AU6844896A

AU6844896A - An absorbent article with asymmetric leg elastics

Info

Publication number: AU6844896A
Application number: AU68448/96A
Authority: AU
Inventors: Geoffrey Walter Frost; Mark Gordon Heath; Thomas Harold Roessler; Daniel Robert Schlinz; Paul Theodore Van Gompel
Original assignee: Kimberly Clark Corp
Current assignee: Kimberly Clark Worldwide Inc
Priority date: 1995-09-22
Filing date: 1996-08-08
Publication date: 1997-04-09
Anticipated expiration: 2016-08-08
Also published as: AR003998A1; JPH11512328A; CA2230130A1; BR9610566A; CO4750809A1; WO1997010785A1; MX9802118A; IL123695A0; AU702904B2; EP0851748A1

Description

AN ABSORBENT ARTICLE WITH ASYMMETRIC LEG ELASTICS

Field of the Invention

The present invention relates to elasticized absorbent articles. More particularly, the present invention relates to absorbent articles having elasticized leg openings.

Background of the Invention

Absorbent articles, such as disposable diapers, have included elasticized leg bands to provide elasticized gathers at the leg openings of the article. Each elasticized leg band can include various types of elastic members, such as single elastomeric strip, multiple elastomeric strips, or multiple elastomeric strands or threads arranged in separated, parallel or non-parallel configurations. The elastic members can be assembled into the article with a linear or curvilinear configuration and the curved leg elastic members can further include a reflexed curvature. Articles having the elasticized leg bands can provide improved fit and leakage protection, as compared to articles which do not include the elasticized leg bands.

Conventional elasticizing systems, such as those described above, have, however, continued to exhibit shortcomings. For example, the conventional elastic systems can increase the bulk at the crotch region of the article, and can allow excessive sagging at the waistband region of the article. Conventional systems have also provided insufficient conformance to the different, varied shapes present at the front and rear of a wearer's body. As a result, there has been a continued need for improved elastic systems for the leg band regions of articles, such as disposable diapers. Bπef Descnption of the Invention

The present invention can provide a distinctive article which includes a longitudinal direction, a lateral direction, laterally opposed side margins, longitudinally opposed end margins and an intermediate section which is located between the end margins at a longitudinally medial region of the article The article includes a backsheet, and an inboard elastic member connected to gather at least one side margin of the backsheet A substantially, longitudinally extending outboard elastic member is connected to substantially, longitudinally gather the at least one side margin The outboard elastic member is located laterally outboard of the inboard elastic member to provide a set of elastic members which are arranged in a staggered overlapping relation A major portion of a longitudinal end edge of the outboard elastic member is configured substantially coterminous with a terminal side edge of the at least one side margin at the intermediate portion of the article

A particular aspect of the invention provides an absorbent article having a front waistband portion, a back waistband portion, and intermediate crotch portion which interconnects the front and the back waistband portions, laterally opposed side margins, a longitudinal direction and a lateral direction The article includes a backsheet Iayer and a liquid permeable topsheet layer which is supeφosed and connected in facing relation to the backsheet An absorbent structure is sandwiched between the backsheet and the topsheet layer A first inboard elastic member is connected to gather a first of said side margins of the article, and a second inboard elastic member is connected to gather a second of the side margins A first, substantially longitudinally extending outboard elastic member is connected to substantially longitudinally gather the first side margin, and the first outboard elastic member is located laterally outboard of the first inboard elastic member to provide a first set of elastic members which are arranged in a first staggered overlapping relation A major portion of a longitudinal end edge of the first outboard elastic member is configured substantially coterminous with a terminal edge of a first side margin in the intermediate portion of the article A second, substantially longitudinally extending outboard elastic member is connected to substantially longitudinally gather the second side margin, and the second outboard elastic member is located laterally outboard of the second inboard elastic member to provide a second set of elastic members which are arranged in a second staggered overlapping relation A major portion of a longitudinal end edge of the second outboard elastic member is configured substantially coterminous with a terminal edge of the second side margin in the intermediate portion of the article

In its vaπous aspects, the article of the present invention can be more effectively produced on high speed manufactunng lines and can be readily constructed to provide a desired conformity to the different, natural body lines and shapes which are typically present at the front and back regions of a wearer's body The article can also exhibit less bunching at its crotch region and can provide reduced bulk in the crotch When the article is worn, the article can also exhibit less sagging at the waistband regions, and can provide improved body conformance and fit As a result, the article can be readily configured to exhibit improved resistance to leakage and to provide improved aesthetics

Bnef Descnption of the Drawings

The invention will be more fully understood and further advantages will become apparent when reference is made to the following detailed descnption and accompanying drawings in which

Fig 1 representatively shows a partially cut-away, top view of an article of the invention,

Fig 2 representatively shows a schematic, lateral cross-sectional view of the article, which is taken along line 2-2 of Fig 1 ,

Fig 3 representatively shows a schematic, longitudinal cross-sectional view of the article of Fig 1 ,

Fig 4 representatively shows a top view of a fastening system which is employed with the present invention,

Fig 5 representatively shows a schematic, lateral cross-sectional view of the fastening system of Fig 4 Detailed Descnption of the Invention

The structures of the present invention will be descnbed with respect to their use in disposable absorbent articles, which can be placed against or in proximity to the body of the wearer to absorb and contain vaπous exudates discharged from the body The articles are intended to be discarded after a limited peπod of use, and are not intended to be laundered or otherwise restored for reuse It should be understood, however, that the potential uses of the structures of the present invention are not limited to disposable absorbent articles While the present descnption will particularly be made in the context of a diaper article, it should be further understood that the present invention is also applicable to other disposable personal care absorbent articles, such as adult incontinence garments, sanitary napkins, children's training pants and the like

With reference to Fig 1 , an article, such as diaper 10, has a longitudinal direction 26, a lateral cross-direction 24, laterally opposed side margins 20, longitudinally opposed end margins 22, and an intermediate section 16 which is located between the end margins 22 at a longitudinally medial region of the article The article includes a backsheet layer 30, and an inboard elastic member 34 which is operably connected to gather at least one side margin of the backsheet A substantially longitudinally extending outboard elastic member 38 is also operably connected to substantially longitudinally gather the at least one side margin The outboard elastic member is located laterally outboard of the inboard elastic member 34 to provide a first set 33 of elastic members which are arranged in a first, staggered overlapping relation At least a major portion of a longitudinal end edge 82 of the outboard elastic member 38 is configured substantially coterminous with a terminal side edge 74 of a selected portion of the at least one side margin The coterminous structure is positioned in the intermediate portion 16 of the article

Another aspect of the invention provides an absorbent article, such as diaper 10, having a front waistband portion 12, a back waistband portion 14, and intermediate crotch portion 16 which interconnects the front and the back waistband portions, laterally opposed side margins 20, a longitudinal direction 26 and a lateral direction 24 The article includes a backsheet Iayer 30 and a liquid permeable topsheet Iayer 28 which is supeφosed and connected in facing relation to the backsheet An absorbent structure 32 is sandwiched between the backsheet 30 and the topsheet Iayer 28 A first inboard elastic member 34 is connected to gather a first of said side margins 20 of the article, and a second inboard elastic member 34 is connected to gather a second of the side margins 20 A first, substantially longitudinally extending outboard elastic member 38 is connected to substantially longitudinally gather the first side margin 20, and the first outboard elastic member is located laterally outboard of the first inboard elastic member to provide a first set 33 of elastic members which are arranged in a first staggered overlapping relation At least a major portion of a longitudinal end edge 82 of the first outboard elastic member is configured substantially coterminous with a terminal edge 74 of a first side margin in the intermediate portion 16 of the article A second, substantially longitudinally extending, outboard elastic member 38 is connected to substantially longitudinally gather the second side margin 20, and the second outboard elastic member is located laterally outboard of the second inboard elastic member 34 to provide a second set 37 of elastic members which are arranged in a second staggered overlapping relation At least a major portion of a longitudinal end edge of the second outboard elastic member is configured substantially coterminous with a terminal edge 74 of the second side margin 20 in the intermediate portion 16 of the article

Examples of other articles which include a system of dual, longitudinally-asymmetπc leg elastics are descπbed in U S Patent Application Senal No 259,288 of T Roessler et al entitled ABSORBENT ARTICLE HAVING DUAL ASYMMETRIC LEG ELASTICS, and filed June 13, 1994 (Attorney docket No 11 ,397), and a technique for making an article having longitudinally asymmetnc leg elastics is descπbed in U S Patent Application Seπal No 08/554,110 of T Roessler et al , entitled A METHOD AND APPARATUS FOR MAKING AN ABSORBENT ARTICLE WITH ASYMMETRIC LEG ELASTICS, and filed November 6, 1995 (Attomey docket No 11,770) The entire disclosures of these documents are incoφorated herein by reference in a manner that is consistent (not in conflict) herewith

Fig 1 is a representative plan view of diaper 10 of the present invention in its flat-out, uncontracted state (i e , with all elastic induced gatheπng and contraction removed)

Portions of the structure are partially cut away to more clearly show the inteπor construction of diaper 10, and the surface of the diaper which contacts the wearer is facing the viewer The outer edges of the diaper define a peπphery in which the longitudinally extending side edge margins are designated 20 and the laterally extending end edge margins are designated 22 The side edges define leg openings for the diaper, and optionally, are curvilinear and contoured The end edges are shown as straight, but optionally, may be curvilinear

Diaper 10 typically includes a porous, liquid permeable topsheet 28, a substantially liquid impermeable backsheet 30, an absorbent structure 32, positioned and connected between the topsheet and backsheet, a surge management portion 46, and elastic members, such as leg elastics 34 and waist elastics 42 The surge management portion is positioned in liquid communication with the absoΦent structure, and the absorbent structure includes a retention portion 48 The topsheet 28, backsheet 30, absorbent structure 32, surge management portion 46 and the elastic members 34 and 42 may be assembled in a vaπety of well-known diaper configurations In addition, the diaper can include a system of containment flaps 62, and can include side panel members 56. A fastening system, such as a mechanism which includes fastener tabs 36, can be employed to secure the article on the wearer

As representatively shown, the topsheet 28 and backsheet 30 may be generally coextensive, and may have length and width dimensions which are generally larger than the corresponding dimensions of absorbent structure 32 Topsheet 28 is associated with and supeπmposed on backsheet 30, thereby defining the peπphery of diaper 10 The waistband regions compnse those upper portions of diaper 10, which when worn, wholly or partially cover or encircle the waist or mid-lower torso of the wearer The intermediate, crotch region 16 lies between and interconnects waistband regions 12 and 14, and compnses that portion of diaper 10 which, when worn, is positioned between the legs of the wearer and covers the lower torso of the wearer Thus, the crotch region 16 is an area where repeated fluid surge typically occur in the diaper or other disposable absorbent article

Topsheet 28 presents a body-facing surface which is compliant, soft-feeling, and non¬ irritating to the wearer's skin Further, the topsheet 28 can be less hydrophilic than the retention portion 48, and is sufficiently porous to be liquid permeable, permitting liquid to penetrate through its thickness A suitable topsheet 28 may be manufactured from a wide selection of web matenals, such as porous foams, reticulated foams, apertured plastic films, natural fibers (for example, wood or cotton fibers), synthetic fibers (for example, polyester or polypropylene fibers), or a combination of natural and synthetic fibers. Topsheet 28 is typically employed to help isolate the wearer's skin from liquids held in absorbent structure 32 Vaπous woven and nonwoven fabπcs can be used for topsheet 28 For example, the topsheet may be composed of a meltblown or spunbonded web of polyolefin fibers The topsheet may also be a bonded-carded-web composed of natural and/or synthetic fibers

For the puφoses of the present descnption, the term "nonwoven web" means a web of mateπal which is formed without the aid of a textile weaving or knitting process The term "fabπcs" is used to refer to all of the woven, knitted and nonwoven fibrous webs

The topsheet fabπcs may be composed of a substantially hydrophobic and substantially nonwettable mateπal, and the hydrophobic mateπal may optionally be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity In a particular embodiment of the invention, topsheet 28 can be a nonwoven, spunbond polypropylene fabπc composed of about 2 8-3 2 denier fibers formed into a web having a basis weight of about 22 gsm and density of about

0 06 gm/cc The fabπc can be surface treated with a selected amount of surfactant, such as about 0 28% Tπton X-102 surfactant The surfactant can be applied by any conventional means, such as spraying, pπnting, brush coating or the like

The surfactant matenal, such as a conventional wetting agent, can be applied to a medial section of the topsheet Iayer 28 to provide a greater wettability of the medial section, as compared to a remainder of the topsheet layer 28 In particular configurations, the cross- directional width of the medial section can be substantially equal to or less than the cross-directional width of the surge management portion 46 In alternative configurations, the medial section width can be substantially equal to or less than a cross-directional spacing between a pair of adhesive stπps employed to secure the containment flaps 62 onto topsheet 28 and to form a leak resistant bamer seal onto the backsheet 30

The surfactant-treated medial section can be approximately centered with respect to the longitudinal centerline of the diaper, and can extend along substantially the entire length of the topsheet Iayer Alternatively, the surfactant treated medial section can be constructed to extend along only a predetermined portion of the topsheet length The vaπous configurations of the invention can include elasticized containment flaps 62 The shown configurations, for example, include two containment flaps 62 which are connected to the bodyside surface of topsheet Iayer 28 Suitable constructions and arrangements for containment flaps 62 are descπbed, for example, in U S Patent No 4,704,116 issued November 3, 1987, to K Enloe, the disclosure of which is hereby incoφorated by reference in a manner that is consistent (not contradictory) herewith Other configurations of the containment flaps 62 are descπbed in U S Patent Application Seπal No 206,816 of R Everett et al , filed March 4, 1994 and entitled ABSORBENT ARTICLE HAVING AN IMPROVED SURGE MANAGEMENT (Attomey docket No 11,375), the disclosure of which is hereby incoφorated by reference in a manner that is consistent herewith

The containment flaps can be attached to topsheet Iayer 28 along length-wise extending fixed regions, such as fixed edges 64, of the flaps A movable edge 66 of each containment flap includes a flap elastic member 68 which can compπse one or more individual strands of elastomeπc mateπal For example, a plurality of elastic strands may be configured in a spatially separated, generally parallel arrangement, and a suitable elastic strand can, for example, be composed of a 470 decitex Lycra® elastomer Elastic member 68 is connected to the movable edge of the containment flap in an elastically contractible condition such that the contraction of the elastic components thereof gathers and shortens the edge of the containment flap As a result, the movable edge of each containment flap tends to position itself in a spaced relation away from the bodyside surfaces of topsheet 28 and/or surge management portion 46 toward a generally upnght and approximately peφendicular configuration, especially in the crotch section of the diaper In the shown embodiment, for example, the moveable edge of the bamer flap is connected to the flap elastics by partially doubling the flap mateπal back upon itself by a limited amount which is sufficient to enclose flap elastics 68

At least a pair of containment or bamer flaps 62 are connected to laterally opposed, longitudinally extending regions of topsheet Iayer 28, and the connected topsheet regions are located generally adjacent to laterally opposed side edge regions of the medial section of topsheet layer 28 The connected topsheet regions are typically located substantially laterally inboard of all of the leg elastics of the diaper article 10, but may optionally be located outboard of all of the leg elastics, or outboard of only a portion of the leg elastics In one aspect of the invention, for example, the base of each containment flap can be attached along the topsheet within a lateral spacing which is provided by a length-wise extending region positioned between the particular inboard elastic member 34 and outboard elastic member 38 that are associated with the containment flap The base attachment of the containment flap may be configured to operably extend through the topsheet and connect to the backsheet 30 to provide an operable, length-wise extending bamer or sealing line

The containment flaps may, for example, be constructed of a fibrous mateπal which is similar to the matenal compnsmg topsheet 28, or similar to the mateπal compnsing surge management portion 46 Other conventional mateπals, such as polymer films, may also be employed In other aspects of the invention, bamer flaps 62 are constructed of a matenal which is permeable only to gas, such as ambient air Alternative configurations of the invention can include bamer flaps which are constructed of a matenal which is resistant to a passage of aqueous liquid, such as uπne, therethrough For example, bamer flaps 62 may be constructed of a spunbond-meltblown-spunbond (SMS) laminate matenal in the illustrated embodiment, for example, the bamer flaps can be constructed of a SMS matenal having a basis weight of about 0 85 osy (about 28 gsm) The spunbond layers are composed of polypropylene fibers, and the meltblown Iayer is composed of meltblown polypropylene fibers

In the vaπous configurations of the invention, such as where the bamer flaps 62 are configured to be permeable to gas while having a resistance and limited permeability to aqueous liquid, the liquid resistant matenal can have a construction which is capable of supporting a hydrohead of at least about 45 cm of water substantially without leakage therethrough A suitable technique for determining the resistance of a mateπal to liquid penetration is Federal Test Method Standard FTMS 191 Method 5514, dated 31 December 1968

Backsheet 30 may be composed of a liquid permeable mateπal, but preferably compnses a mateπal which is configured to be substantially impermeable to liquids For example, a typical backsheet can be manufactured from a thin plastic film, or other flexible liquid-impermeable matenal Such "flexible" matenals are compliant and will readily conform to the general shape and contours of the wearer's body Backsheet 30 can help prevent the exudates contained in absorbent structure 32 from wetting articles such as bedsheets and overgarments which contact diaper 10 In particular embodiments of the invention, backsheet 30 is a polyethylene film having a thickness of from about 0 012 mm (about 0 5 mil) to about 0 051 mm (about 2 0 mils) In the shown embodiment, for example, the backsheet is a film having a thickness of about 0 032 mm (about 1 25 mil) Alternative constructions of the backsheet may compπse a woven or non-woven fibrous web Iayer which has been totally or partially constructed or treated to impart a desired level of liquid impermeability to selected regions of the backsheet that are adjacent or proximate the absorbent body Backsheet 30 typically provides the outer cover of the article Optionally, however, the article may compπse a separate outer cover member which is in addition to the backsheet

Backsheet 30 may include a micro-porous, "breathable" mateπal which permits gases to escape from absorbent structure 32 while still substantially preventing liquid exudates from passing through the backsheet For example, the breathable backsheet may be composed of a microporous polymer film or a nonwoven fabπc which has been coated or otherwise treated to impart a desired level of liquid impermeability For example, a suitable microporous film is a PMP-1 mateπal, which is available from Mitsui Toatsu Chemicals, Inc , a company having offices in Tokyo, Japan, or an XKO-8044 polyolefin film available from 3M Company of Minneapolis, Minnesota The backsheet can also be embossed or otherwise be provided with a matte finish to exhibit a more aesthetically pleasing appearance

The size of backsheet 30 is typically determined by the size of absorbent structure 32 and the exact diaper design selected Backsheet 30, for example, may have a generally T-shape, a generally l-shape or a modified hourglass shape, and may extend beyond the terminal edges of absorbent structure 32 by a selected distance, such as a distance within the range of about 1 3 -2 5 cm (about 0 5 - 1 0 inch), to provide side margins

Topsheet 28 and backsheet 30 are connected or otherwise associated together in an operable manner As used therein, the term "associated" encompasses configurations in which topsheet 28 is directly joined to backsheet 30 by affixing topsheet 28 directly to backsheet 30, and configurations wherein topsheet 28 is joined to backsheet 30 by affixing topsheet 28 to intermediate members which in tum are affixed to backsheet 30 Topsheet 28 and backsheet 30 can be affixed directly to each other in selected regions, such as in areas along the diaper peπphery, by attachment means (not shown), such as

- io - an adhesive, sonic bonds, thermal bonds or any other attachment means known in the art For example, a uniform continuous Iayer of adhesive, a pattemed layer of adhesive, a sprayed pattem of adhesive or an array of separate lines, swirls or spots of construction adhesive may be used to affix topsheet 28 to backsheet 30 It should be readily appreciated that the above-descnbed attachment means may also be employed to interconnect and assemble together the vaπous other component parts of the article descnbed herein

In the representatively shown embodiment of the invention, the topsheet Iayer 28 is disposed and secured in facing relation with the backsheet Iayer 30 to retain and hold the retention portion 48 and the surge management 46 between the backsheet layer and the topsheet Iayer The marginal side regions of topsheet layer 28 are operably connected to corresponding marginal side regions of the backsheet Iayer 30 Each of the attached marginal side regions of the topsheet and backsheet layers is located laterally outboard of its corresponding, associated side edge region of the surge management portion 46

In particular configurations of the invention, the topsheet 28 can include attached marginal end regions, which are located longitudinally outboard of the end edge regions of the retention portion 48 and/or surge management portion 46 Similarly, the backsheet 30 can include attached marginal end regions, which can be located longitudinally outboard of the end edge regions of the retention portion and/or surge management portion

Elastic members 34 and 38 are disposed adjacent to the peπphery of diaper 10 along each of the shown laterally opposed pair of longitudinally extending side edges 20 The leg elastic members 34 and 38 can be connected to either or both of the topsheet and backsheet layers to provide elasticized side margins of the diaper article, and can be constructed to draw and hold diaper 10 against the legs of the wearer Waist elastic members 42 may also be disposed adjacent to either or both of the end edges of diaper 10 to provide elasticized waistbands Examples of suitable elasticized waistbands are descπbed in U S Patent 4,861,652 entitled DIAPER ARTICLE WITH ELASTICIZED

WAIST PANEL, and issued August 29, 1989 to M Lippert et al , the entire disclosure of which is incoφorated herein by reference in a manner that is consistent herewith

The vanous elastic members 34, 38 and 42 are secured to diaper 10 in an elastically contractible condition so that in a normal under strain configuration, the elastic members effectively contract against diaper 10 The elastic members can be secured in an elastically contractible condition in at least two ways, for example, the elastic members may be stretched and secured while diaper 10 is in an uncontracted condition Alternatively, diaper 10 may be contracted, for example, by pleating, and the elastic members secured and connected to diaper 10 while the elastic members are in their unrelaxed or unstretched condition Still other means, such as heat-shπnk elastic mateπal, may be used to gather the garment

In the configuration illustrated in Fig 1 , leg elastic members 34 and 38, in combination, extend essentially along the complete length of the diaper crotch region 16 of diaper 10, which typically is the region of the article appointed for placement between the legs of the wearer Alternatively, the elastic members 34 may extend the entire length of diaper 10, or any other length suitable for providing the arrangement of elastically contractible lines desired for the particular diaper design

The elastic members 34, 38 and 42 may have any of a multitude of alternative configurations For example, the width of the individual elastic members may be vaned from 0 25 millimeters (0 01 inches) to 25 millimeters (1 0 inches) or more The elastic members may compnse a single strand or stnp of elastic mateπal, or may compnse a plurality of parallel or non-parallel strands of elastic matenal The elastic members may be applied in a rectilinear or curvilinear arrangement Where multiple strands are employed, the individual strands may be constmcted to provide substantially equal elastic forces, or may be constructed to provide different elastic forces For example, the individual strands may be of different diameter or other size, or may be configured with different amounts of elongation to thereby provide a gradient or other vanation of elastic tensions Where the strands are non-parallel, two or more of the strands may intersect or otherwise interconnect within the elastic member The elastic members may be affixed to the diaper in any of several ways which are known in the art For example, the elastic members may be ultrasonically bonded, heat and pressure sealed using a vaπety of bonding pattems, or adhesively bonded to diaper 10 with sprayed or swirled pattems of hotmelt or other type of adhesive

In the illustrated embodiments of the invention, for example, leg elastic members 34 and/or 38 may compπse a camer sheet to which are attached a grouped set of elastics composed of a plurality of individual elastic strands The elastic strands may intersect or be interconnected, or may be entirely separated from one another The camer sheet may, for example, compπse a 0 002 cm thick film of unembossed polypropylene mateπal The elastic strands can, for example, be composed of LYCRA® elastomer available from DuPont, a business having offices in Wilmington, Delaware Each elastic strand is typically within the range of about 620-1050 decitex (dtx), and preferably, is about

940 dtx in an embodiment of the invention wherein three strands are employed for each elasticized legband In addition, leg elastics 34 and/or 38 may be generally straight or optionally curved For example, the curved elastics can be inwardly bowed toward the longitudinal centerline of the diaper In particular arrangements, the curvature of the elastics may not be configured or positioned symmetπcally relative to the lateral centerline of the diaper The curved elastics may have an inwardly bowed and outwardly bowed, reflex-type of curvature, and the length-wise center of the elastics may be offset by a selected distance toward either the front or rear waistband of the diaper to provide desired fit and appearance

In the vaπous configurations of the invention, the system of elastic members can form elasticized gathers at appointed leg opening portions of the article which are located along at least a portion of the lateral side margins 20 In the shown configuration, the elasticizing means includes a first group of laterally opposed, longitudinally extending, inboard leg elastic members 34 which are located in the article side margins in at least the intermediate portion 16 of the article The inboard leg elastic members 34 may be substantially symmetπcally arranged with respect to the longitudinal length 27 of the article Alternatively, the inboard leg elastic members may be arranged asymmetπcally with respect to the article length, and optionally can have a selected offset or bias toward the front waistband portion 12 of the article An outboard grouping of laterally opposed, longitudinally extending leg elastic members 38 are constructed separate from the inboard group of leg elastic members 34, and are located in the article side margins 20 in at least the intermediate portion 16 of the article The outboard leg elastic members are arranged asymmetπcally with respect to the article length 27 Desirably, the outboard elastic members have a selected bias or offset toward the back waistband portion 14 of the article In desired arrangements, one or more of the inboard and outboard leg elastic members can include a plurality of separate, generally longitudinally extending, elastomeπc strands With the representatively shown arrangements, a substantial entirety of the end edges of the outboard elastics are substantially coterminous with terminal side edges of the backsheet 30 The major portion of the longitudinal end edges of the first and second outboard elastic members 38 may or may not be substantially coterminous with the topsheet Iayer 28 in the intermediate portion of the article Desirably, the longitudinal end edges of the outboard elastic members 38 are constructed to be substantially coterminous with the topsheet Iayer

In particular aspects of the invention, the inboard elastic member 34 can have a length- to-width aspect ratio of at least about 4 1 In another aspect of the invention, the outboard elastic member 38 has a length-to-width aspect ratio of at least about 4 1. In other aspects of the invention, each of the first and second inboard elastic members can have a length-to-width aspect ratio of at least about 4 1 In addition each of the first and second outboard elastic members 38 can have a length-to-width aspect ratio of at least about 4 1 Alternatively, the individual inboard and/or outboard elastic members can have an aspect ratio which is at least about 6 1 , and optionally, is at least about 10 1 Larger aspect ratios of up to 100 1 may also be employed, as desired to provide selected benefits

Each inboard leg elastic member 34 can intersect its associated, cooperating outboard elastic member 38 Optionally, the entirety of the inboard elastic can be laterally spaced from its correspondingly associated outboard leg elastic member by a selected minimum, lateral spacing distance In particular aspects of the invention, the minimum lateral spacing distance can be not less than about 0 5 cm Alternatively, the lateral spacing distance can be not less than about 1 cm, and optionally, can be not less than about 5 cm In other aspects of the invention, the lateral spacing distance between the corresponding inboard and outboard leg elastic members can be not more than about 20 cm Alternatively, the lateral spacing distance can be not more than about 15 cm, and optionally, can be not more than about 10 cm to provide desired performance

In a particular aspect of the invention, at least one side margin 20 of the article has a terminal side edge 74 with a section thereof having a outwardly concave, substantially C-shape indent edge 84 The indent edge extends across not more than about 50 percent of a total, straight-line, longitudinal length 27 of the article, with a substantial entirety of the longitudinal end edge 82 of the associated outboard elastic member 38 configured substantially coterminous with the indent edge 84 of the side margin 20 at the intermediate portion 16 of the article

Desirably, both side margins of the article have similar C-shape indent edges, with the C-shapes on the opposite sides configured substantially as mirror images of each other

Thus, the second side margin 20 of the article can also have a longitudinally extending, terminal side edge 74 with a section thereof having a second, outwardly concave, substantially C-shape indent edge 84 The second indent edge 84 extends along not more than about 50 percent of the total length of the article, with a substantial entirety of the longitudinal end edge 82 of the second outboard elastic member 38 configured substantially coterminous with the indent edge 84 of a second side margin 20 in the intermediate portion 16 of the article

The vaπous arrangements of the invention can be configured with one or more of the indent edges 84 extending across not more than about 40% of the total length of the article Alternatively, the indent edges may extend over not more than about 30%, and optionally, not more than about 25% of the total article length In addition, the indent edges 84 may have a length-wise extent which is small as 5% of the total article length

In the vaπous arrangements of the invention, the outboard elastic, particulariy its terminal side and/or end edges, is desirably configured to substantially avoid bndging an inwardly bowed edge, such as the C-shape indent edge 84, of the backsheet along at least one of the side margins of the article Thus, another aspect of the invention provides an article wherein the first side margin 20 of the article has a first terminal side edge 74 with a section thereof having a first outwardly concave, substantially C-shape indent edge 84

The longitudinal end edge 82 of the first outboard elastic member 38 is configured substantially coterminous with the indent edge 84 of the first side margin 20 in the intermediate portion 16 of the article, and the first outboard elastic member 38 is configured to substantially avoid bπdging beyond and/or across the indent edge 84

Desirably, both outboard elastics are configured to substantially avoid bπdging an inwardly bowed edge, such as the C-shape indent edge 84, of the backsheet along both of the side margins of the article Thus, the second side margin 20 of the article can have a second terminal side edge 74 with a section thereof having a second outwardly concave, substantially C-shape indent edge 84 The longitudinal end edge 82 of the second outboard elastic member 38 is configured substantially coterminous with the indent edge 84 of the second side margin 20 in the intermediate portion 16 of the article, and the second outboard elastic member 38 is configured to substantially avoid bπdging the indent edge 84

The vaπous arrangements of the invention can include sets 33 or 37 of elastic members which are longitudinally asymmetnc, with one end portion of the elastic set having a configuration which differs from the configuration at the opposite end portion of the elastic set More particularly, the asymmetπc elastic set can include a greater proportion of the elastic matenal toward one of its longitudinal ends, desirably the end of the elastic set which is proximate the back waistband portion 14 of the article

In the illustrated configuration, for example, the inboard elastic members 34 are longer than their associated, rearwardly biased outboard elastic members 38, and overlap an approximate entirety of the outboard elastic members The vaπous aspects of the invention can also be configured to have an end portion of each inboard leg elastic member 34 arranged in a longitudinally overlapping relation with respect to a selected end portion of its correspondingly associated and cooperating outboard leg elastic member 38 Each inboard leg elastic member can be arranged substantially parallel to its associated outboard leg elastic member along the region of overlap Alternatively, each inboard leg elastic member 34 can be arranged substantially non-parallel to its associated outboard leg elastic member 38 along the region of overlap In particular configurations, the corresponding inboard and outboard leg elastics may be mutually partially-overlapping, the inboard leg elastic member may partially overlap its corresponding outboard leg elastic member, and the outboard leg elastic member may partially overlap its corresponding inboard leg elastic member

An absorbent body, such as absorbent structure 32, is positioned between topsheet 28 and backsheet 30 to form diaper 10 The absorbent body has a construction which is generally compressible, conformable, non-irπtating to the wearer's skin, and capable of absoΦing and retaining liquid body exudates It should be understood that, for puφoses of this invention, the absorbent structure may compπse a single, integral piece of mateπal, or alternatively, may compπse a plurality of individual separate pieces of mateπal which are operably assembled together Where the absoΦent structure compnses a single, substantially integral piece of mateπal, the mateπal could include the desired structural features formed into selected spatial regions thereof Where the absorbent structure compnses multiple pieces, the pieces may be configured as discrete layers or as other nonlayered shapes and configurations Furthermore, the individual pieces may be coextensive or non-coextensive, depending upon the requirements of the product It is preferred, however, that each of the individual pieces be arranged in an operable, intimate contact along at least a portion of its boundary with at least one other adjacent piece of the absorbent structure Preferably, each piece is connected to an adjacent portion of the absorbent structure by a suitable bonding and/or fiber entanglement mechanism, such as ultrasonic or adhesive bonding, or mechanical or hydraulic needling

In the embodiment representatively shown in Fig 1, absorbent structure 32 includes a liquid-acquisition, target zone, and has a contoured, curvilinear peπphery, particularly along its side edges The two generally mirror-image, inwardly bowed, lateral edges provide for a narrower inteπnediate section suitable for positioning in the crotch of the wearer In the shown absorbent structure 32, a front section thereof includes two transversely spaced ear regions and a central region The target zone encompasses the area where repeated liquid surges typically occur in absorbent structure 32 When the diaper is worn, the ear regions are configured to generally engage the sides of the wearer's waist and torso, and central region is configured to generally engage the medial portion of the wearer's waist and torso

AbsoΦent structure 32 may be manufactured in a wide vanety of sizes and shapes (for example rectangular, trapezoidal, T-shape, l-shape hourglass shape, etc ) and from a wide vaπety of mateπals The size and the absoΦent capacity of absoΦent structure 32 should be compatible with the size of the intended wearer and the liquid loading imparted by the intended use of the absorbent article Further, the size and the absorbent capacity of absorbent structure 32 can be vaned to accommodate wearers ranging from infants through adults In addition, it has been found that with the present invention, the densities and/or basis weights of the respective surge management 46 and retention 48 portions as well as their relative ratios, can be vaned In a particular aspect of the invention, the absoΦent structure has an absorbent capacity of at least about 300 gm of synthetic unne Alternatively, the absorbent structure can have an absorbent capacity of at least about 400 gm of synthetic uπne to provide improved performance Vaπous types of wettable, hydrophilic fibrous matenal can be used to form the component parts of absoΦent structure 32 Examples of suitable fibers include naturally occumng organic fibers composed of intnnsically wettable mateπal, such as cellulosic fibers, synthetic fibers composed of cellulose or cellulose denvatives, such as rayon fibers, inorganic fibers composed of an inherently wettable mateπal, such as glass fibers synthetic fibers made from inherently wettable thermoplastic polymers, such as particular polyester or polyamide fibers, and synthetic fibers composed of a nonwettable thermoplastic polymer, such as polypropylene fibers, which have been hydrophilized by appropnate means The fibers may be hydrophilized, for example, by treatment with silica, treatment with a mateπal which has a suitable hydrophilic moiety and is not readily removable from the fiber, or by sheathing the nonwettable, hydrophobic fiber with a hydrophilic polymer duπng or after the formation of the fiber For the puφoses of the present invention, it is contemplated that selected blends of the vaπous types of fibers mentioned above may also be employed

As used herein, the term "hydrophilic" descnbes fibers or the surfaces of fibers which are wetted by the aqueous liquids in contact with the fibers The degree of wetting of the matenals can, in turn, be descnbed in terms of the contact angles and the surface tensions of the liquids and matenals involved Equipment and techniques suitable for measuπng the wettability of particular fiber matenals or blends of fiber matenals used for the surge management portion 46 can be provided by a Cahn SFA-222 Surface Force Analyzer System, or a substantially equivalent system When measured with this system, fibers having contact angles less than 90° are designated "wettable" or hydrophilic, while fibers having contact angles greater than 90° are designated "nonwettable" or hydrophobic

The retention portion 48 can compπse a matπx of hydrophilic fibers, such as a web of cellulosic fluff, mixed with particles of high-absorbency matenal In particular arrangements, the retention portion 48 may compπse a mixture of superabsorbent hydrogel-forming particles and synthetic polymer meltblown fibers, or a mixture of superabsorbent particles with a fibrous coform mateπal compnsing a blend of natural fibers and/or synthetic polymer fibers The superabsorbent particles may be substantially homogeneously mixed with the hydrophilic fibers, or may be nonuniformly mixed For example, the concentrations of superabsorbent particles may be arranged in a non-step- wise gradient through a substantial portion of the thickness (z-direction) of the absorbent structure, with lower concentrations toward the bodyside of the absorbent structure and relatively higher concentrations toward the outerside of the absoΦent structure Suitable z-gradient configurations are descnbed in U S Patent 4,699,823 issued October 13, 1987 to Kellenberger et al , the disclosure of which is incoφorated herein by reference in a manner that is consistent with the present descnption The superabsoΦent particles may also be arranged in a generally discrete Iayer within the matnx of hydrophilic fibers or may be configured as discrete, separate pocket regions of superabsoΦent mateπal In addition, two or more different types of superabsoΦent may be selectively positioned at different locations within or along the fiber matπx

The high-absoΦency mateπal may compπse absorbent gelling mateπals, such as superabsorbents The absorbent gelling mateπals can be natural, synthetic and modified natural polymers and matenals In addition, the absoΦent gelling matenals can be inorganic mateπals, such as silica gels, or organic compounds such as cross-linked polymers The term "cross-linked" refers to any means for effectively rendenng normally water-soluble matenals substantially water insoluble but swellable Such means can include, for example, physical entanglement, crystalline domains, covalent bonds, ionic complexes and associations, hydrophilic associations, such as hydrogen bonding, and hydrophobic associations or Van der Waals forces

[Examples of synthetic absorbent gelling matenal polymers include the alkali metal and ammonium salts of poly(acrylιc acid) and poly (methacrylic aαd), poly(acrylamιdes), poly(vιnyl ethers), maleic anhydπde copolymers with vinyl ethers and alpha-olefins, poly(vιnyl pyrrolidone), poly(vιnylmoφholιnone), poly(vιnyl alcohol), and mixtures and copolymers thereof Further polymers suitable for use in the absoΦent stmcture include natural and modified natural polymers, such as hydrolyzed acrylonitnle-grafted starch, acrylic acid grafted starch, methyl cellulose, carboxymethyl cellulose, hydroxypropyl cellulose, and the natural gums, such as alginates, xanthan gum, locust bean gum and the like Mixtures of natural and wholly or partially synthetic absorbent polymers can also be useful in the present invention Other suitable absorbent gelling mateπals are disclosed by Assarsson et al in U S Patent 3,901 ,236 issued August 26, 1975 Processes for prepanng synthetic absoΦent gelling polymers are disclosed in U S Patent 4,076,663 issued February 28, 1978 to Masuda et al and U S Patent 4,286,082 issued August 25, 1981 to Tsubakimoto et al Synthetic absoΦent gelling materials typically are xerogels which form hydrogels when wetted. The term "hydrogel", however, has commonly been used to also refer to both the wetted and unwetted forms of the mateπal.

As mentioned previously, the high-absorbency matenal used in the retention portion 48 is generally in the form of discrete particles. The particles can be of any desired shape, for example, spiral or semi-spiral, cubic, rod-like, polyhedral, etc Shapes having a large greatest dimension/smallest dimension ratio, like needles, flakes, and fibers, are also contemplated for use herein. Conglomerates of particles of absorbent gelling material may also be used in the retention portion 48

Preferred for use are particles having an average size of from about 20 microns to about 1 millimeter. "Particle size" as used herein means the weighted average of the smallest dimension of the individual particles.

Suitable high-absorbency materials can have particular charactenstics of Absorbent Capacity (sometimes referred to as "AC"), Deformation Under Load (sometimes referred to as "DUL"), and the Wicking Index (sometimes referred to as "Wl"). These parameters are descπbed in detail in U.S. Patent Application Seπal No. 757,787 of S. Byerly et al., entitled ABSORBENT COMPOSITES AND ABSORBENT ARTICLES CONTAINING

SAME and filed on September 11, 1991 (Attomey Docket No. 10,174), the disclosure of which is hereby incoφorated by reference in a manner that is consistent with the present specification.

In a particular aspect of the invention, the absorbent retention portion 48 compnses a matrix of substantially hydrophilic fibers having a quantity of high-absorbency material distributed therein. Selected superabsorbent polymers having improved absorbent properties can be important for maximizing the performance while retaining the desired thinness of the absoΦent article. To provide improved performance, the particles of superabsorbent mateπal can be selected to provide an absorbency-under-load (AUL) value which is within the range of about 25-40, and provide a AbsoΦent Capacity (AC) value which is within the range of about 32-48. The rate of liquid uptake by the superabsorbent mateπal is within the range of about 3-15 g/g (grams liquid per gram superabsorbent) at 30 seconds of absorbency under load, 6.5-21 g/g at 5 minutes absorbency under load and 25-40 g/g at 60 minutes absorbency under load. A suitable method for determining AUL is described in detail in U.S. Patent Application Serial No. 184,302 of S. Kellenberger and entitled ABSORBENT PRODUCTS CONTAINING HYDROGELS WITH ABILITY TO SWELL AGAINST PRESSURE (Attomey docket No. 8786); European Patent Application No. EP 0 339 461 A1, published November 2, 1989; the disclosure of which is hereby incoφorated by reference in a manner that is consistent with the present specification.

An example of superabsorbent polymer suitable for use in the present invention is SAN WET IM 3900 polymer available from Hoechst Celanese, a business having offices in Portsmouth, Virginia. Other suitable superabsorbents may include W45926 polymer obtained from Stockhausen, a business having offices in Greensboro, North Carolina.

The matrix of hydrophilic fibers comprising the retention portion 48 may be a Iayer of cellulosic wood pulp fluff, and the particles of superabsorbent polymer can be distributed within the matrix of hydrophilic fibers. The hydrophilic fibers and high-absorbency particles can be provided in a fiber-to-particle ratio which is not more than about 75:25, altematively, is not more than about 70:30, and optionally, is not more than about 55:45, by weight. In further aspects of the invention, the fiber-to-particle ratio is not less than about 25:75, preferably is not less than about 30:70 and more preferably is not less than about 45:55, by weight. Such fiber-to-particle ratios can be particularly desirable in the target zone of the absorbent structure. In particular embodiments of the invention, the fiber-to-particle weight ratio is not more than about 65:35 and is not less than about 50:50 to provide desired performance.

The hydrophilic fibers and high-absorbency particles can form an average composite basis weight which is within the range of about 400-900 gsm. Again, such basis weight is particularly desirable in the target zone of the absoΦent structure. In certain aspects of the invention, the average composite basis weight is within the range of about 500-800 gsm, and preferably is within the range of about 550-750 gsm to provide desired performance.

To provide the desired thinness dimension to the various configurations of the absoΦent article of the invention, the retention portion 48 can be configured with a bulk thickness which is not more than about 0.6 cm. Preferably, the bulk thickness is not more than about 0.53 cm, and more preferably is not more than about 0.5 cm to provide improved benefits. The bulk thickness is determined under a restraining pressure of 0.2 psi (1.38 kPa).

The density of the retention portion 48 or other components of the absoΦent article can be calculated from its basis weight and thickness. With respect to diapers, for example, the weight and thickness are measured on newly unpacked, unfolded and dry diapers at a restraining pressure of 0.2 psi (1.38 kPa). Conventional thickness measuring devices may be employed to determine the thickness needed to calculate the density.

In the illustrated embodiments of the invention, for example, the absoΦent retention portion 48 includes 4-22 grams of wood pulp fluff, preferably includes about 8-14 grams of fluff and more preferably includes about 10-12 grams of fluff to provide desired benefits. The wood pulp fluff generally provides shape and form to diaper 10, and carries and positions the particles of superabsorbent polymer or other high-absorbency material. The retention portion 48 can contain about 7-12 grams of superabsoΦent polymer, and in the shown embodiment, contains about 8.5 grams of superabsorbent polymer. Sufficient superabsorbent polymer is incoφorated into the retention portion 48 to provide an adequate total absoΦent capacity of at least about 300 gm of urine. For example, a medium size diaper for an infant weighing about 13-23 lb (about 5.9-10.5 kg) can typically have a total retention capacity of about 500 grams of urine.

The fluff and superabsoΦent particles can be selectively placed into desired zones of the retention portion 48. For example, the fluff basis weight may vary across the width dimension of the retention portion 48. Altematively, relatively larger amounts of fluff may be positioned toward the front waistband end of the retention portion. For example, see U.S. Patent 4,585,448 issued April 29, 1986, to K. Enloe. In the illustrated embodiment, the majority of the superabsorbent material may be distributed down a medial region of the retention portion 48 which extends along the length dimension of the retention portion and measures about 3.5-4.5 inches (about 8.9-1 1.4 cm) in width. In addition, the superabsoΦent material may have a selected zoned placement to reduce the amount of superabsorbent material located proximate the side and end edges of the retention portion. The reduced amounts of superabsoΦent material at the edges of the retention portion can improve the containment of the superabsorbent particles within the fibrous fluff matrix of the retention portion 48. The pulsed, zoned placement of the superabsoΦent mateπal can, for example, be achieved by the method and apparatus descπbed in U S Patent 5,028,224 to C Pieper et al , entitled METHOD AND APPARATUS FOR INTERMITTENTLY DEPOSITING PARTICULATE MATERIAL IN A SUBSTRATE and issued July 2, 1991 (Attomey docket No 8761), the disclosure of which is hereby incoφorated by reference in a manner that is consistent herewith

In a particular aspect of the invention, absoΦent stmcture 32 can be generally T-shaped with the laterally extending cross-bar of the "T" generally corresponding to the front waistband portion of the absorbent article for improved performance, especially for male infants In the illustrated embodiments, for example, the retention portion across the ear section of the front waistband region of the article has a cross-directional width of about 9 0 inches (about 22 9 cm), the narrowest portion of the crotch section has a width of about 3 5 inches (about 8 9 cm) and the back waistband region has a width of about 4 5 inches (about 11 4 cm)

The entire absoΦent stmcture 32, or any individual portion thereof, such as the retention portion, can be overwrapped in a hydrophilic high wet-strength envelope web, such as a high wet-strength tissue or a synthetic fibrous web Such overwrapping web can also increase the in-use integπty of the absorbent stmcture The web can be suitably bonded, such as with adhesive, to absoΦent stmcture 32 and to other components of the product constmction

Due to the high concentrations of superabsoΦent particles, or other high-absorbency mateπal in the retention portion 48, there can be an increased difficulty with regard to containing the high-absoΦency particles within the retention portion and restncting the movement or migration of the superabsorbent onto the bodyside of the diaper To improve the containment of the high-absorbency mateπal, absorbent stmcture 32 can include an improved overwrap, such as a wrap sheet 70, placed immediately adjacent and around the retention portion 48 The wrap sheet is preferably a Iayer of absorbent mateπal which covers the major bodyside and outerside surfaces of the retention portion, and preferably encloses substantially all of the peπpheral edges of the retention portion to form a substantially complete envelope thereabout Alternatively, the wrap sheet can provide an absorbent wrap which covers the major bodyside and outerside surfaces of the retention portion, and encloses substantially only the lateral side edges of the retention portion Accordingly, both the linear and the inwardly curved portions of the lateral side edges of the wrap sheet would be closed about the retention portion In such an arrangement, however, the end edges of the wrap sheet may not be completely closed around the end edges of the retention portion at the waistband regions of the article

AbsoΦent wrap 70 may compπse a multi-element wrapsheet which includes a separate bodyside wrap Iayer and a separate outerside wrap Iayer, each of which extends past all or some of the penpheral edges of the retention portion 48, as representatively shown in Fig 1 Such a configuration of the wrap sheet can, for example, facilitate the formation of a substantially complete sealing and closure around the peπpheral edges of the retention portion 48 In the back waistband portion of the illustrated diaper, the absorbent wrap may also be configured to extend an increased distance away from the peπphery of the retention portion to add opacity and strength to the back ear sections of the diaper In the illustrated embodiment, for example, the bodyside and outerside layers of absoΦent wrap 70 extend at least about 1/2 inch (about 1 27 cm) beyond the peπpheral edges of the retention portion to provide an outwardly protmding, flange-type bonding area over which the peπphery of the bodyside portion of the absoΦent wrap may be completely or partially connected to the peπphery of the outerside portion of the absorbent wrap

The bodyside and outerside layers of wrap sheet 70 may be composed of substantially the same matenal, or may be composed of different mateπals For example, the outerside layer of the wrap sheet may be composed of a relatively lower basis weight matenal having a relatively high porosity, such as a wet strength cellulosic tissue composed of softwood pulp The bodyside Iayer of the wrap sheet may compnse one of the previously descnbed wrap sheet mateπals which has a relatively low porosity The low porosity bodyside layer can better prevent the migration of superabsorbent particles onto the wearer's skin, and the high porosity, lower basis weight outerside layer can help reduce costs

To provide the bonding between the bodyside and outerside portions of the absorbent wrap 70, an adhesive, such as National Starch 72-3723 adhesive, can be pπnted onto the appointed bonding areas of the absoΦent wrap with, for example, a rotogravure-type system With alternative arrangements having an absoΦent wrap composed of a nonwoven meltblown fibrous web, the peripheral sealing of the bodyside and outerside wrap layers may be accomplished by employing hot calendeπng to provide a sealed stnp region around the peπphery of the retention portion

Due to the thinness of the retention portion 48 and the high superabsorbent concentrations within the retention portion, the liquid uptake rates of the retention portion, by itself, may be too low, or may not be adequately sustained over three insults of liquid into the absoΦent stmcture The addition of a porous, liquid-permeable Iayer of surge management mateπal, however, can advantageously improve the overall uptake rate of the composite absoΦent stmcture Surge management portion 46 is typically less hydrophilic than the retention portion 48, and has an operable level of density and basis weight to quickly collect and temporaπly hold liquid surges, to transport the liquid from its initial entrance point and to substantially completely release the liquid to other parts of the absorbent stmcture 32, particularly the retention portion 48 This configuration can help prevent the liquid from pooling and collecting on the portion of the absorbent garment positioned against the wearer's skin, thereby reducing the feeling of wetness by the wearer

Vaπous woven and nonwoven fabπcs can be used to constmct the surge management portion 46 For example, the surge management portion may be a Iayer composed of a meltblown or spunbonded web of polyolefin fibers The surge management Iayer may also be a bonded-carded-web or an airiaid web composed of natural and synthetic fibers The bonded-carded-web may, for example, be a powder-bonded-carded web, an infrared bonded carded web, or a through-air-bonded-carded web The infrared and through-air bonded carded webs can optionally include a mixture of different fibers, and the fiber lengths within a selected fabπc web may be within the range of about 1 0-3 0 inch (about 2 54-7 62 cm) The surge management portion may be composed of a substantially hydrophobic mateπal, and the hydrophobic mateπal may optionally be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity

The representative diaper 10 can include a surge management portion 46 which is arranged in a direct, contacting liquid communication with an adjacent portion of the absorbent retention portion 48 As representatively shown, surge management portion 46 may be configured for placement adjacent an outwardly facing, outerside of topsheet 28. Optionally, the surge management portion can be placed adjacent an inwardly facing bodyside surface of topsheet layer 28 The shown configuration of the surge management portion is operably connected to the topsheet Iayer with a conventional pattem of adhesive, such as a swirl adhesive pattem In addition, the surge management portion can be operably connected to the bodyside layer of wrapsheet 70 with a conventional pattem of adhesive The amount of adhesive add-on should be sufficient to provide the desired levels of bonding, but should be low enough to avoid excessively restπcting the movement of liquid from the topsheet Iayer, through the surge management portion and through the wrapsheet Iayer

The retention portion 48 is positioned in liquid communication with the surge management portion 46 to receive liquids released from the surge management portion, and to hold and store the liquid In the shown embodiments, the surge management portion 46 is provided by a separate Iayer which is positioned over another, separate Iayer compnsing the retention portion, thereby forming a dual-layer arrangement The surge management portion serves to quickly collect and temporaπly hold discharged liquids, to transport such liquids from the point of initial contact and spread the liquid to other parts of the surge management portion, and then to substantially completely release such liquids into the Iayer or layers compnsing the retention portion 48

The representatively shown configuration of the surge management portion is substantially free of absorbent gelling mateπal Surge management portion 46 may, however, contain a very small amount of particulate gelling mateπal to help acquire an initial liquid surge, but the amount should not be excessive When excessive amounts of particulate absorbent gelling mateπal are maintained in the target zone, however, the particles can cause the stmcture to retain and hold unacceptably high amounts of the liquid in addition, the transport of liquids away from the target zone to other sections of absorbent stmcture 32, particularly the retention portion 48, can be undesirably impaired As mentioned previously, surge layer 46 can be a separately formed layer, which lies adjacent the outwardly facing surface of topsheet 28 between the retention portion and topsheet Thus, surge management portion 46 need not compπse the entire thickness of absorbent stmcture 32 The retention portion can optionally include a recess area which wholly or partially surrounds surge management portion 46, or the retention portion can be entirely positioned below the surge management portion The arrangement which includes the recess in the retention portion 48 can advantageously increase the area of contact and liquid communication between the retention portion and surge management portion 48 It should be understood, however, that surge management portion 46 could optionally be constmcted to extend through the entire thickness of absoΦent stmcture 32 so that the capillary flow of liquid into the retention portion 48 occurs pπmaπly in a generally sideways (X-Y) direction

The surge management portion can be of any desired shape which is consistent with the absorbency requirements of the absorbent stmcture 32 Suitable shapes include for example, circular, rectangular, tπangular, trapezoidal, oblong, dog-boned, hourglass- shaped, or oval Preferred shapes of the surge management portion are those that increase the contacting, liquid communicating surface area between surge management portion 46 and the retention portion 48 so that the relative capillanty difference between the portions can be fully utilized In certain embodiments, for example, the surge management portion can be generally rectangular-shaped

In the vanous configurations of the invention, the surge management portion 46 may extend over the complete length of the retention portion 48, or may extend over only a part of the retention portion length Where the surge management portion extends only partially along the length of the retention portion, the surge management portion may be selectively positioned anywhere along absorbent stmcture 32 For example, surge management portion 46 may function more efficiently when it is offset toward the front waistband of the garment and transversely centered within a front section of absorbent stmcture 32 Thus, surge management portion 46 can be approximately centered about the longitudinal center line of absoΦent stmcture 32, and positioned pnmaπly in a central region of a front section of the absorbent stmcture 32

In other aspects of the invention, the end edges of the surge management portion can be spaced longitudinally inboard from the end edges of the retention portion 48 In particular configurations of the invention, the corresponding, relatively adjacent front end edge of surge management portion 46 can be spaced a predetermined discrete distance from a front waistband end edge of the retention portion 48

It has been found that an effective fabπc for constructing the surge management portion can be distinctively characteπzed by particular parameters Such parameters include, for example, basis weight, permeability, porosity, surface area per void volume (SA W), compression resiliency and saturation capacity Further parameters can include a bonding matπx which will help stabilize the pore size stmcture, and hydrophilicity The bond-matπx and the blend of fiber deniers can advantageously provide for and substantially maintain a desired pore size stmcture

Additional details regarding the surge matenals and suitable techniques for determining the above-descπbed parameters are set forth in U S Patent Application Seπal No 206,986 of C Ellis and D Bishop, entitled, FIBROUS NONWOVEN WEB SURGE LAYER FOR PERSONAL CARE ABSORBENT ARTICLES AND THE LIKE, and filed March 4, 1994 (Attomey docket No 11,256), and U S Patent Application Seπal No 206,069 of C Ellis and R Everett, entitled, IMPROVED SURGE MANAGEMENT

FIBROUS NONWOVEN WEB FOR PERSONAL CARE ABSORBENT ARTICLES AND THE LIKE, and filed March 4, 1994 (Attomey docket No 11 ,387), the disclosures of which are hereby incoφorated by reference in a manner that is consistent herewith

In particular configurations of the invention, the surge matenal can include bicomponent fibers For example, polypropylene/polyethylene bicomponent fibers may be employed to form the bicomponent fiber portion of any of the descπbed fabncs In addition, the bicomponent fibers may be flat cπmped or helically cπmped

The representatively shown article has a selected fastening system 40 connected thereto With reference to Figs 4 and 5, the fastening system can compπse a panel member 56 which includes a panel mateπal The panel member 56 has first and second, opposed major facing surfaces 50 and 52, an appointed inboard region 54, and an appointed outboard region 58 which includes a terminal outboard edge 60 thereof A reinforcement stnp 88 includes a reinforcing, stiffening matenal, and is laminated to the first surface 50 of the side panel member 56 at the outboard region 58 of the side panel The reinforcement stnp can have a terminal outboard edge 90 which is coterminous with the outboard edge 60 of the panel member 56 A fastener tab 36 is laminated to the second surface 52 of the panel member 56 and includes a user-bond region 41 thereof which extends from the panel member The fastener tab includes first and second, opposed major surfaces 76 and 78, and includes a secunng means 44 located on at least one of the major surfaces of the fastener tab

A fastening system 40 is connected to the article at either, and preferably both, of the laterally opposed end regions 72 of at least one of the front and rear waistband sections The side panel member 56 of each fastening system is desirably constmcted to be elastically stretchable at least along a laterally extending cross-direction 24 of the article.

Examples of articles which include elasticized side panels and selectively configured fastener tabs are described in U.S. Patent Application Serial No. 168,615 of T. Roessler et al., entitled DYNAMIC FITTING DIAPER, and filed December 16, 1993 (Attomey docket No. 10,961); and in U.S. Patent Application Serial No. 415,382 of D. Fries, entitled AN ABSORBENT ARTICLE HAVING A LAMINATED TAPE and filed April 3, 1995 (Attomey docket No. 11 ,990). Various techniques for forming the desired fastening systems are described in U.S. Patent No. 5,399,219 of T. Roessler et al., entitled

METHOD FOR MAKING A FASTENING SYSTEM FOR A DYNAMIC FITTING DIAPER and issued March 21 , 1995 (Attomey docket No. 11 ,186); in U.S. Patent Application Serial No. 286,086 of D. Fries, entitled A PROCESS FOR ASSEMBLING ELASTICIZED EAR PORTIONS and filed August 3, 1994 (Attomey docket No. 11 ,169); and in U.S. Patent Application Serial No. 415,383 of D. Fries, entitled AN ASSEMBLY PROCESS

FOR A LAMINATED TAPE and filed April 3, 1995 (Attomey docket No. 11,950). The disclosures of the above-described documents are incoφorated herein by reference in a manner that is consistent (not in conflict) herewith.

In the shown configuration, the side panel members 56 are separately provided, component pieces which are operably connected and attached to form laterally opposed end sections of the back waistband portion of the backsheet 30. In particular, each side panel is affixed to extend laterally away from a corresponding terminal edge of the backsheet layer. The side panels can be composed of a substantially non-elastomeric material, such as polymer films, woven fabrics, nonwoven fabrics or the like, as well as combinations thereof. In particular aspects of the invention, the side panels are composed of an elasticized material, such as a stretch-bonded-laminate (SBL) material, a neck-bonded-laminate (NBL) material, an elastomeric film, an elastomeric foam material, or the like. For example, suitable meltblown elastomeric fibrous webs are described in U.S. Patent 4,663,220 issued May 5, 1987 to T. Wisneski et al., the disclosure of which is hereby incoφorated by reference. Examples of composite fabrics comprising at least one layer of nonwoven textile fabric secured to a fibrous elastic Iayer are described in European Patent Application No. EP 0 110 010 published on April 8, 1987 with the inventors listed as J. Taylor et al., the disclosure of which is hereby incoφorated by reference Examples of NBL mateπals are descπbed in U S Patent 5,226,992 issued July 13, 1993 to Mormon, the disclosure of which is hereby incoφorated by reference

The reinforcement stnp 88, can be composed of a separately provided stiffening mateπal, which may be laminated, directly or indirectly, to a first surface of the side panel member 56 at the outboard region of the side panel The shown reinforcement stnp extends along substantially the entire length of the outboard end portion of the panel member 56 In addition, the reinforcement stnp has a length which is greater than the length dimension of the secunng means 44 on the user-bond portion 41 of the fastener tab 36 The reinforcement stnp 88 can, for example, be composed of a release tape, and the release tape can include a substrate composed of a polymer film, such as a polypropylene film Suitable release tape mateπals are available from Avery Coφ , a business having offices located in Painesville, Ohio

The release tape configuration of the reinforcement stnp 88 can have a release surface 98 and an oppositely located attachment surface 100 A suitable release matenal, which has a limited low level adhesion to conventional pressure-sensitive adhesives, is positioned and distnbuted over the release surface 98, and a suitable attachment mechanism, such as a layer of constmction adhesive, is distπbuted over the attachment surface 100 The constmction adhesive is employed to affix the reinforcement stnp 88 onto an appointed section of the final article In particular, the stnp of release tape can be operably bonded and laminated to the outboard region 58 of the panel member 56 along the first surface 50 of the panel member The shown stnp of release tape is configured with its terminal outboard edge 90 positioned substantially coterminous and substantially coextensive with the outboard edge 60 of the panel member 56 In addition, the width of the release tape along the cross-direction 24 is equal to or greater than the width of the secunng means 44 provided on the user-bond region 41 of the fastener tab 36

The fastening system includes a fastener tab 36, which provides a mechanism for holding the article on the wearer The fastener tab includes a tab substrate, which may be composed of vaπous substrate mateπals For example, the shown embodiment of the tab substrate can be composed of a polymer film, such as a polypropylene film Suitable film mateπals are available from Avery Coφ , a business having offices located in Painesville, Ohio Alternatively, the substrate may be composed of a woven or nonwoven fabπc, such as spunbonded nonwoven fabπc

The tab substrate 86 includes a securement surface 76 and a user surface 78, and a selected secunng means is positioned onto the securement surface of the tab substrate

The secunng means may be provided by an adhesive, a cohesive mateπal, a cooperating component of a interengaging, mechanical fastener, snaps, pins or buckles and the like, as well as combinations thereof For example, the secunng means may include a hook component or loop component of a hook-and-loop fastener In the shown configuration, the secunng means is provided by a Iayer of pnmary adhesive 44 distπbuted over the secunng surface, and the fastening system provides an adhesive fastener tab The fastener tabs can be constmcted to releasably adhere to an appointed landing zone patch 92 attached to the front waistband section of the diaper to provide a refastenable adhesive fastening system

With the shown adhesive secunng means, the Iayer of pnmary adhesive can be employed to operably laminate and affix an appointed factory-bond region 39 of the fastener tab 36 to the outboard region 58 of the panel member 56 along the second surface 52 of the panel member Alternatively, other types of connecting means, such as thermal bonds, sonic bonds, mechanical stitching, stapling and the like, as well as combinations thereof, may be employed to permanently attach the fastener tab to the panel member For example, ultrasonic bonds may be employed to provide supplemental bonding

The factory-bond section 39 of the fastener tab 36 can overlap the outboard edge of the panel member 56, and the fastener tab extends beyond the panel member to provide the user-bond region 41 of the tab The substantially coterminous, terminal edges 60 and 90 of the panel member and reinforcement stnp, respectively, can advantageously combine and cooperate to provide a relatively abmpt change or discontinuity in the thickness of the fastening system The terminal edges provide a composite edge which can define a region of potential stress concentration in the fastener tab when the distal, free end of the fastener tab is inwardly folded into a storage position The discrete stress concentration along the coterminous edges 60 and 90 of the panel member and reinforcement stnp can more reliably define a desired fold line, and the fold line can be more readily established without the use of conventional weakening procedures, such as sconng As a result, the stmcture of the fastening system can provide for a more effective and consistent folding operation while maintaining the strength and reliability of the individual fastening tabs 36

In a particular arrangement of the invention, the fastener tab can have a relatively wide user-bond section in combination with a relatively narrower intermediate section The intermediate section is positioned between the user-bond and factory-bond sections of the fastener tab in a further aspect of the invention, the fastener tab 36 can include a finger tab region 80 The finger tab is substantially non-secunng, and provides an area that can be grasped by the user without contaminating or otherwise distuΦing the secunng means The finger tab may include a Iayer of panel mateπal, and a iayer of reinforcement mateπal In a particular embodiment, for example, the finger tab is configured with the Iayer of panel matenal sandwiched between the Iayer of reinforcement mateπal and the finger tab substrate to provide a laminated finger tab which can be easier to locate and grasp

Having descπbed the invention in rather full detail, it will be readily apparent that vaπous changes and modifications can be made without departing from the spiπt of the invention All of such changes and modifications are contemplated as being within the scope of the invention as defined by the subjoined claims

Claims

We claim:

1. An article having a longitudinal direction, a lateral direction, laterally opposed side margins, longitudinally opposed end margins and an intermediate section which is located between said end margins at a longitudinally medial region of said article, said article comprising: a backsheet, an inboard elastic member connected to gather at least one side margin of said backsheet; a substantially longitudinally extending outboard elastic member connected to substantially longitudinally gather said at least one side margin, said outboard elastic member located laterally outboard of said inboard elastic member to provide a set of elastic members which are arranged in a staggered overlapping relation, a major portion of a longitudinal end edge of said outboard elastic member configured substantially coterminous with a terminal side edge of said at least one side margin in said intermediate portion of said article.

2. An article as recited in claim 1, wherein said outboard elastic member is configured to substantially avoid bridging an inwardly bowed edge of said backsheet

3 An article as recited in claim 1 , wherein said at least one side margin has a terminal side edge with a section thereof having a outwardly concave, substantially C- shape indent edge, said indent edge extending along not more than about 50% of a total length of said article, with a substantial entirety of said longitudinal end edge of said outboard elastic member configured substantially coterminous with said indent edge of said side margin in said intermediate portion of said article.

4. An article as recited in claim 1 , wherein the of said outboard elastic member has a length-to-width aspect ratio of at least about 4:1

5. An article as recited in claim 1, wherein said major portion of said longitudinal end edge of said outboard elastic member is substantially coterminous with said topsheet Iayer in said intemiediate portion of said article 6 An article as recited in claim 1, wherein said inboard elastic member is composed of an elastomenc stnp

7 An article as recited in claim 1 , wherein said outboard elastic member is composed of an elastomeπc stnp

8 An article as recited in claim 1 , wherein said inboard elastic member is composed of a composite compnsing a plurality of elastomeric strands connected to a camer stnp

9 An article as recited in claim 8, wherein said inboard elastic member includes a plurality of elastomenc strands which are substantially parallel to each another

10 An article as recited in claim 1 , wherein said outboard elastic member is composed of a composite compnsing a plurality of elastomenc strands connected to a camer stnp

11 An article as recited in claim 10, wherein said outboard elastic member includes a plurality of elastomeπc strands which are substantially parallel to each other

12 An absoΦent article having front and back waistband portions, an intermediate portion which interconnects said front and back waistband portions, laterally opposed side margins, a longitudinal direction and a lateral direction, said article compnsing a backsheet, a liquid permeable topsheet Iayer supeφosed and connected in facing relation to said backsheet, an absoΦent stmcture sandwiched between said backsheet and said topsheet layer, a first inboard elastic member connected to gather a first of said side margins of said article, and a second inboard elastic member connected to gather a second of said side margins, a first, substantially longitudinally extending outboard elastic member connected to substantially longitudinally gather said first side margin, said first outboard elastic member located laterally outboard of said first inboard elastic member to provide a first set of elastic members which are arranged in a first staggered overlapping relation, a major portion of a longitudinal end edge of said first outboard elastic member configured substantially coterminous with a terminal edge of said first side margin in said intermediate portion of said article, and a second, substantially longitudinally extending outboard elastic member connected to substantially longitudinally gather said second side margin, said second outboard elastic member located laterally outboard of said second inboard elastic member to provide a second set of elastic members which are aπanged in a second staggered overlapping relation, a major portion of a longitudinal end edge of said second outboard elastic member configured substantially coterminous with a terminal edge of said second side margin in said intermediate portion of said article

13 An article as recited in claim 12, wherein each of said first and second outboard elastic members is configured to substantially avoid bndging an inwardly bowed edge of said backsheet

14 An article as recited in claim 12, wherein said first side margin of said article has a first terminal side edge with a section thereof having a first outwardly concave, substantially C-shape indent edge, said first indent edge extending along not more than about 50% of a total length of said article, with a substantial entirety of said longitudinal end edge of said first outboard elastic member configured substantially coterminous with said indent edge of said first side margin in said intermediate portion of said article; and wherein said second side margin of said article has a second terminal side edge with a section thereof having a second outwardly concave, substantially C-shape indent edge, said second indent edge extending along not more than about 50% of the total length of said article, with a substantial entirety of said longitudinal end edge of said second outboard elastic member configured substantially coterminous with said indent edge of said second side margin in said intermediate portion of said article 15 An article as recited in claim 12, wherein said first side margin of said article has a first terminal side edge with a section thereof having a first outwardly concave, substantially C-shape indent edge, said longitudinal end edge of said first outboard elastic member is configured substantially coterminous with said indent edge of said first side margin in said intermediate portion of said article, said first outboard elastic member configured to substantially avoid bndging said indent edge, and wherein said second side margin of said article has a second terminal side edge with a section thereof having a second outwardly concave, substantially C-shape indent edge, said longitudinal end edge of said second outboard elastic member is configured substantially coterminous with said indent edge of said second side margin in said intermediate portion of said article, said second outboard elastic member configured to substantially avoid bndging said indent edge

16 An article as recited in claim 12, wherein each of said first and second outboard elastic members has a length-to-width aspect ratio of at least about 4 1

17 An article as recited in claim 12, wherein said major portion of said longitudinal end edge of said first outboard elastic member and said major portion of said longitudinal end edge of said second outboard elastic member are substantially coterminous with said topsheet layer in said intermediate portion of said article

18 An article as recited in claim 12, wherein at least one of said inboard and outboard elastic members is composed of an elastomenc stnp

19 An article as recited in claim 12, wherein at least one of said inboard and outboard elastic members composed of a composite compnsing a plurality of elastomenc strands connected to a camer stnp

20 An article as recited in claim 19, wherein said inboard elastic members include a plurality of elastomenc strands which are substantially parallel to each another