side panels 330. The waistband 122 may comprise an elastomeric laminate 302 having a plurality of elastics 316 comprising greater than about 10 elastic strands having an Average-Strand-Spacing of less than 4 mm and Average-Pre-Strain from about 75% to about 300%. 19. The first and second substrate layers 306 and 308 may each have a basis weight from about 6 grams per square meter to about 30 grams per square meter. The first and second side panels 330 may be joined to a portion of the absorbent article 100 at or adjacent the respective distal side edges of the of the side panel 330 to form a closed-form pant. Alternatively, the side panels 330 may remain unattached, e.g. unfastened, at or adjacent the distal side edges of the side panel and thus may be packaged in an open-form.
In another embodiment, an absorbent article 100, comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125. The absorbent article having first and second side panels 330 wherein the proximal side edges of the first and second side panels 330 are joined to the chassis 200 at or adjacent the laterally opposing side edges 237 of the chassis 200 in the back waist region 38. The first and second side panels 330 may comprise an elastomeric laminate 302 having a first plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308. The first plurality of elastics 316 comprising greater than about 50 elastic strands and an Average-Strand-Spacing of less than 2.5 mm and an Average-Pre-Strain from about 75% to about 300%. The absorbent article also having third and fourth side panels 330 wherein the proximal side edges of the third and fourth side panels 330 are joined to the chassis 200 at or adjacent the laterally opposing side edges 237 of the chassis 200 in the front waist region 36. The third and fourth side panels 330 may comprise an elastomeric laminate 302 having a second plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308. The second plurality of elastics 316 comprising greater than about 50 elastic strands and an Average-Strand-Spacing of less than 2.5 mm and an Average-Pre-Strain from about 75% to about 300%. The absorbent article 100 may also comprise a waistband 122 disposed in one or both of the front waist region 36 and the back waist region 38 of the center chassis 200 and the waistband 122 may be disposed between but not overlapping with the first, second, third or fourth side panels 330. Alternatively, the waistband 122 may overlap with a portion of one or more of the first, second, third and fourth side panels 330. The waistband 122 may comprise an elastomeric laminate 302 having a plurality of elastics 316 comprising greater than about 10 elastic strands having an Average-Strand-Spacing of less than 5 mm and Average-Pre-Strain from about 75% to about 300%. 19. The first and second substrate layers 306 and 308 may each have a basis weight from about 6 grams per square meter to about 30 grams per square meter. The first and second side panels 330 in the back waist region 38 may be joined to the third and fourth side panels 330 in the front waist region 36 at or adjacent their respective distal side edges to form a closed-form pant. Alternatively, the first and second side panels 330 may remain unattached, e.g. unfastened, to the third and fourth side panels 330 and thus may be packaged in an open-form.
In another embodiment, an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and one or more elastomeric laminates 302 joined to or forming a portion of the chassis 200. The elastomeric laminate 302 comprising a first plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308 wherein the first plurality of elastics 316 comprises greater than 40 elastic strands having an Average-Strand-Spacing of less than about 3 mm, an Average-Dtex of less than about 600, an Average-Pre-Strain of less than about 350%. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a belt 430, a side panel 330, a topsheet 124, backsheet 125 and an ear panel 530. The elastomeric laminate 302 may comprise one or more sections having a Section-Modulus of less than about 15 gf/mm, alternatively from about 3 gf/mm to about 12 gf/mm. The elastomeric laminate 302 having an Open Area greater than about 70%, alternatively from about 75% to about 90%. The elastomeric laminate 302 having a Pressure-Under-Strand of less than about 1.0 psi alternatively from about 0.2 psi to about 0.8 psi.
In another embodiment, an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and one or more elastomeric laminates 302 joined to or forming a portion of the chassis 200. The elastomeric laminate 302 comprising a first plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308 wherein the first plurality of elastics 316 comprises from about 42 to about 1000 elastic strands having an Average-Strand-Spacing from about 0.125 mm to about 2.9 mm, an Average-Dtex from about 10 to about 500 and an Average-Pre-Strain of less than about 150%. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a belt 430, a side panel 330, a topsheet 124, backsheet 125 and an ear panel 530. The elastomeric laminate 302 may comprise one or more sections having a Section-Modulus of less than about 15 gf/mm, alternatively from about 3 gf/mm to about 12 gf/mm. The elastomeric laminate 302 having an Open Area greater than about 70%, alternatively from about 75% to about 90%. The elastomeric laminate 302 having a Pressure-Under-Strand of less than about 1.0 psi alternatively from about 0.2 psi to about 0.8 psi.
In another embodiment, an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and one or more elastomeric laminates 302 joined to or forming a portion of the chassis 200. The elastomeric laminate 302 comprising a first plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308 wherein the first plurality of elastics 316 comprises from about 125 to about 625 elastic strands having an Average-Strand-Spacing of less than about 1.0 mm, an Average-Dtex from about 20 to about 350 and an Average-Pre-Strain from about 75% to about 300%. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a belt 430, a side panel 330, a topsheet 124, backsheet 125 and an ear panel 530. The elastomeric laminate 302 may comprise one or more sections having a Section-Modulus of less than about 15 gf/mm, alternatively from about 3 gf/mm to about 12 gf/mm. The elastomeric laminate 302 having an Open Area greater than about 70%, alternatively from about 75% to about 90%. The elastomeric laminate 302 having a Pressure-Under-Strand of less than about 1.0 psi alternatively from about 0.2 psi to about 0.8 psi.
In another embodiment, an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and one or more elastomeric laminates 302 joined to or forming a portion of the chassis 200. The elastomeric laminate 302 comprising a first plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308 wherein the first plurality of elastics 316 comprises from about 44 to about 350 elastic strands having an Average-Strand-Spacing from about 0.375 mm to about 2.7 mm, an Average-Dtex of less than about 155 and an Average-Pre-Strain from about 75% to about 300%. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a belt 430, a side panel 330, a topsheet 124, backsheet 125 and an ear panel 530. The elastomeric laminate 302 may comprise one or more sections having a Section-Modulus of less than about 15 gf/mm, alternatively from about 3 gf/mm to about 12 gf/mm. The elastomeric laminate 302 having an Open Area greater than about 70%, alternatively from about 75% to about 90%. The elastomeric laminate 302 having a Pressure-Under-Strand of less than about 1.0 psi alternatively from about 0.2 psi to about 0.8 psi.
In another embodiment, an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and one or more elastomeric laminates 302 joined to or forming a portion of the chassis 200. The elastomeric laminate 302 comprising a first plurality of elastics 316 disposed between a first substrate layer 306 and a second substrate layer 308 wherein the first plurality of elastics 316 comprises from about 10 to about 200 elastic strands having an Average-Strand-Spacing from about 0.25 mm to about 5 mm, an Average-Dtex from about 25 to about 500 and an Average-Pre-Strain from about 75% to about 300%. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a waistband 122, a waistcap 123, an inner leg cuff 150, an outer leg cuff 140, and a transverse barrier 165. The elastomeric laminate 302 may comprise one or more sections having a Section-Modulus of less than about 15 gf/mm, alternatively from about 3 gf/mm to about 12 gf/mm. The elastomeric laminate 302 having an Open Area greater than about 70%, alternatively from about 75% to about 90%. The elastomeric laminate 302 having a Pressure-Under-Strand of less than about 1.0 psi alternatively from about 0.2 psi to about 0.8 psi.
Surface TopographyIn the Surface Topography Method, an elastic laminate specimen is removed from an absorbent article and extended across and in contact with the convex surface of a transparent horizontal cylindrical tubing segment, allowing the areal surface topology of the body facing side of the laminate to be measured through the transparent tubing segment using optical profilometry. The 3D surface data are then sampled and processed to extract several parameters that describe the Percent Contact Area and 2-98% Height of the elastic laminate specimen surface as well as the Rugosity frequency and Rugosity Wavelength.
The epidermis is the outermost layer of the skin. Categorized into five horizontal layers, the epidermis actually consists of anywhere between 50 cell layers (in thin areas) to 100 cell layers (in thick areas). The average epidermal thickness is 0.1 millimeters or 100 micrometers, which is about the thickness of one sheet of paper. The dermis which is the layer immediately below the epidermis can have a thickness of between 1.0 mm and 1.5 mm. For comparison, we have selected a first setting to determine the Percent Contact Area corresponding with the thickness of the epidermis, 100 micrometers, a second setting at 2× the epidermis or 200 micrometers and a third setting at 3× the epidermis of 300 micrometers.
It is apparent from the surface topography measurements that the inventive elastomeric laminate 302 examples have significantly greater Percent Contact Area at 100 um (1.5× to 1.9×), 200 um (1.8× to 2.5×) and 300 um (1.9× to 2.7×) compared to the prior art structures in table 8 for both waistband 122 applications as well as belt 430 applications (see
In addition to surface topography, it is also important to ensure the skin maintains the proper level of hydration and does not become overly hydrated such as by occlusion. Overly hydrated skin such as skin that has been occluded especially in warmer climates can be more prone to skin marking and damage. Thus, it is also an objective of such inventive elastomeric laminate 302 to provide adequate breathability, Air Permeability through the structure, to help maintain the skin at the proper hydration level working collaboratively with the smooth surface of the inventive elastomeric laminate to provide optimum skin condition with no skin marking or damage. Therefore, it is desirable for the inventive elastomeric laminate 302 to have a level of Air Permeability at 0 gf/mm (no extension) of greater than about 40 cubic meters/square meter/minute and/or a level of Air Permeability at 3 gf/mm (slight extension) of greater than about 60 cubic meters/square meter/minute and/or a level of Air Permeability at 7 gf/mm (moderate extension) of greater than about 80 cubic meters/square meter/minute.
Therefore, it would be beneficial to have an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and an elastomeric laminate 302 joined to the chassis 200 whereby the elastomeric laminate 302 comprises a first plurality of elastics 316 disposed between first and second substrate layers 306 and 308. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a belt 430, a side panel 330, topsheet 124, and an ear panel 530. The elastomeric laminate 302 may have a percent surface contact at 100 um of greater than about 10% and/or a percent surface contact at 200 um of greater than about 20% and/or a percent surface contact at 300 um or greater than about 28%. In addition, the elastomeric laminate 302 may have a 2%-98% Height Value of less than about 1.6. The elastomeric laminate 302 may have a level of Air Permeability at 0 gf/mm (no extension) of from about 40 cubic meters/square meter/minute to about 80 cubic meters/square meter/minute and/or a level of Air Permeability at 3 gf/mm (slight extension) of from about 60 cubic meters/square meter/minute to about 120 cubic meters/square meter/minute and/or a level of Air Permeability at 7 gf/mm (moderate extension) of from about 80 cubic meters/square meter/minute to about 160 cubic meters/square meter/minute. The elastomeric laminate 302 may also have an Air Permeability at 0 gf/mm of from about 40 to about 120 m3/m2/min.
It would also be beneficial to have an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and an elastomeric laminate 302 joined to the chassis 200 whereby the elastomeric laminate 302 comprises a first plurality of elastics 316 disposed between first and second substrate layers 306 and 308. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a waistband 122, a waistcap 123, an inner leg cuff 150, an outer leg cuff 140, and a transverse barrier 165. The elastomeric laminate 302 may have a percent surface contact at 100 um of greater than about 13% and/or a percent surface contact at 200 um of greater than about 27% and/or a percent surface contact at 300 um of greater than about 39%. In addition, the elastomeric laminate 302 may have a 2%-98% Height Value of less than about 1.6. The elastomeric laminate 302 may have a level of Air Permeability at 0 gf/mm (no extension) of greater than about 40 cubic meters/square meter/minute and/or a level of Air Permeability at 3 gf/mm (slight extension) of greater than about 60 cubic meters/square meter/minute and/or a level of Air Permeability at 7 gf/mm (moderate extension) of greater than about 80 cubic meters/square meter/minute. The elastomeric laminate 302 may also have an Air Permeability at 0 gf/mm of from about 40 to about 120 m3/m2/min.
In addition to the skin health and skin marking benefits associated with the smooth textures enabled by the elastomeric laminate 302 as illustrated above by the profilometry data the structure of the elastomeric laminate 302 also delivers a significant improvement in graphics clarity and control. Many absorbent articles, taped diapers and pants, intended for use on infants and young children comprise a large number of graphical elements disposed on the outer surface of the article as well as the inner surface. Many elastomeric structures such as the belts 430 of the prior art have structures that are course with large rugosities and undulating surfaces which distort the graphics on the surface of the article. The surface of the elastomeric laminate 302 of the present invention is significantly smoother and as a result does not distort or mask the graphics on the surface. The magnitude of the difference is captured in Table 6 below.
The measurement involves stretching the article to its full width and scribing a line on the outer surface of the article extending from the upper left corner of the belt at or adjacent the intersection of the side seam and the waist edge to the lower right corner of the belt at or adjacent the intersection of the side seam and the leg edge. For the examples in Table 6, a 6 mm wide line was scribed on the surface. The article is then allowed to return to its relaxed state. A rectangular box is created based on the dimensions of the contracted line. The width of the box if measured and reported above. A distortion factor is then calculated by taking the final box dimension and dividing it by the original width of the line. It can be seen from the data above that the inventive elastomeric laminate 302 has a distortion factor of 1 meaning it demonstrated little or no distortion from the fully extended state to the contracted state. The elastic belt 430 products of the prior art have significantly higher distortion factors with all of the samples having a distortion factor of 4 or greater, 4 to 5 time higher than the distortion factor of the inventive elastomeric laminate 302.
Therefore, it would be beneficial to have an absorbent article 100 comprising a chassis 200 having a topsheet 124, a backsheet 125 and an absorbent core 128 disposed between the topsheet 124 and the backsheet 125 and an elastomeric laminate 302 joined to the chassis 200 whereby the elastomeric laminate 302 comprises a first plurality of elastics 316 disposed between first and second substrate layers 306 and 308. The elastomeric laminate 302 may form at least a portion of at least one of the group consisting of a belt 430, a side panel 330, topsheet 124, and an ear panel 530. The elastomeric laminate 302 may have a percent surface contact at 100 um of greater than about 10% and/or a percent surface contact at 200 um of greater than about 20% and/or a percent surface contact at 300 um or greater than about 28%. In addition, the elastomeric laminate 302 may have a 2%-98% Height Value of less than about 1.6. The elastomeric laminate 302 may also have a Graphic Distortion Ratio (illustrated in
Components of absorbent articles comprising elastomeric laminates 302 may be sectioned to enable measurement and detailed characterization of the structure. Waistband 122 (see
Other components such as the chassis 200, topsheet 124 (see
With regard to the chassis 200, topsheet 124 (see
With regard to the chassis 200, topsheet 124, and backsheet 125 (see
Tables 6-9 illustrate combinations of structural parameters enabled by the inventive elastomeric laminates of the present disclosure that cannot be realized by elastic structures of the prior art or currently marketed products. For example, although the inventive elastomeric laminate of the present invention in the tables have a Section-Modulus of 7.9 gf/mm, higher than any of the prior art references and the inventive elastomeric laminate also has the lowest Pressure-Under-Strand 0.35 psi. The inventive elastomeric laminates also have a very smooth surface delivering higher Percent Contact Area than any other prior art product in the tables above and the highest Rugosity Frequency all while delivering the unique combination of low Caliper (thinness) and high Caliper Retention Value. All of these inventive elastomeric laminate benefits are derived from Average-Dtex lower than any of the prior art references, combined with Average-Strand-Spacing lower than any of the prior art references.
EXAMPLE 1 Belt Pant Article (see, for example, FIG. 11)Example 1 is a belted pant absorbent article. The pant comprises a belt laminate disposed in both the waist regions and the following materials and construction.
- Outer Belt Layer (first substrate layer 306): 13 gsm spunbond nonwoven
- Inner Belt Layer (second substrate layer 308): 13 gsm spunbond nonwoven
- Backsheet Film 126: 12 gsm liquid impermeable polyethylene film
- Core Wrap: 10 gsm hydrophilic spunbond nonwoven
- AGM: absorbent gelling material
- Distribution Layer: crosslinked cellulosic fiber
- Acquisition Layer: 43 gsm synthetic acquisition layer
- Topsheet 124: 12 gsm hydrophilic spunbond nonwoven
- Belt Elastic Profile: Table 1, group B
- Cuff Elastic Profile: Table 4, group C
The belt 430 of Example 1 may present on a wearer consistent with the images ofFIGS. 72B, and 73B . Further, the cuffs 52 of Example 1 may present consistent with the images ofFIGS. 76B, and 77B .
Example 2 is a side panel taped absorbent article. The taped article comprises a pair of side panels disposed in a first waist region and the following materials and construction.
- Elastomeric Ear Panel Outer Layer (first substrate layer 306): 17 gsm carded nonwoven
- Elastomeric Ear Panel Inner Layer (second substrate layer 308): 17 gsm spunbond nonwoven
- Backsheet Film 126: 12 gsm liquid impermeable polyethylene film
- Core Wrap: 10 gsm hydrophilic spunbond nonwoven
- AGM: absorbent gelling material
- Distribution Layer: crosslinked cellulosic fiber
- Acquisition Layer: 43 gsm synthetic acquisition layer
- Topsheet 124: 12 gsm hydrophilic spunbond nonwoven
- Side Panel Elastic Profile: Table 2, group A
- Cuff Elastic Profile: Table 4, group B
- Front Waistband: Table 3, group A
- Back Waistband: Table 3, group A
The elastomeric ear panels 530 of Example 2 may present on a wearer consistent with the images inFIGS. 70B, and 71B . Further, the cuffs 52 of Example 2 may present consistent with the images ofFIGS. 76B, and 77B . Still further, the front and back waistbands 122 of Example 2 may present consistent with the images ofFIGS. 74B, and 75B .
Example 3 is a belted taped absorbent article. The taped article comprises a belt disposed in a first waist region and the following materials and construction.
- Outer Belt Layer (first substrate layer 306): 15 gsm spunbond nonwoven
- Inner Belt Layer (second substrate layer 308): 10 gsm spunbond nonwoven
- Backsheet Film 126: 12 gsm liquid impermeable polyethylene film
- Core Wrap: 10 gsm hydrophilic spunbond nonwoven
- AGM: absorbent gelling material
- Distribution Layer: crosslinked cellulosic fiber
- Acquisition Layer: 43 gsm synthetic acquisition layer
- Topsheet 124: 12 gsm hydrophilic spunbond nonwoven
- Belt Elastic Profile: Table 1, group B
- Cuff Elastic Profile: Table 4, group A
- Front Waistband: Table 3, group B
The belt 430 of Example 3 may present on a wearer consistent with the images ofFIGS. 72B, and 73B . Further, the cuffs 52 of Example 3 may present consistent with the images ofFIGS. 76B, and 77B . Still further, the front waistband 122 of Example 3 may present consistent with the images ofFIGS. 74B, and 75B .
Example 4 is a side panel pant absorbent article. The pant article has a pair of side panels disposed in each waist region and comprises the following materials and construction.
- Side Panel Outer Layer (first substrate layer 306): 17 gsm carded nonwoven
- Side Panel Inner Layer (second substrate layer 308): 17 gsm spunbond nonwoven
- Backsheet Film 126: 12 gsm liquid impermeable polyethylene film
- Core Wrap: 10 gsm hydrophilic spunbond nonwoven
- AGM: absorbent gelling material
- Distribution Layer: crosslinked cellulosic fiber
- Acquisition Layer: 43 gsm synthetic acquisition layer
- Topsheet 124: 12 gsm hydrophilic spunbond nonwoven
- Front Side Panel Elastic Profile: Table 2, group B
- BackSide Panel Elastic Profile: Table 2, group B
- Cuff Elastic Profile: Table 4, group A
- Front Waistband: Table 3, group C
- Back Waistband: Table 3, group C
The side panels 330 of Example 4 may present on a wearer consistent with the images inFIGS. 70B , and 71B. Further, the cuffs 52 of Example 4 may present consistent with the images ofFIGS. 76B , and 77B. Still further, the front and back waistbands 122 of Example 4 may present consistent with the images ofFIGS. 74B, and 75B .
Example 5 is a belted pant absorbent article. The pant comprises a belt laminate disposed in both the waist regions and the following materials and construction.
- Outer Belt Flap Layer (first substrate layer 306): 13 gsm spunbond nonwoven
- Inner Belt Flap Layer (second substrate layer 308): 13 gsm spunbond nonwoven
- Backsheet Film 126: 12 gsm liquid impermeable polyethylene film
- Core Wrap: 10 gsm hydrophilic spunbond nonwoven
- AGM: absorbent gelling material
- Distribution Layer: crosslinked cellulosic fiber
- Acquisition Layer: 43 gsm synthetic acquisition layer
- Topsheet 124: 12 gsm hydrophilic spunbond nonwoven
- Belt Elastic Profile: Table 1, group C
- Cuff Elastic Profile: Table 4, group B
The belt 430 of Example 5 may present on a wearer consistent with the images ofFIGS. 72B, and 73B . Further, the cuffs 52 of Example 5 may present consistent with the images ofFIGS. 76B, and 77B .
1. An absorbent article, comprising:
a chassis comprising a topsheet, a backsheet and an absorbent core disposed between the topsheet and the backsheet;
a first belt;
a longitudinal centerline extending from the midpoint of a front waist edge of the absorbent article to a midpoint of a back waist edge of the absorbent article;
a lateral centerline extending perpendicular to the longitudinal centerline through a midpoint of the longitudinal centerline;
wherein the first belt is formed at least in part by an elastomeric laminate comprising a first substrate layer, a second substrate layer and a first plurality of elastics disposed between the first and second substrate layers;
wherein the first plurality of elastics comprises greater than about 40 elastic strands disposed at an Average-Strand-Spacing of less than 4 mm, having an Average-Dtex of less than 600, and having an Average-Pre-Strain of less than 400%; and
wherein a basis weight of each of the first and second substrate layers is from about 6 grams per square meter to about 30 grams per square meter.
2. The absorbent article of claim 1, wherein the first plurality of elastics comprises greater than about 100 strands.
3. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 3 mm.
4. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 400.
5. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 350%.
6. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 2 mm.
7. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 300.
8. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 300%.
9. The absorbent article according to any of the preceding claims, wherein the elastomeric laminate comprising the first plurality of elastics has an Pressure-Under-Strand of less than about 1 psi.
10. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises greater than about 150 strands.
11. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 1.5 mm.
12. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 250.
13. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 300%.
14. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises greater than about 200 strands.
15. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 1 mm.
16. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 200.
17. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 250%.
18. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises greater than about 250 strands.
19. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 0.75 mm.
20. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 150.
21. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 200%.
22. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises greater than about 500 strands.
23. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 0.5 mm.
24. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 125.
25. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 175%.
26. The absorbent article according to any of the preceding claims, wherein the elastomeric laminate comprising the first plurality of elastics has a Pressure-Under-Strand of less than about 0.75 psi.
27. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each comprise PolyUrethane Urea.
28. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each comprise a silicone oil coating.
29. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each are joined to the inner and outer nonwoven layers via an adhesive.
30. The absorbent article according to any one of claims 29, wherein the adhesive is selected from the group consisting of Styrenic block copolymers, Polyolefins, Ethylene-vinyl Acetates, Polyurethanes, Ethylene-propylene copolymers, Propylene-ethylene copolymers, Polyolefin block polymers, Polyolefin homo-polymers, Polyesters, Polyamides, Silicones, Cyanoacrylics, Acrylics, butyl rubber, and combinations thereof.
31. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each consists essentially of PolyUrethane Urea.
32. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each consists of PolyUrethane Urea.
33. The absorbent article according to any one of claims 29, wherein the adhesive is selected from the group consisting of thermoplastic, thermoset, hot-melt, pressure sensitive, solvent-based, and reactive thermoset.
34. A method for producing the disposable absorbent article of any of the preceding claims, comprising the step of unwinding the first plurality of elastics are unwound from a single beam to form the elastomeric laminate.
Example Claim Set 2:1. An absorbent article, comprising:
a chassis comprising a topsheet, a backsheet and an absorbent core disposed between the topsheet and the backsheet;
a first panel that may be a first side panel or an a first ear panel;
a second panel that may be a second side panel or a second ear panel;
a longitudinal centerline extending from a midpoint of a front waist edge of the absorbent article to a midpoint of a back waist edge of the absorbent article;
- a lateral centerline extending perpendicular to the longitudinal centerline through the midpoint of the longitudinal centerline;
wherein the first and second panels are formed at least in part by an elastomeric laminate comprising a first substrate layer, a second substrate layer, and a first plurality of elastics disposed between the first and second substrate layers;
wherein the first plurality of elastics comprises greater than about 10 elastic strands disposed at an Average-Strand-Spacing of less than 4 mm, and having an Average-Dtex of less than 600 and an Average-Pre-Strain of less than 400%; and
wherein a basis weight of each of the first and second substrate layers is from about 6 grams per square meter to about 30 grams per square meter.
2. The absorbent article of claim 1, wherein the first plurality of elastics comprises greater than about 20 strands.
3. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 3 mm.
4. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 400.
5. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 350%.
6. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 2 mm.
7. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 300.
8. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 300%.
9. The absorbent article according to any of the preceding claims, wherein the elastomeric laminate comprising the first plurality of elastics has an Pressure-Under-Strand of less than about 1 psi.
10. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises greater than about 40 strands.
11. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 1.5 mm.
12. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 250.
13. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 300%.
14. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises greater than about 80 strands.
15. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 1 mm.
16. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 200.
17. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 250%.
18. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises greater than about 115 strands.
19. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 0.75 mm.
20. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 150.
21. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 200%.
22. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises greater than about 150 strands.
23. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 0.5 mm.
24. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 125.
25. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 175%.
26. The absorbent article according to any of the preceding claims, wherein the elastomeric laminate comprising the first plurality of elastics has an Pressure-Under-Strand of less than about 0.75 psi.
27. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each comprise PolyUrethane Urea.
28. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each comprise a silicone oil coating.
29. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each are joined to the inner and outer nonwoven layers via an adhesive.
30. The absorbent article according to any one of claims 29, wherein the adhesive is selected from the group consisting of Styrenic block copolymers, Polyolefins, Ethylene-vinyl Acetates, Polyurethanes, Ethylene-propylene copolymers, Propylene-ethylene copolymers, Polyolefin block polymers, Polyolefin homo-polymers, Polyesters, Polyamides, Silicones, Cyanoacrylics, Acrylics, butyl rubber, and combinations thereof.
31. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each consists essentially of PolyUrethane Urea.
32. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each consists of PolyUrethane Urea.
33. The absorbent article according to any one of claims 29, wherein the adhesive is selected from the group consisting of thermoplastic, thermoset, hot-melt, pressure sensitive, solvent-based, and reactive thermoset.
34. A method for producing the disposable absorbent article of any of the preceding claims, comprising the step of unwinding the first plurality of elastics are unwound from a single beam to form the elastomeric laminate.
Example Claim Set 3:1. An absorbent article, comprising:
a chassis comprising a topsheet, a backsheet and an absorbent core disposed between the topsheet and the backsheet;
an elastomeric laminate forming at least a portion of one or more absorbent article components selected from the group consisting of a waistband, a waistcap, an inner leg cuff, an outer leg cuff, and a transverse barrier;
a longitudinal centerline extending from a midpoint of a front waist edge of the absorbent article to a midpoint of a back waist edge of the absorbent article;
a lateral centerline extending perpendicular to the longitudinal centerline through a midpoint of the longitudinal centerline;
wherein the elastomeric laminate comprises a first substrate layer, a second substrate layer and a first plurality of elastics disposed between the first and second substrate layers;
wherein the first plurality of elastics comprises from about 10 to about 200 elastic strands disposed at an Average-Strand-Spacing of from about 0.25 to about 5 mm, and having an Average-Dtex from about 10 to about 600 and an Average-Pre-Strain of from about 75% to about 400%; and
wherein a basis weight of each of the first and second substrate layers is from about 6 grams per square meter to about 30 grams per square meter.
2. The absorbent article of claim 1, wherein the first plurality of elastics comprises from about 15 to about 175 elastic strands.
3. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 3 mm.
4. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 400.
5. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 350%.
6. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 2 mm.
7. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 300.
8. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 300%.
9. The absorbent article according to any of the preceding claims, wherein the elastomeric laminate comprising the first plurality of elastics has an Pressure-Under-Strand of less than about 1 psi.
10. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises from about 20 to about 160 elastic strands.
11. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 1.5 mm.
12. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 250.
13. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 300%.
14. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises from about 25 to about 140 elastic strands.
15. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 1 mm.
16. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 200.
17. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 250%.
18. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises from about 35 to about 120 elastic strands.
19. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 0.75 mm.
20. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 150.
21. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 200%.
22. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics comprises from about 45 to about 100 elastic strands.
23. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics is disposed at an Average-Strand-Spacing of less than 0.5 mm.
24. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Dtex of less than 125.
25. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics has an Average-Pre-Strain of less than 175%.
26. The absorbent article according to any of the preceding claims, wherein the elastomeric laminate comprising the first plurality of elastics has an Pressure-Under-Strand of less than about 0.75 psi.
27. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each comprise PolyUrethane Urea.
28. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each comprise a silicone oil coating.
29. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each are joined to the inner and outer nonwoven layers via an adhesive.
30. The absorbent article according to any one of claims 29, wherein the adhesive is selected from the group consisting of Styrenic block copolymers, Polyolefins, Ethylene-vinyl Acetates, Polyurethanes, Ethylene-propylene copolymers, Propylene-ethylene copolymers, Polyolefin block polymers, Polyolefin homo-polymers, Polyesters, Polyamides, Silicones, Cyanoacrylics, Acrylics, butyl rubber, and combinations thereof.
31. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each consists essentially of PolyUrethane Urea.
32. The absorbent article according to any of the preceding claims, wherein the first plurality of elastics, the second plurality of elastics, and the third plurality of elastics each consists of PolyUrethane Urea.
33. The absorbent article according to any one of claims 29, wherein the adhesive is selected from the group consisting of thermoplastic, thermoset, hot-melt, pressure sensitive, solvent-based, and reactive thermoset.
34. A method for producing the disposable absorbent article of any of the preceding claims, comprising the step of unwinding the first plurality of elastics are unwound from a single beam to form the elastomeric laminate.
Methods General Sample PreparationThe General Sample Preparation is intended to be used for methods that do not have specific sample preparation instructions within the method itself.
The When collecting a specimen for testing, the specimen must contain a plurality of elastic strands and/or an elastic material; film, elastic scrim, elastic foam, elastic ribbons, elastic strips, etc. In situations where the elastic material and/or elastic strands is not fully secured within the sample, the test specimen must be obtained in a way that elastic material and/or elastic strands within the test region of the specimen are as they were intended and not altered as a result of collection of the specimen. If the elastic material or any elastic strands release, creep or become separated within or from the laminate, the specimen is discarded and a new specimen prepared.
For pants, remove the side panels where they are attached to the chassis and separate the side panels at the side seams. Identify the elastic material that transverses the entire width of the panel. Identify the longitudinally distal most edge of the elastic material or elastic strand (closest to the waist edge) and the longitudinally proximal most edge of the elastic material or elastic strand (closest to the leg edge) determine the midpoint between the distal most elastic strand or elastic material edge and the proximal most elastic strand or elastic material edge. Cut a 40 mm wide strip laterally across the entire panel centered at the midpoint. Repeat for each front and rear side panel that contains elastic material and/or elastic strands.
For taped, remove ear panels where they are attached to the chassis. Identify the elastic material that transverses the entire width of the panel. Identify the distal most elastic material edge or elastic strand (closest to the waist edge) and the proximal most elastic material edge or elastic strand (closest to the leg edge) determine the midpoint between the distal most elastic strand or elastic material edge and the proximal most elastic strand or elastic material edge. Cut a 40 mm wide strip laterally across the entire ear panel centered at the midpoint. Repeat for each front and rear ear panel that contains elastic material and/or elastic strands.
For a belted article, mark the product on the front and back by extending a line from along the side of the core to the waist edge. Remove the belt from the article, using an appropriate means (e.g. freeze spray), taking care not to delaminate the belt or release the elastics. Separate the front belt from the back belt along any seams. Identify the distal most elastic material edge or elastic strand (closest to the waist edge) and the proximal most elastic material edge or strand (closest to the leg edge) determine the midpoint between the distal most elastic strand or elastic material edge and the proximal most elastic strand or elastic material edge. Cut a 40 mm wide strip parallel to the waist edge if linear or to the elastic strands if linear and centered at the midpoint, across the entire belt portion. If the strip has a region that does not contain elastic strands or elastic material (e.g., a portion that overlapped the core, etc.) cut along the ends of the elastic strands/elastic material, to remove the non-elastic region and treat as two specimens.
For waistbands, they are tested as a single piece of material. Remove the belt from the article, using an appropriate means (e.g. freeze spray), taking care not to delaminate the belt or release the elastics.
For the leg cuffs, each of the leg cuffs are tested as a single piece of material. The inner leg cuff sample is considered to be the portion of the inner leg cuff that extends from the proximal most edge of the inner leg cuff to and including the distal most elastic of the inner leg cuff and extending longitudinally to the front and back waist edges of the chassis. The outer leg cuff sample is considered to be the portion of the outer leg cuff that extends from the distal most edge of the outer leg cuff to and including the proximal most elastic of the outer leg cuff and extending longitudinally to the front and back waist edges of the chassis.
For all specimen strips calculate a Span Corrected Width (SCW) is calculated as:
where d is the distance (mm) between the two distal strands, and n is the number of strands, when n>1. Clamp the strip at each end and measure the length between the clamps to the nearest 1 mm. Apply a weight equal to 3 g/mm SCW. After 10 seconds measure the final weight to the nearest 1 mm. Calculate the elongation as (Final Length−Initial Length)/Initial length.
Product Measurement Preparation for Donning-Ratio, Product Length-to-Waist Silhouette and Product Hip-to-Waist Silhouette
- All measurements are conducted at 22° C.+/−2° and 50% RH+/−20%.
This method is used to prepare pant type products for subsequent dimensional measurement. The method provides a consistent means of opening a product that has been removed from a bag. This method is applicable to all forms of pant products. A constant rate of extension tensile testing machine with computer interface is used.
- A load cell is chosen so that the load cell capacity ensures accuracy of a 5N load to within 0.1N.
“C” (604) and “O” (605) Bar attachments each with a rod radius of 9.50 mm that extend longer than the length of the longest side seam. Refer to
Calibrate tensile tester equipment according to the instrument manufacturer's recommendations.
- The initial gauge length is determined by removing 10 sample products from the bag, unfolding the pant products (607) and laying them flat as illustrated in
FIG. 90 , below and measuring the distance between the sides of the pant at the waist as shown (606). The average of the waist measurement will be used as the initial gauge length for the specific set of specimens. The initial gauge length is the distance from the uppermost edge of the upper bar to the lowermost edge of the lower bar.
Apply the whole product (607) to the bars as shown in
- Pull Sample to 5N Force then hold for 10 seconds. Return to initial gauge length.
- Crosshead Speed=254.0 mm/min, Data acquisition rate=50 Hz.
- Cycles=1
Remove the specimen from the bars while minimizing manipulation. Lay the specimen flat with the front side facing upward as shown in
- Repeat for all 10 specimens
Each of the measurements below is to be conducted on 10 separate like specimens and the average of the 10 separate like specimens is considered to be the measurement for that specific specimen set.
Relaxed Product Length (600)Relaxed Product Length is the longitudinal distance between the longitudinally distal most point in the crotch region and the longitudinally distal most point along the front waist edge. The longitudinal distance is measured parallel to the longitudinal axis of the product. Refer to
Relaxed Product Hip Width is the lateral distance from the laterally distal most point of the left side edge of the product at the upper edge of the left leg opening to the laterally distal most point of the right side edge of the product at the upper edge of the right leg opening. Refer to
Relaxed Product Waist Width is the lateral distance from the distal most point at the right side of the front waist edge to the distal most point at the left side of the front waist edge. The lateral distance is measured perpendicular to the longitudinal axis of the product. Refer to
Relaxed Product Crotch Width is the lateral distance from the laterally distal most point of the left side edge of the product at the lower edge of the left leg opening to the laterally distal most point of the right side edge of the product at the lower edge of the right leg opening. Refer to
The Bending Length and Flexural Rigidity at the waist is measured as the cantilever bending value as determined using ASTM Method D1388, Option A Cantilever Test with the modifications described below. The test apparatus described in the D1388 is used without modification. Articles are conditioned at 23° C.±2° C. and 50%±2% relative humidity for 2 hr prior to analysis and then tested under the same environmental conditions.
The method is applied to a dry nonwoven laminate specimen dissected from an absorbent article rather than a fabric. For a belted article cut the belt at the side seams and remove the belt from the rest of the article using for example a cryogenic spay (e.g. Quick-Freeze, Miller-Stephenson Company, Danbury, Conn.). For pants, remove the side panel from the chassis and separate/cut along the side seam. The specimen is cut as a 25.4 mm strip parallel to the longitudinal axis of the product, starting at the waist and extending toward the crotch of the product. The length of the specimen can be less than the 200 mm cited in D1388, but must be at least 10 mm longer than the overhang length determined during testing. If the waist of the specimen is folded over, leave the fold intact for testing.
The specimen is placed on the platform with the garment facing side down and the end proximal to the waist as the leading edge. The bend is performed as described in D1388. Record the overhang length (OL) to the nearest 1 mm. Calculate the Bending Length (BL) as the Overhang Length divided by 2 and report to the nearest 1 mm. Take the specimen and measure the overhang length from the leading edge and cut across the strip. Measure and record the mass of the overhang piece and record to the nearest 0.001 g. From the mass and the dimensions of the overhang piece calculate the basis weight (BW) and record to the nearest 0.01 g/m2.
Water Vapor Transmission RateWater Vapor Transmission Rate (WVTR) is measured using the wet cup approach to determine the rate for a stretch laminate under strain. A cylindrical cup is filled with water, maintaining a constant headspace between the water surface and a specimen sealed over the cup's upper opening. The vapor loss is measured gravimetrically after heating the assembled cup for a specified time in an oven. Glass straight walled, cylindrical vials, 95 mm tall with a 17.8 mm internal diameter at the opening are used as WVTR test cup. Articles are preconditioned at 23° C.±2° C. and 50%±2% relative humidity for two hours prior to testing and all testing is performed under the same environmental conditions.
The test is intended for use with stretch laminate of the sample article such as belts, side panels, ears, waist bands, cuffs etc. tested in their relaxed state. Specimens are prepared as describe in General Sample Preparation force 3 articles for each test set.
One edge of laminate that is perpendicular to the machine direction (MD) of the laminate is secured to a lab bench. The specimen is then extended in the machine direction to a length equivalent to 3 gf per mm width and secured. A circle is marked on the laminate with a diameter corresponding to the diameter of the test cup. A test cup is filled with distilled water accurately to a level 25.0 mm±0.1 mm from the upper lip of the cup's opening. The specimen is placed, body-facing surface of the laminate downward, over the cup's opening. The specimen is extended such that the marked circle aligns with the cup's opening and secured around the vial's circumference with an elastic band. The specimen is further sealed by wrapping 0.25″ wide Teflon tape around the cup's circumference. The Teflon tape is applied up to the top edge of the vial but should not cover any portion of the vial's opening. The mass of the cup assembly is weighed to the nearest 0.0001 gram. This is the starting mass (SM). The cup assemblies are placed upright in a mechanical convection oven (e.g. Lindberg/BlueM oven available from Thermo Scientific or equivalent) maintained at 38° C.±2° C. for 12 hours, taking care to avoid contact between the water in the cups and the specimens. After 24 hours has elapsed, the cup assemblies are removed from the oven and allowed to come to room temperature. The mass of each cup assembly is measured to the nearest 0.0001 gram. This is the final mass (FM). The WVTR is calculated using the following equation:
WVTR (g/m2/24 hrs)=([SM (g)−FM (g)]/surface area (m2))/24 hrs
In like fashion, analyze a total of 3 replicates for each stretch laminate and record their WVTR result. Calculate the arithmetic mean WVTR for each stretch laminate set and reported to the nearest 1 g/m2/24 hrs.
Air PermeabilityAir permeability is tested using a TexTest FX3300 Air Permeability Tester (available from Advanced Testing Instruments, Greer, S.C.) with a custom made 1 cm2 aperture (also available from Advanced Testing Instruments). Standardize the instrument according to the manufacturer's procedures. Precondition the articles at about 23° C.±2° C. and about 50%±2% relative humidity for two hours prior to testing. Articles are preconditioned at 23° C.±2° C. and 50%±2% relative humidity for two hours prior to testing and all testing is performed under the same environmental conditions.
The test is intended for use with stretch laminate of the sample article such as belts, side panels, ears, waist bands, etc. Stretch components are removed from the article using, for example, cryogenic spay (e.g. Quick-Freeze, Miller-Stephenson Company, Danbury, Conn.) or cutting. Specimens are dissected from the laminate avoiding material seams or other structures not integral to the stretch. Stretch laminates are harvested from 3 articles for each test set.
Cut a specimen from the stretch region of the laminate that is 25 mm by 25 mm. For a specimen with unevenly spaced strands, a Span Corrected Width (SCW) is calculated as:
where d is the distance (mm) between the two distal strands, and n is the number of strands, when n>1. Using the Span Corrected Width determine the elongation need to achieve 3 g/mm SCW and 7 g/mm SCW by hanging weights on a substantially similar specimen and measuring the elongation.
The on the instrument's air pressure is set for 125 Pa. Place a specimen in its relaxed state with the body-facing side downward on the port plate. The stretch region must completely cover the instruments port. Close the sample ring and adjust the measuring range until it is within specification. Record the air permeability for the un-extended specimen to the nearest 0.1 m3/m2/min.
Select one of the edges of laminate that is perpendicular to the machine direction (MD) and secure it to the port plate of the instrument using adhesive tape. The specimen is then extended in the machine direction to a length equivalent to 3 gf/mm and secured. The stretch region must completely cover the port. Close the sample ring and adjust the measuring range until the it is within specification. Record the air permeability for the 3 g/mm to the nearest 0.1 m3/m2/min. Repeat in like fashion for the 7 g/mm extension and record the air permeability for the 3 g/mm to the nearest 0.1 m3/m2/min.
A total of five measures are made on replicate specimens for each stretch laminate. Calculate and report the arithmetic average for air permeability at the 0 gf/mm, 3 gf/mm, and 7 gf/mm elongation and report each to the nearest 0.1 m3/m2/min.
Caliper (Caliper Retention Value)Caliper is measured using a foot and anvil type digital caliper such as an Ono Sokki GS 503/DG 3610 caliper gage or equivalent. The instrument is operated and calibrated as per the manufacturer's instructions. A circular 25.4 mm diameter foot that applies a confining pressure of 0.69 kPa.
The test is intended for use with stretch laminate of the sample article such as belts, side panels, ears, waist bands, cuffs etc. tested in their relaxed state. Specimens are prepared as describe in General Sample Preparation force 3 articles for each test set.
Place the specimen, with the body-facing side downward on the anvil. The middle of the test strip is centered underneath the foot. Lower the foot at approximately 0.5 mm sec, and read the value after 5.0 sec. Record as the caliper for 0 gf/mm elongation to the nearest 0.01 mm
Select one of the edges of laminate that is perpendicular to the prominent stretch direction and secure it to the anvil using adhesive tape. The specimen is then extended in the machine direction to a length equivalent to 3 gf/mm and secured. The equivalent target site is centered under the foot. Lower the foot at approximately 0.5 mm sec, and read the value after 5.0 sec. Record as the caliper for 3 gf/mm elongation to the nearest 0.01 mm. Repeat in like fashion for the 7 g/mm extension and record the caliper for the 7 g/mm to the nearest 0.01 mm.
A total of five measures are made on replicate specimens for each stretch laminate. Calculate and report the arithmetic average for caliper at the 0 gf/mm, 3 gf/mm, and 7 gf/mm elongation and report each to the nearest 0.01 mm. The percentage at 3 gf/mm and 7 gf/mm is considered to be the Caliper Retention Value.
Average-Strand-SpacingUsing a ruler calibrated against a certified NIST ruler and accurate to 0.5 mm, measure the distance between the two distal strands within a section to the nearest 0.5 mm, and then divide by the number of strands in that section−1
- Average-Strand-Spacing=d/(n−1) where n>1
- report to the nearest 0.1 mm.
Pressure-Under-Strand (also Referred to as Average Pressure-Under-Strand)
Defined as the average pressure imparted by each individual elastic strand of a section under specific conditions. These conditions are defined as (refer to
-
- The section is pulled to a Stress of 7 gf/mm (within a consumer preferred range of stresses as determined experimentally)
- The section is pulled over a cylinder whose circumference is defined as a Representative-Circumference
- Where:
Pressure-Under-Strand (psi)=1.422*Strand-Force/(2*Representative-Radius*Average-Strand-Diameter)
Representative-Radius (mm)=Representative-Circumference/(2*pi)
Representative-Circumference(mm)=460 mm
Stress (gf/mm)=(Summation of Strand-Forces within a section)/(Section-Width)
Section-Width (mm)=(Number of Elastics in the section)*Average-Strand-Spacing (mm)
Strand-Force (gf)=Strand-Strain (%)*0.046875*Average-Dtex
Strand-Strain (%)=strain in each elastic strand within a section
Average-Strand-Diameter (mm)=2*sqrt (Strand-Cross-Sectional-Area/pi)
Strand-Cross-Sectional-Area (mm2)=Average-Dtex/Strand-Density/10,000
Strand-Density (g/cc)=1.15 g/cc (industry standard for PolyUrethaneUrea based spandex elastics)
Dtex (g/10,000 m)=Standard textile unit of measure. Dtex is weight in grams for 10,000 m of the material
Average-Pre-Strain=Amount of stretch in elastic strands in a section prior to combining with substrate layer(s).
Maximum-Strain=Average-Pre-Strain. This is the maximum amount of strain each section can be pulled to. It cannot exceed the Average-Pre-Strain.
Maximum-Section-Force=Summation of each strand in the section pulled to the Maximum-Strain.
Defined as the modulus of a given section. Section-Modulus (also referred to as modulus) is the linear slope of the stress vs strain data of the section between 3 gf/mm and 7 gf/mm (refer to
Section-Modulus=[7 gf/mm−3 gf/mm]/[(section strain at 7 gf/mm)−(section strain at 3 gf/mm)]
section strain at 7 gf/mm=7 gf/mm*(Average-Strand-Spacing)/DTEX-FACTOR
section strain at 3 gf/mm=3 gf/mm*(Average-Strand-Spacing)/DTEX-FACTOR
Average-Strand-Spacing (mm)=d/(n−1)
-
- d is the distance (mm) between the two distal strands of the section
- n is the number of strands, when n>1
- DTEX-FACTOR=37.5*Average-Dtex/800 (dtex as measured, specified)
- Section-Modulus is reported in units of (gf/mm)
The Average Decitex Method is used to calculate the Average-Dtex on a length-weighted basis for elastic fibers present in an entire article, or in a specimen of interest extracted from an article. The decitex value is the mass in grams of a fiber present in 10,000 meters of that material in the relaxed state. The decitex value of elastic fibers or elastic laminates containing elastic fibers is often reported by manufacturers as part of a specification for an elastic fiber or an elastic laminate including elastic fibers. The Average-Dtex is to be calculated from these specifications if available. Alternatively, if these specified values are not known, the decitex value of an individual elastic fiber is measured by determining the cross-sectional area of a fiber in a relaxed state via a suitable microscopy technique such as scanning electron microscopy (SEM), determining the composition of the fiber via Fourier Transform Infrared (FT-IR) spectroscopy, and then using a literature value for density of the composition to calculate the mass in grams of the fiber present in 10,000 meters of the fiber. The manufacturer-provided or experimentally measured decitex values for the individual elastic fibers removed from an entire article, or specimen extracted from an article, are used in the expression below in which the length-weighted average of decitex value among elastic fibers present is determined.
The lengths of elastic fibers present in an article or specimen extracted from an article is calculated from overall dimensions of and the elastic fiber pre-strain ratio associated with components of the article with these or the specimen, respectively, if known. Alternatively, dimensions and/or elastic fiber pre-strain ratios are not known, an absorbent article or specimen extracted from an absorbent article is disassembled and all elastic fibers are removed. This disassembly can be done, for example, with gentle heating to soften adhesives, with a cryogenic spray (e.g. Quick-Freeze, Miller-Stephenson Company, Danbury, Conn.), or with an appropriate solvent that will remove adhesive but not swell, alter, or destroy elastic fibers. The length of each elastic fiber in its relaxed state is measured and recorded in millimeters (mm) to the nearest mm.
Calculation of Average-DtexFor each of the individual elastic fibers fi of relaxed length Li and fiber decitex value di (obtained either from the manufacturer's specifications or measured experimentally) present in an absorbent article, or specimen extracted from an absorbent article, the Average-Dtex for that absorbent article or specimen extracted from an absorbent article is defined as:
where n is the total number of elastic fibers present in an absorbent article or specimen extracted from an absorbent article. The Average-Dtex is reported to the nearest integer value of decitex (grams per 10 000 m).
If the decitex value of any individual fiber is not known from specifications, it is experimentally determined as described below, and the resulting fiber decitex value(s) are used in the above equation to determine Average-Dtex.
Experimental Determination of Decitex Value for a FiberFor each of the elastic fibers removed from an absorbent article or specimen extracted from an absorbent article according to the procedure described above, the length of each elastic fiber Lk in its relaxed state is measured and recorded in millimeters (mm) to the nearest mm. Each elastic fiber is analyzed via FT-IR spectroscopy to determine its composition, and its density ρk is determined from available literature values. Finally, each fiber is analyzed via SEM. The fiber is cut in three approximately equal locations perpendicularly along its length with a sharp blade to create a clean cross-section for SEM analysis. Three fiber segments with these cross sections exposed are mounted on an SEM sample holder in a relaxed state, sputter coated with gold, introduced into an SEM for analysis, and imaged at a resolution sufficient to clearly elucidate fiber cross sections. Fiber cross sections are oriented as perpendicular as possible to the detector to minimize any oblique distortion in the measured cross sections. Fiber cross sections may vary in shape, and some fibers may consist of a plurality of individual filaments. Regardless, the area of each of the three fiber cross sections is determined (for example, using diameters for round fibers, major and minor axes for elliptical fibers, and image analysis for more complicated shapes), and the average of the three areas ak for the elastic fiber, in units of micrometers squared (μm2), is recorded to the nearest 0.1 μm2. The decitex dk of the kth elastic fiber measured is calculated by:
dk=10 000 m×ak×ρk×10−6
where dk is in units of grams (per calculated 10,000 meter length), ak is in units of μm2, and ρk is in units of grams per cubic centimeter (g/cm3). For any elastic fiber analyzed, the experimentally determined Lk and dk values are subsequently used in the expression above for Average-Dtex.
Surface Topography (Percent Contact Area, Rugosity Frequency, Rugosity Wavelength and 2-98% Height Value)In the Surface Topography Method, an elastic laminate specimen is removed from an absorbent article and extended across and in contact with the convex surface of a transparent horizontal cylindrical tubing segment, allowing the areal surface topology of the body facing side of the laminate to be measured through the transparent tubing segment using optical profilometry. The 3D surface data are then sampled and processed to extract several parameters that describe the percent contact area and height of the elastic laminate specimen surface as well as the frequency and wavelength of its associated rugosities. All sample preparation and testing is performed in a conditioned room maintained at about 23±2° C. and about 50±2% relative humidity, and samples are equilibrated in this environment for at least 24 hours prior to testing.
Sample PreparationSPECIMEN PREP DESCRIPTION—M. Purdon developing language to guide sampling at center of belt or side panel strands.
Each elastic laminate specimen extracted from an article is mounted on a horizontal tubing segment as described below. The tubing segment is cut from a sufficient length of optically clear, colorless cast acrylic cylindrical tubing having an outer diameter of 8.0 inches (203 mm) and a wall thickness of 0.1875 inches (4.76 mm). The segment has a dimension of 4.0 inches (102 mm) along an axis parallel to the central cylindrical axis of the parent tubing and a circumferential outer arc length of 5.5 inches (140 mm).
The elastic laminate specimen is extended in its primary stretch direction to a ratio corresponding to its extension at 3 g/mm (mass per linear width), where its width is determined by the Span Corrected Width metric as defined in the Caliper Test Method, and in which the extension is the average ratio measured under static load for the first ten seconds during which it is applied. In this extended state, the extended elastic laminate specimen is oriented such that its body-facing surface is in contact with the convex surface of the tubing segment and that the axis of extension is oriented around the circumference of the tubing segment. The extended laminate is secured at both ends to the transparent tubing segment such that the body-facing surface of the laminate is viewable through the concave side of the transparent tubing segment.
Five replicate elastic laminate specimens are isolated and prepared in this way from five equivalent absorbent articles for analysis.
3D Surface Image AcquisitionA three-dimensional (3D) surface topography image of the body facing surface of the extended elastic laminate specimen is obtained using a DLP-based, structured-light 3D surface topography measurement system (a suitable surface topography measurement system is the MikroCAD Premium instrument commercially available from LMI Technologies Inc., Vancouver, Canada, or equivalent). The system includes the following main components: a) a Digital Light Processing (DLP) projector with direct digital controlled micro-mirrors; b) a CCD camera with at least a 1600×1200 pixel resolution; c) projection optics adapted to a measuring area of at least 60 mm×45 mm; d) recording optics adapted to a measuring area of 60 mm×45 mm; e) a table tripod based on a small hard stone plate; f) a blue LED light source; g) a measuring, control, and evaluation computer running surface texture analysis software (a suitable software is MikroCAD software with Mountains Map technology, or equivalent); and h) calibration plates for lateral (XY) and vertical (Z) calibration available from the vendor.
The optical 3D surface topography measurement system measures the surface height of a sample using the digital micro-mirror pattern fringe projection technique. The nature of this pattern projection technique allows the surface topography of a specimen to be interrogated through a transparent material. The result of the measurement is a 3D data set of surface height (defined as the Z-axis) versus displacement in the horizontal (XY) plane. This 3D data set can also be thought of as an image in which every pixel in the image there is associated an XY displacement, and the value of the pixel is the recorded Z-axis height value. The system has a field of view of 60×45 mm with an XY pixel resolution of approximately 37 microns, and a height resolution of 0.5 microns, with a total possible height range of 32 mm.
The instrument is calibrated according to manufacturer's specifications using the calibration plates for lateral (XY plane) and vertical (Z-axis) available from the vendor.
The elastic laminate specimen mounted on the transparent tubing segment is positioned with the concave surface of the tubing segment surface facing upward so that the body facing surface is facing upward and visible through the transparent material. The tubing segment is placed on a stand such that the convex (downward-facing) specimen surface in the region to be analyzed is suspended freely and not resting on a surface. The tubing segment is oriented such that its circumferential direction (that direction or axis along which the laminate is stretched) is centered and perpendicular relative to the long axis of the camera's field of view (or either of the central axes if the field of view is square). A 3D surface topology image of the elastic laminate specimen is collected by following the instrument manufacturer's recommended measurement procedures, which may include focusing the measurement system and performing a brightness adjustment. No pre-filtering options are used. The collected height image file is saved to the evaluation computer running the surface texture analysis software.
If the field of view of the 3D surface topography measurement system exceeds the evaluation region on the elastic laminate specimen the image may be cropped to remove extraneous areas and retain a rectangular field of view of the relevant portion, while maintaining the XY resolution, prior to performing the analysis.
3D Surface Image AnalysisThe 3D surface topography image is opened in the surface texture analysis software. The following filtering procedure is then performed on each image: 1) removal of invalid or non-measured points; 2) a 5×5 pixel median filter to remove noise; 3) a 5×5 pixel mean filter to smooth the surface; and 4) subtraction of a two-dimensional, second-order polynomial (determined via least-squares fit of the surface topology image) to remove the general form and flatten the surface. The second-order polynomial is defined by the following equation:
f(x, y)=c1+c2x+c3y+c4x2+c5y2+c6xy
Each data set that has been processed to this point as described above is referred to as a “preprocessed specimen data set.” The highest points of the resulting topology image correspond to those areas in contact with the convex surface of the tubing segment, and the lowest points are those points most distal below the convex surface of the tubing segment.
Contact Surface Areas and 2-98% Height ValueFor each of the 3D surface topography images of the five replicate specimens, the following analysis is performed on preprocessed specimen data sets. The Percent Surface Contact Area and 2-98% Height measurements are derived from the Areal Material Ratio (Abbott-Firestone) curve described in the ISO 13565-2:1996 standard extrapolated to surfaces. This curve is the cumulative curve of the surface height distribution histogram versus the range of surface heights measured. A material ratio is the ratio, expressed as a percent, of the area corresponding to points with heights equal to or above an intersecting plane passing through the surface at a given height, or cut depth, to the cross-sectional area of the evaluation region (field of view area). The height at a material ratio of 2% is initially identified. A cut depth of 100 μm below this height is then identified, and the material ratio at this depth is recorded as the Percent Surface Contact Area at 100 μm. This procedure is repeated at a cut depth of 200 μm and 300 μm below the identified height at a material ratio of 2%, and the material ratio at these depths are recorded as the Percent Surface Contact Area at 200 μm and the Percent Surface Contact Area at 300 μm respectively. All of the Percent Contact Area values are recorded to the nearest 0.1%.
The 2-98% Height of the specimen surface is defined as the difference in heights between two material ratios that exclude a small percentage of the highest peaks and lowest valleys. The 2-98% Height of the specimen surface is the height between the two cutting depths corresponding to a material ratio value of 2% to the material ratio of 98%, and is recorded to the nearest 0.01 mm.
Rugosity Frequency and Rugosity WavelengthThe preprocessed 3D surface topology images for each specimen are subjected to Fourier transform spatial frequency analysis to determine Rugosity Frequency and Rugosity Wavelength.
Each 3D surface topology image is deconstructed into individual line profiles by isolating each entire row of single data points that run in the dimension parallel to the elastic strands (if present and evident) of the elastic laminate, or, more generally, perpendicular to the rugosity exhibited by the elastic laminate in the relaxed state. These line profiles are therefore data sets in the form of height (in millimeters) versus distance (in millimeters).
For each replicate 3D surface topology image deconstructed, each line profile is mean centered, and a fast Fourier transform (FFT) is applied to calculate the frequency amplitude spectrum of each line profile. The Fourier transform amplitude versus spatial frequency spectra of all extracted line profiles are averaged, and the resulting average amplitude versus spatial frequency spectrum is defined as F(1/d), where 1/d is reciprocal distance in units of mm−1. Finally, the function P(1/d)=d×F2(1/d), the spatial frequency power spectral density with a prefactor of distance d to correct for the expected 1/d noise, is plotted versus 1/d. The value of reciprocal distance 1/d at which P(1/d) is at a maximum is defined as the Rugosity Frequency and is recorded in units of mm−1 to the nearest 0.001 mm−1. The reciprocal of the Rugosity Frequency is defined as the Rugosity Wavelength and is recorded in units of mm to the nearest 0.01 mm.
Reporting of Method ParametersAfter the 3D surface image analysis described above is performed on 3D surface topology images of all five specimen replicates, the following output parameters are defined and reported. The arithmetic mean of all five Percent Surface Contact Area at 100 μm measurements is defined as the Average Percent Surface Contact Area at 100 μm and is reported to the nearest 0.1%. The arithmetic mean of all five Percent Surface Contact Area at 200 μm measurements is defined as the Average Percent Surface Contact Area at 200 μm and is reported to the nearest 0.1%. The arithmetic mean of all five Percent Surface Contact Area at 300 μm measurements is defined as the Average Percent Surface Contact Area at 300 μm and is reported to the nearest 0.1%. The arithmetic mean of all five 2-98% Height measurements is defined as the Average 2-98% Height and is reported in units of mm to the nearest 0.01 mm. The arithmetic mean of all five Rugosity Frequency measurements is defined as the Average Rugosity Frequency and is reported in units of mm to the nearest 0.001 mm−1. The arithmetic mean of all five Rugosity Wavelength measurements is defined as the Average Rugosity Wavelength and is reported in units of mm to the nearest 0.01 mm.
Open AreaDefined as the percentage of a Section not occluded by elastic strands. Un-apertured films have an Open Area 0%. Apertured film Open Area=(area occupied by apertures)/(total film area). None of today's marketed disposable absorbent articles comprising a film in one or more of a belt, sided panel, or ear panel, waistband, cuff, wing are believed to have and Open Area above 50%. Open Area is defined as:
Open Area (%)=(Average-Strand-Diameter)/Average-Strand-Spacing
The Average-Pre-Strain of a specimen are measured on a constant rate of extension tensile tester (a suitable instrument is the MTS Insight using Testworks 4.0 Software, as available from MTS Systems Corp., Eden Prairie, Minn.) using a load cell for which the forces measured are within 1% to 90% of the limit of the cell. Articles are conditioned at 23° C.±2° C. and 50%±2% relative humidity for 2 hours prior to analysis and then tested under the same environmental conditions.
Program the tensile tester to perform an elongation to break after an initial gage length adjustment. First raise the cross head at 10 mm/min up to a force of 0.05N. Set the current gage to the adjusted gage length. Raise the crosshead at a rate of 100 mm/min until the specimen breaks (force drops 20% after maximum peak force). Return the cross head to its original position. Force and extension data is acquired at a rate of 100 Hz throughout the experiment.
Set the nominal gage length to 40 mm using a calibrated caliper block and zero the crosshead. Insert the specimen into the upper grip such that the middle of the test strip is positioned 20 mm below the grip. The specimen may be folded perpendicular to the pull axis, and placed in the grip to achieve this position. After the grip is closed the excess material can be trimmed. Insert the specimen into the lower grips and close. Once again, the strip can be folded, and then trimmed after the grip is closed. Zero the load cell. The specimen should have a minimal slack but less than 0.05 N of force on the load cell. Start the test program.
From the data construct a Force (N) verses Extension (mm). The Average-Pre-Strain is calculated from the bend in the curve corresponding to the extension at which the nonwovens in the elastic are engaged. Plot two lines, corresponding to the region of the curve before the bend (primarily the elastics), and the region after the bend (primarily the nonwovens). Read the extension at which these two lines intersect, and calculate the % Pre-Strain from the extension and the corrected gage length. Record as % Pre-strain 0.1%. Calculate the arithmetic mean of three replicate samples for each elastomeric laminate and Average-Pre-Strain to the nearest 0.1%.
Force Relaxation Over TimeThe Force Relaxation over Time of a specimen is measured on a constant rate of extension tensile tester (a suitable instrument is the MTS Insight using Testworks 4.0 Software, as available from MTS Systems Corp., Eden Prairie, Minn.) using a load cell for which the forces measured are within 1% to 90% of the limit of the cell. Articles are conditioned at 23° C.±2° C. and 50%±2% relative humidity for 2 hours prior to analysis and then tested under the same environmental conditions. Prepare a sample size such that it enables a gauge length of 25.4 mm (parallel to the elastic stretch) at a width of 12.7 mm.
Program the tensile tester to perform an elongation to determine the engineering strain at which the tensile force reaches 0.0294 N/mm.
Prepare and condition a second sample as described above for the Force Relaxation over time test. The test is performed on the same equipment as described above. It is performed at a temperature of 37.8° C. Extend the sample to the strain as determined above. Hold the sample for 10 hours and record the force at a rate of 100 Hz throughout the experiment a chart showing the data for an extruded strand prior art product and an inventive elastomeric laminate comprising beam elastic as described herein is show in
The influence of the gathering of the belt or waist band of an absorbent article on the potential integrity of a Graphic on the front and back of and absorbent article is measured by extending the article, applying a marker stripe and measuring the change in the area the stripe occupies once the tension is removed from the absorbent article. Articles are conditioned at 23° C.±2° C. and 50%±2% relative humidity for 2 hr prior to analysis and then tested under the same environmental conditions.
Place the product on a bench with the front of the article facing upward. Secure the left side seam of the article to the bench and elongate the product to a force of 10 gf/mm of belt width and secure the right side seam to the bench. Using a black marker (e.g. A Sharpie chisel tip permanent marker, or equivalent) apply a continuous 6 mm wide linear stripe from the left hand upper corner to the right hand lower corner of the belt, side panel, ear panel or waistband. Measure the dimensions of a bounding box around the marked stripe and record the length (L1) and width (W1) of the bounding box to the nearest 1 mm. Sample preparation and measurement in the extended state should be performed in less than 2 mins.
Unsecure the article and let the article retract to the untensioned state (5 min.). Measure the dimensions of a bounding box applied around the marked stripe the length (L2) and width (W2) of the bounding box and record to the nearest 1 mm.
Calculate the differences in the area of the figure as (L1×W1)−(L2×W2) and record to the nearest 1 mm2. Repeat the measurement on 5 products and record the average. Calculate the arithmetic average of the Lengths L1 and L2 and widths W1 and W2 and the differences in the areas for the replicates and report the linear measures to the nearest 1 mm and the areas to the nearest mm2. The Graphic Distortion Ratio is determined by dividing the final width W2 by the original width W1. Illustrations of the Graphic Distortion Ratio can be found in
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
Claims
1. An absorbent article, comprising:
- a chassis comprising a topsheet, a backsheet and an absorbent core disposed between the topsheet and the backsheet;
- a first elastomeric laminate comprising a first plurality of elastics between inner and outer nonwovens;
- wherein the first plurality of elastics has an Average-Strand-Spacing from about 0.25 mm to about 4 mm;
- wherein the Average-Dtex of the first plurality of elastics is from about 10 to about 500; and
- wherein the Pressure-Under-Strand of the first plurality of elastics is from about 0.1 to about 1 psi.
2. The absorbent article of claim 1, wherein the first elastomeric laminate forms at least a portion of at least one of the group consisting of a belt, a chassis, a side panel, a topsheet, a backsheet, an ear panel, and combinations thereof, and wherein the first plurality of elastics comprises from about 40 to about 1000 elastic strands.
3. The absorbent article of claim 1, wherein the first elastomeric laminate forms at least a portion of at least one of the group consisting of a waistband, a waistcap, an inner leg cuff, an outer leg cuff, a transverse barrier, and combinations thereof, and wherein the first plurality of elastics comprises from about 10 to about 400 elastic strands.
4. The absorbent article of claim 1, wherein the first plurality of elastics has an Open Area from about 80% to about 90%.
5. The absorbent article of claim 1, wherein the first plurality of elastics has a Pressure-Under-Strand from about 0.3 to about 0.8 psi.
6. The absorbent article according to claim 1, wherein the article further comprises a back belt formed by at least a portion of the first elastomeric laminate, wherein the back belt is divided into 4 equal sections, wherein Section 4 comprises a proximal end edge of the belt, Section 1 comprises a distal end edge of the back belt, Section 2 is proximate to Section 1 and Section 3 is proximate to Section 4, wherein at least two of the sections each have greater than 10 elastic strands, wherein the back belt is disposed in the back waist region, and wherein the back belt comprises one or more sections having a Section-Modulus of between about 4 gf/mm and 10 gf/mm.
7. The absorbent article of claim 1, wherein the article further comprises a first panel formed by at least a portion of the first elastomeric laminate, and wherein the article further comprises a second panel formed by at least a portion of a second elastomeric laminate comprising a second plurality of elastics between inner and outer nonwovens, wherein the second plurality of elastics have an Average-Strand-Spacing from about 0.25 mm to about 4 mm, an Average-Dtex from about 10 to about 500, and a Pressure-Under-Strand from about 0.1 to about 1 psi, and wherein each of the first and second panels comprise greater than about 25 elastic strands, and wherein the first and second panels are laterally opposed and disposed in the back waist region.
8. The absorbent article of claim 1, wherein the article further comprises a waistband formed by at least a portion of the first elastomeric laminate, wherein the waistband comprises greater than 20 elastic strands, wherein the waistband is disposed in the back waist region.
9. The absorbent article of claim 1, wherein the article further comprises an inner leg cuff formed by at least a portion of the first elastomeric laminate, wherein the inner leg cuff comprises greater than 15 elastic strands.
10. The absorbent article of claim 1, wherein the first plurality of elastics has a Percent Contact Area of at least one of: a) greater than about 11% at 100 um, b) greater than about 28% at 200 um, and c) greater than about 51% at 300 um, and wherein the first plurality of elastics has a 2%-98% Height Value of <1.6 mm.
11. The absorbent article of claim 1, wherein the first plurality of elastics has an Air Permeability of at least one of: a) greater than about 40 cubic meters/square meter/minute Air Permeability at 0 gf/mm (no extension); b) greater than about 60 cubic meters/square meter/minute Air Permeability at 3 gf/mm (slight extension); and c) greater than about 80 cubic meters/square meter/minute Air Permeability at 7 gf/mm (moderate extension).
12. The absorbent article of claim 1, wherein the first plurality of elastics has a Water Vapor Transmission Rate of greater than 4000 g/m2/24 hrs.
13. The absorbent article of claim 1, wherein the first plurality of elastics has a Caliper of from about 0.5 mm to about 4 mm at 0 gf/mm (no extension); and a Caliper Retention Value from about 60% to about 95% at 3 gf/mm (slight extension); and/or a Caliper Retention Value from about 40% to about 90% at 7 gf/mm (moderate extension).
14. The absorbent article of claim 1, wherein the first plurality of elastics has a Rugosity Frequency of from about 0.2 mm−1 to about 1 mm−1, and a Rugosity Wavelength of from about 0.5 mm to about 5 mm.
15. An absorbent article of claim 1, wherein the first plurality of elastics has a Cantilever Bending of less than about 40 mm.
16. A package comprising absorbent articles, comprising:
- a package material containing a plurality of absorbent articles and comprising an indicia indicating sizing information used to calculate an Average Targeted Weight, a Donning-Ratio, and a Target Body Length-to-Waist Silhouette;
- each absorbent article of the plurality absorbent articles, comprising: a chassis comprising a topsheet, a backsheet and an absorbent core disposed between the topsheet and the backsheet, wherein the chassis comprises a front end edge and a back end edge; a back belt disposed in the back waist region overlapping and extending longitudinally outboard of the back waist region of the chassis; a front belt disposed in the front waist region overlapping and extending longitudinally outboard of the front waist region of the chassis; a longitudinal axis; a lateral axis; wherein the first plurality of elastics has an Average-Strand-Spacing of less than 4 mm, and wherein the second plurality of elastics has an Average-Strand-Spacing of less than 4 mm; wherein the back belt is divided into 4 equal sections, wherein Section 4 comprises a proximal end edge of the back belt, Section 1 comprises a distal end edge of the back belt, Section 2 is proximate to Section 1 and Section 3 is proximate to Section 4; wherein the front belt is divided into 4 equal sections, wherein Section 4 comprises a proximal end edge of the front belt, Section 1 comprises a distal end edge of the front belt, Section 2 is proximate to Section 1 and Section 3 is proximate to Section 4; and wherein the absorbent article has the Donning-Ratio from about 1.0 and about 1.5.
17. The package of claim 16, wherein the difference between the Target Body Length-to-Waist Silhouette and a Product Length-to-Waist Silhouette is from about −0.3 to about 0.3.
18. The extensible article of claim 16, wherein the Product Hip-to-Waist Silhouette is from about 0.8 to about 1.1.
19. The package of claim 16, wherein one or more of the sections of the back belt has a Section-Modulus of from about 2 gf/mm to about 15 gf/mm, and wherein one or more of the sections of the front belt has a Section-Modulus of from about 2 gf/mm to about 15 gf/mm.
20. An extensible article, comprising:
- a front waist edge;
- a back waist edge;
- a longitudinal axis extending from the midpoint of the front waist edge to the midpoint of the back waist edge;
- a lateral axis extending perpendicular to the longitudinal centerline through the midpoint of the longitudinal centerline;
- a first elastomeric laminate forming at least a portion of a belt, a side panel, or an ear panel in a first waist region;
- a second elastomeric laminate forming at least a portion of a belt, a side panel, or an ear panel in a second waist region;
- a third elastomeric laminate formed by two substrate layers forming at least a portion of the chassis in a crotch region;
- wherein each of the first plurality of elastics, second plurality of elastics, and third plurality of elastics have an Average-Strand-Spacing from about 0.25 mm to about 4 mm;
- wherein the Average-Pre-Strain of each of the first plurality of elastics, second plurality of elastics and third plurality of elastics is from about 50% to about 400%;
- wherein the Average-Dtex of each of the first plurality of elastics, second plurality of elastics, and third plurality of elastics is from about 10 to about 500;
- wherein the third plurality of elastics has one or more of: a) an Average-Strand-Spacing that is greater than one or both of the first and second plurality of elastics, b) an Average-Dtex that is lower than one or both of the first and second plurality of elastics, c) an Average-Pre-Strain that is lower than one or both of the first and second plurality of elastics, and d) a number of elastics that is lower than one or both of the first and second plurality of elastics;
- wherein the elastic strands of each of the first plurality of elastics and second plurality of elastics are disposed substantially parallel to the lateral axis; and
- wherein the elastic strands of the third plurality of elastics are disposed substantially parallel to the longitudinal axis or substantially parallel to the lateral axis.
Type: Application
Filed: Dec 19, 2017
Publication Date: Jun 21, 2018
Inventors: Gary Dean LaVON (Liberty Township, OH), Bret Darren SEITZ (West Chester, OH), Uwe SCHNEIDER (Cincinnati, OH), Joseph Allen ECKSTEIN (Sunman, IN), Sarah Marie WADE (Springfield Township, OH)
Application Number: 15/846,745
