CA2056960A1 - Method for forming disposable garments with a waste containment pocket - Google Patents

Abstract

METHOD FOR FORMING DISPOSABLE
GARMENTS WITH A WASTE CONTAINMENT POCKET

Abstract of the Disclosure A method is disclosed for forming a dispos-able garment with a waste containment pocket defined by a pair of barrier cuffs located on opposed sides of the centerline of the body contacting layer of the garment inboard of its elasticized leg openings. Each barrier cuff is formed by applying a pattern of adhesive alongside of an elastic member maintained in tension on the body contacting layer or a separate strip of material, and then intermittently applying an adhesive pattern onto the elastic member so that it bonds to the body contacting layer or separate strip at longitudinally spaced locations therealong. When the tension on the elastic member is released, gathers or folds are formed in the barrier cuff between those locations where the elastic member was adhered thereto which help the garment conform to the shape of the wearer and prevent the passage of body exudates to the elasticized leg openings.

Description

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Field_of the Invention This invention relates to the method of manufacturing d1sposable garments such as disposable diapers or lncontinent pads, and, more particularly, :~ to the method of forming such garments with elasti-cized barrier pockets or cuffs formed from or attached to the body contacting layer o~ the garment which define a waste containment pocket for body exudates.
: 15 Back round of the Invention Disposable, absorbent garments, such as disposable diapers and adult incontinent briefs, have met with widespread use to absorb and contain body exudates and thus prevent soiling or wetting of clothing, bedding and other articles. Commercially ~2- 20~69~
available disposable diapers, for example, are unitar~
preshaped and prefolded garments which include a moisture-impervious backing layer, a body conkacting layer or liner and a moisture-absorbent core there-between. Elasticized leg openings are formed at thesides of the diaper to improve comfort of the garment and its ability to contain body exudates.
One problem with disposable diapers, incon-tinent briefs and other garments of the type described - 10 above is that the elasticized leg openings have not proven to be entirely effective in retaining body exudates, particularly loose or liquified fecal material. It has been found that s~ch material can leak through the e1asticized leg openings because the disposable garment fails to constrain the free flow of the exudate material and no structure is provided to hold such material within the body contacting liner of the diaper. As a result, the exudate material tends to float along the liquid receiving surface o~ the diaper and work its way past the elasticized leg flap~.
This problem has been addressed in improved disposable garments such as disclosed, for example, in U.S. Patent Nos. 4,704,116 to Enloe and 4,738,677 to Foreman. The disposable garments disclosed in each of these patents include an exudate material containment pocket formed inwardly of the elasticized leg openings -3~ 6~
on either side of the centerline o~ th~ garmellt This containmen~ area or poc~et is formed by spaced, longitudinally extendin~ barrier cuf~s or ~laps which are either integrally formed in the body contacting 5layer of thP diaper or formed from separate strips which are adhered to such body contacting layer. If the barrier cuffs are integrally formed in the body contacting layer of the garment, each cuf~ is formed by folding the body contacting layer upon itself in a 10longitudinal direction to obtain opposed longitudinal sections of materlal which are adhered together One ~"fold" or barrier cuff i5 made in the body contacting layer on either side of the centerline of the garment.
Alternatively, separate strips of material are folded 15in half and adhered together to form each barrier cuff, and these cuffs are then bonded to the body contacting layer of the disposable garment on opposite sides of the centerline thereof.
Preferably, an elastic member such as a bead 20of natural rubber, elastic tape or the like is adhered between the opposed sections of material forminy the barrier cuffs. These elastic members are bonded in place by ultrasonic bonding, heat/pressure sealing and/or adhesive beads such as disclosed, for example, 25in U.S. Patent Nos. 4,081,301 to Buell and 4,253,461 to Strickland et al. The elastic member within each flap or cuff forms gathers therealong where the .

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elastic member is adhered there~o, and these gakhers help the barrier cuf~s to conform to the shape of the wearer ~or better ~it and to prevent the passage of body exudates to the elasticized leg openings of the garment.
One problem with the barrier cu~fs or flaps forming the waste containment pockets in the dispos-able garments described above involves the manner in which the barrier cuffs or flaps are adhered together and/or to the body contacting layer of the garment.
As mentioned above, the opposed material sections forming each barrier cuff or flap must be bonded together and the elastic member associated with each flap must be bonded between such material sections.
Whether the barrier cuffs or flaps are integrally formed from the body contacting layer of the dispos-able garment, or the flaps are separately formed and then adhered to such body contacting layer, c:ontinuous or intermittent extruded beads of hot melt adhesive are typically employed to e~ect a bond therebetween.

It has been observed that such adhesive bonding techniques, particularly when employed on the non-woven, ~ibrous material utilized in forming the - body contacting layer of a disposable gar~ent, often results in the utilization of more adhesive than is required. A relatively thick, extruded bead of hot ` melt adhesive, whether applied continuously or ' -5- 2~
intermittently, is highly viscous and does not readily spread out over the surface of the material formi~g the barrier CU~X5. Because the strength of the bond produced by hot mel~ adhesive is dependent to a large extent on the surface area of contact between the material to be bonded, a relatively large amount of adhesive is needed to bond the opposed sections of material forming the barrier cuff and to adhere the elastic member thereto.
Another problem with the formation of the waste containment pocket of such disposahle garments " is that two separate bonding operations must be conducted ~o form the barrier cuffs or flaps. In one opera,tion,.,a,dhesive or other bonding means is used to adhere the opposed sections of material forming the barrier cuffs. A second operation and/or additional bonding equipment is then required to adhere the elastic member between the sections forming the barrier cuffs or flaps. These two separate bonding operations add expense and difficulty to the man-ufacturing process.
Summar of the Invention It is therefore among the objectives of this invention to provide a method of forming a disposable garment with a waste containment pocket defined by spaced, elasticized barrier cuffs or flaps which - reduces the quantity of adhesive required to form the ~6- 20~ 0 barrier cuf~s, which simplifies the manufacturing operation and which reduces the expense of forming the waste containment pocket.
These objectives are ,accomplished in a method of forming a waste containment pocket in a disposable garment defined by spaced barrier cu~s or flaps in which each barrier cu~f is formed in a single bonding operation, using a relatively small quantity of adhesive. In one preferred embodiment, the adhe-sive dispenser is effective to apply a controlled,spiral pattern of an elongated adhesive fiber onto a ~longitudinally extending section of material alon~ one side of an,elastic member held in tension atop such material. , The spiral pattern of adhesive from such dispenser is intermittently diverted around and/or onto the elastic member so that it adheres to the material at longitudinally spaced locations there-along. In an alternative embodiment, two adhesive dispensers mounted side-by-side are employed where`in one dispenser applies a spiral pattern of an elongat,ed adhesive fiber alongside the elastic member and the other dispenser intermittently applies adhesive onto the elastic member at longitudinally spaced locations therealong. In either embodiment, the longitudinalLy extending section of material is subse~uently folded upon itself so that it adheres together with the - elastic member contained therein to form the barrier 20~6~
.. , 7--cuff. When the tensi.on is removed from the elastic member, it returns to its original length and farms gathers in the barrier cu~.
This invention is there~ore predicated upon the concept of applying a thin adhesive fiber pattern onto at least one side of a longitudinally extending section of material which is folded to form the sides of a barrier cuff, and adhering an elastic member hetween the sides of the barrier cuff at longitudi-nally spaced locations along the length of the elasticmember, preferably at opposite ends of the elastic , member where it is cut to form an individual dispos-able garmen't. One advantage of this method is that a relatively small quantit~ of adhesive is required to effect a bond between the sides of the strip or section of material forming the barrier cuff. In each of the presently preferred embodiments, one or more adhesive dispensers are employed of the. type disclos~d in U.S. Patent No. 4,785,996. This adhesive dispen~er is ef~ective to apply a thin, elongated strand or fiber of adh~sive in a spiral spray pattern onto the material forming the barrier cuff. The thin, adhesive strand or fiber covers a relatively large area of the longitudinally extending section or strip of material forming the barrier cuff, and thP adhesive fiber is thin compared to a conventional extruded bead of :

~" -8- 2~ 60 adhesive. As a re5ult, the sides of the barrier cu~f are adhered together with an acceptable bond using a lesser quantity of adhesive than would be required ; with extruded adhesive beads.
S In one presently preferred embodiment of this invention, the barrier cu~fs or ~laps defining the waste containment pocket of the disposable garment are integrally formed in the body contacting layer of the garment~ In this embodiment, a pair of tensioned, elastic membars are laid onto or immediately above a moving section of the body contacting layer of the "
disposable gaxment. Adhesive dispensers are posi-tioned wit.h~respect to the body contacting layer so as to apply a spiral pattern of an elongated adhesive fiber alongside and substantially parallel to each elastic member, but not in contact therewith.
In one embodiment, the adhesive pattern alongside each elastic member is intermittently diverted onto the elastic members so that they are adhered to the body contacting layer at longitudinally spaced locations therealong. This diversion of the path of the adhesive pattern is accomplished, for example, by impacting the adhesive discharged from each adhesive dispenser with a jet of air before it contacts the body contacting layer. In an alternative embodiment, a pair of adhesive dispensers are mo~nted side-by-side above each- of the elastic members placed ` ` ~ 2 ~

on the body contacting layer or the disposable gar-ment. One of the dispensers in each pair is posi-tioned to dispense a spiral pattern of an elongated adhesive fiber alongside a respective elastic member, while khe other dispenser in each pair is operated intermittently to dispense an elongated adhesive flber at longitudinally spaced locations along the elas-tic member.
The longitudinally extending section of the body contacting layer adjacent each elastic member which received the adhesive is then folded over the elastlc member onto the section of the body contac~ing layer on t~e opposite side of the elastic member. A
barrier cuff or flap is thus formed on opposite sides of the centerline of the body contacting layer, each consisting of two longitudinally extending sections of the body contacting layer material ~ith an elastic member therebetween. The elastic member o~ each barrier cuff is not adhered to the body contacting layer except in those locations where the adhes.iv~ was diverted, or intermittenkly dispensed, onto the elastic member. Preferably, the elastic member is adhered to the body contacting layer at least in those areas which~form opposed ends of individual disposable garments after the body contacting layer and elastic member are cut to length.

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When the tension of the elastic members is released, i.e., by cutting the b~dy contactirlg layer to length in the course of forming the disposable garment, the elastic members return to their original length and form gathers in the body contacting layer.
The gathers of the two barrier cuffs on either side o~
the centerline of the body contacting layer are preferably positioned in alignment with one another and in alignment with the elasticized leg openings in the finished disposable garment. These gathers of each barrier cuff aid in resisting passage of body exudates from the center of the disposable garment outwardly .toward the elasticized leg openings and also help the yarment to ~onform to the body of the wearer.
In an alternative embodiment of this inven-tion, the barrier cuffs are formed from separate longitudinally extending sections or strips of mate-rial and then adhered to the body contacting layer of the disposable garment instead o being integrally formed from the body contacting layer. The individual barrier cuffs are formed in the same manner as described above except that each strip is folded in half over an elastic member located in the middle thereof, and then one folded strip or barrier cuff is adhered to the body contacting layer on opposite sides of the centerllne of the disposable garment to form the waste containment poc~et therebetween.

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Descri~tian of the Drawlnqs The structure, operation and advantages of the presently preferr~d embodiment o~ this invention will become further apparent, upon consideration o~
the following description taken in conjunction with the accompanying drawings, wherein:
Fig. 1 is a schematic view of the adhesive dispensing devices applyin~ adhesive patterns onto the body contacting layer o~ a disposable garment;
Fig. 2 is a side elevational view of the apparatus of Fig. l;
Fig. 3 is a view of the body contacting layer of ~,ig. 1 which is folded upon itself to form opposed barrier cuffs;
Fig. 4 is a schematic, perspective view in partial cross section of a disposable diaper incorpor-ating the barrier cuffs formed in accordance with the steps illustrated in Figs. 1-3;
Fig. 5 is a schematic, perspective vlew of a dispensing device applying a pattern o~ adhesive onto a strip of material to form a sin~le barrier cuff;
Fig. 6 is the strip of material illustrated in Fig. 5 folded on itself to form one barrier cuff;
Fig. 7 is a schematic view of adhesive dispensers applying spaced patterns of adhesive onto the body contacting layer of a disposable garment, -12- 2~
Fig. 8 is a ~chematic view of two barrier cuf~s of the type shown in ~ig. 6 which are adhered to a body contactlny layer of a disposable garment along the adhesive patterns applied thereto in the step of Fig. 7;
Fig. 9 is a schematic view similar to Fig. 1 but of an alternative embodiment of adhesive dispen-sers applying adhesive patterns onto the body contact-i.ng layer of a disposable garment: and Fig. lO is a view similar to Fig. 5, but using the alternative dispenser arrangement of Fig. 9.
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etailed Descri~tion of the Invention ~eferrlng now to Flgs. 1-4, one method is depicted for formLng a waste containment pocket 10 in a disposable garment such as a disposable diaper 12.
See Fig. 4. The disposable diaper 12 includes a moisture-impervious backing sheet 14, a body contact-ing liner or layer 16 and an absorbent, non-woven core or pad 18 therebetween. The diaper 12 is formed with a front waist section 20, a rear wais~ section 22 and elasticlzed leg openings 24, 26 on either side of the waste containment pocket 10 which are equidistant from the cen~erline 2R of the diaper 12.
The method of this invention is directed to : 25 the formation of the waste containment pocket 10 which functions to substantially prevent the passage or leakage of body exudates, and particularly loose fecal .

- ~13- 2~6~0 material, from the cente.r portion of the disposable diaper 12 outwardly and through the elasticized leg openings 24, 26. In the embodiments o~ Figs. 1-4, and Fig. 9, the waste containment pocket lO i5 formed as an integral part of the body contacting layer 16. In the embodiments of Figs. 5-8, and Fig. lO, discussed below, the waste containment poc~et lO is formed by attaching separate sections to the body contacting layer 16 on either side of the centerline 28 of the disposable diaper 12.
As shown in Fig. l, a flat sheet of the body . contacting layer 16 lS movable on a conveyor (not shown) beneath a pair of adhe5ive dispensing devices 30 and 32 which are each carried by a support 33 and which communicate with an adhesive source 34. Each of the adhesive dispensing devices 30, 32 is of the type disclosed in U.S. Patent No. 4,785,996 to Ziecker st al, the disclosure of which is incorporated by refer-ence in its entirety herein. The structural details of the dispensing devices 30, 32 form no part o~ this invention per se, and reference should be made to the 4,785,996 patent for the details thereof.
The dispensing devices 30, 32 are each effective to apply a thin, elongated strand or fiber of adhesive in a spiral spray pattern 36 onto the body contacting layer 16. As discussed in detail in the 4,785,9g6 patent, a bead of adhesive is extruded from -14~
the dispensiny devices 30, 32 and impacted ~ h jets of air directed tangentiall~ thereto which attenua~e or stretch the adhesive bead forming an elongated strand or fiber which is spun or tT,Iisted by the air jets to form the resulting spiral spray pattern 36.
In the presently preferred embodiment, elastic members 38 and 40 are placed onto or immedi-ately above the body contacting layer 16 beneath the dispensing devices 30, 32, respectively. These elastic members 38, 40 are maintained under tension as the body contacting layer 16 passes beneath the ~dispensing devices 30, 32, but are permitted to retract orl,move back to their normal length when the tension is released as discussed below. The elastic members 38, 40 are of the type commonly utiliz~d in the elasticized leg openings of disposable diapers and can be ~ormed of such materials as natural rubber, elastic tape, a bead o~ elastomeric adhesive and the like.
As shown in Figs. l and 2, the elastic member 38 is positioned with respect to the dispensing device 30 such that a longitudinally extending spiral spray pattern 36 is applied onto the body contacting layer 16 along one side 42 of the elastic member 38 2~ without contacting the elastic member 38 or the body contacting layer 16 on the other side 43 of the elastic member 38. A second adhesive pattern 36 is ~` -15- 2~
applied by the di5pensing device 32 on the opposite side of the body contacting layer 16 aLong one side 44 of the elastic member 40 without contacting ~he - elastic member 40 or the body contacting layer 16 on the opposite side 45 of the elastic member 40.
~ n the embodiment of Fig. 1, an air tube 46 is mounted to each support 33 which carries the dispensing devices 30, 32, and these air tubes 44 each have a discharge opening 47 oriented at an angle with respect to the body contacting layer 16. The air tubes 44, 46 are each connec~ed to a source of pres-surized air 48, shown schematically in Fig. 1, and are effective 'to ejeat a jet of air through their dis-charge openings 47 against the spray patterns 36.
Each jet of air impacts a spiral spray pattern 36 before~it contacts the surface of the body contacting layer 16 so that the adhesive patterns 36 are deflected or diverted around and/or onto the elastic members 38 and 40 instead of bein~ appLied parallel thereto.
In the presently pre~erred embodiment, a controller 50 is connected to the pressurized air source 48. The controller 50 is operative to supply pressurized air intermittently or periodically to the air tubes 46 so that the adhesive patterns 36 are intermittently diverted onto the elastic members 38, 40 along the body contacting layer 16. The air jets -16~
impact the spray patterns 36 with su~ficien~ velocity to both enlarge the width of such patterns 36, and to cause them to cross over the elastic members ~8 and 40 without breaking up. A5 shown in Fig f 1, one pattern 36 is diverted from the body contacting layer 16 on one side 42 of the elastic member 38 onto and/or ~ around the ~elastic member 38 and a portion of the body ; contacting layer 16 on the opposite side 43 of the elastic member 38 at longitudinally spaced areas 49 therealong. Similarly, the other pattern 36 is diverted from the body contacting layer 16 on one side . . , 44 of the elastic member 40 onto and~or around such elastic me~ber 40 and a portion af the body contacting layer 16 on the opposite side 45 of the elastic member 40 at longitudinally spaced areas 49 therealong. The elastic members 38, 40 are therefore adhered to opposite sides of the body contacting layer I6 at such longitudinally spaced areas 49. Preferably, the adhesive spray pattern 36 is diverted onto the elastic members 38, 40 at least in tho5e areas which fonn opposite ends of the disposable diaper 12 after the body contacting layer 16 and elastic members 38, 40 are cut to length.
In an alternative embodiment illustrated in Fig. 9, substantially the same adhesive spray patterns are applied to the body contacting layer 16 but with a different arrangement of adhesive dispensers. In this ~17 2 ~ 6 0 embodiment, a pair o~ adhesive dispensers 90 and 92 are mounted side-by-side to a support 94 immediately above the elastic member 38, and a second pair of adhesive dispensers 96 and 98 are mounted by a support S 100 immedlately above ~he other elastic member 40 atop the body contacting layer 16. The adhesive dispensers go, 92 and 96, 98 are preferably o~ the same type as dispensers 30, 32 of Fig. 1. Each pair of adhesive dispensers 90, 92 and 96, 98 are connected to an adhesive suppIy 102, and to a controller 104 which communicates w1th a source of pressurized, control air (not shown).
~he adhesive dispenser 90 is positioned with respect to the elastic member 38 to apply a spiral adhesive pattern 106 of the same type and configura-tion as adhesive pattern 36 described above. Such adhesive pattern 106 is positioned alongside but not in contact with the elastic member 38. At selected, longitudinally spaced locations along the elaskic member 38, the controller 104 is e~ective to operate adhesive dispenser 92 to apply a spi.ral, elonyated adhesive fiber pattern loa around and/or onto the elastic member 38. While the adhesive dispenser 92 ls operating, the adhesive dispenser 90 is preferably continuously operated to obtain the uninterrupted adhes1ve pattern 106 shown in Fig. 9.

-18- 2 ~ 6 The pair of adhesi~e dispensers 96 and 9 operate in the same fashion as dispensers 90, 92.
Adhesive dispenser 98 is positioned with respect to the elastic member 40 to lay down a spiral adhesive pattern 110 alongside but not in contact with the elastic member 40 while the adhesive dispense~ 98 is operated intermlttently to discharged longitudinally spaced patterns 112 of a spira~ elangated adhesive fiher around and/or onto the elastic member 40.
The construction of Fig. 9 therefore pro-duces substantially the same patterns of adhesive onto the body contacting layer 16 and elastic members 38, 40 as in ~he embodiment of Fig. 1. In both embodi-ments, it is important to obtain adhesive patterns wherein the elastic members 38 and 40 are only bonded to the body contacting layer 15 at longitudinally spaced locations while an elongated, substantially continuous adhesive pattern is applied alongside the elastic members 38 and 40 directly onto the body contacting layer 16.
Having applied adhesive ro the, body contact-ing layer 16 and at longitudinally spaced locations along the elastic members 38, 40, ~;ith the embodiment of either Figs. 1 and 2, or Fig. 9, the waste contain-ment pocket 10 of an individual disposable diaper 12can now be formed. With reference to Figs. 3 and 4, the waste containment pocket 10 is defined by a pair 19 2~S~
of opposed barrier cu~fs or flaps 54 and S6 locaked on opposite sides of the centerline z8 o~ the diaper 12 inboard of the elasticized le~ openings 24, 26, respectively. In the embodiments of Figs. 1-4, and Fig. 9, these barrier cu~fs 54 and 56 are integrally formed in the body contacting layer 16 in the folding operation depicted in Fig. 3. After a spiral spray pattern 36 or 106 has been applied to opposite sides of the body contacting layer 16, and 5elected areas of the ~lastic members 38, 40 have been adhered to the body contacting layer 16, the section 42 of the body ~contacting layer 16 on the lefthand side of Figs. 1 and 9 which received the adhesive patterns 36 and 106, respectively, is folded over onto the section 43 of , the body contacting layer 16 on the opposite side of each elastic member 38 to form barrier cuff 54.
Similarly, the section 44 of the body contacting layer 16 on the righthand portlon of Figs. 1 and 9 which received the adhesive pattern 36 or 110, respectively, is folded over onto the section 45 on ~he opposite side of elastic member 40 to form barrier cuf~ 56. As shown in Fig. 3, the resulting barrier cuffs 54, 56 comprise opposed sides 42, 43 and 44, 45, respec-tively, with an elastic member 38 or 40 therebetween.
When the body contacting layer 16 is adhered to the remainlng elements of the disposable diaper 12 as shown in Fig. 4, these barrier cuffs 54 and 56 are :,. .

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located on opposite sides of the cen~erline 28 o~ each indivi.dual diaper 12 ~o define the waste containment pocket 10 thereof and are spacea inwardly of the elasticized leg openings 24, 26, resp~ctively.
As mentioned above, the elastic members 38 and 40 are maintained in a tension throughout the steps of applylng the spiral patterns 36 of adhesive and folding the body contacting layer 16 to form the barrier cuffs 54 and 56. When the tension is released from the elastic members 38, 40, such as by cutting them and the body contacting layer 16 to length to form an lndividual disposable diaper 12, the elastic members 3a, 40 "snap back" or return to their original ; length. In the course of returning to their original length, each elastic member 38, 40 forms gathers 52 in the barrier cuffs 54 and 56, respectively. Prefer-ably, the elastic members 38, 40 are adnered to the ; body contacting layer 16 at locations which form the opposed ends of an individual diaper 12, thus forming gathers 52 therehetween which are ].ocated approxi-mately in the center of the barrier cu~fs 54 and 56.
The yather5 52 help the diaper 12 to conform to the shape of the wearer, as well as resist the passage of exudate material from the waste containment pocket 10 outwardly to the eIasticized leg openings 24, 26.
Referring now to Figs. 5-8 and 10, an alternative-embodiment of the method of this invention :

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is illustrated wherein the waste containment pocket 10 of the disposable diaper 12 is de~ined by two identi-cal barrier cuffs 60 whlch are adhered to the body contactinq layer 16, but not integrally formed ~here-with. In one preferred emhodiment, shown in Fig. 5, asingle dispensing device 63 identical to dispensing devices 30 and 32 and carried by a support 64 applies a spiral pattern 65 of adhesive onto a relatively : narrow section or strip 66 of material such as th~
same type of non-woven material forming the body contacting layer 16, or another suitable material. An elastic membér 68 of the same type as elastic members 38 and 40~15 located in the middle of the strip 66 and maintained under tension thereon. The adhesive pattern 65 is applied to one side 72 of the strlp 66 and extends substantially parallel to but not in contact with the elastic member 68 of the other side 73 of strip 66. An air tube 74, which is operated in the identical manner as air tubes 46 described above by a controller ~not shown), intermittently diverts the adhesive pattern 65 onto the elastic rnember 68 and a portion of the side 73 of strip 66 at longitudinally spaced areas 76 therealong.
In an altPrnative embodiment illustrated in Fig. lO, a pair of dispensing devices 114 and 116 are mounted to a support 117 which are identical in construction and operation to the dispensers 90, 92 ~ -~2- 2~
and dispenser5 96, 98 described above in connection with Fiy. 9. Dispenser device 114 is operated inter-mittently to apply a 5piral pa~tern 118 o~ adhesive around and onto the elastic member 68 at longitudi-nally spaced intervals therealong. The dispensingdevice 116 applies a continuous spiral pattern 120 of adhesive on one side 72 of strip 66, and this pattern 120 extends substantially parallel to but not in contact with the elastic member 68 as in the embodi-ment of Fig. 5. The opposite side 73 of strip 66 isthus substantially free of adhesive except for those areas where the adhesive pattern 118 extends onto the elastic member 68 and overlaps onto slde 73 A
The strip 66 is then folded in half so that : 15 its sides 72 and 73 adhere together and the elastic - member~68 is captured therebetween to form the barrier cuff 60. Two barrier cuffs 60 are then attached to the surface of the body contacting layer 16 on oppo site sides of the centerline 28 to define the waste containment pocket 10. As shown ln Fi~s. 7 and 8, the inner end of each barrier cuff 60 is folded to form a flap 80, and this flap 80 is brought into contact with one of the beads or patterns 82 of adhesive applied on opposite sides of the centerline of the body contact-; 25 ing layer 16 by suitable adhesive dispensers 84, 86 which are preferahly of the same type as dispensers : 30, 32 and 63. Alternatively, each individual barrier -23~ 6~
cuff 60 can be attached to the body contacting layer 16 by other means such as sonic bonding, the applica-tion of adhesive directly to flap 80 or the like.
When the tension is released on the elastic member 68 S of each barrier cuff 60, such as by cutting the body contacting layer 16 or strip 66 to length, pleats or yathers (not shown) are formed in each barrier cuf~ 78 as in the embodiment of Figs. 1-4.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof.
For example, Figs. l, 2 and 5 illustrate an air tube 46 or 74 as one means for divertinq or redirecting the path of the adhesive patterns 36 or 65 applied to the body contacting layer 16 or to the strip 66. It is contemplated that other means could be employed to divert the adhesive path such as a mechanism to intermittently move the adhesive dispen-sers 30, 32 and 63 perpendicularly relative to the direction of movement of the body contacting layer 16 or strip 66 to form longitudinally s~aced areas 49 or ^ _~ ~24- 2~
76 therealong where the adhesi~e bonds the elas~ic members 38, 40 or 68 to the body contacting layer 16 or strip 66.
Therefore, it is intended that the inven~ion S not be limited to the particular e~bodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

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Claims (6)

1. The method of forming a waste containment pocket in a disposable garment, comprising:
applying adhesive onto a body contacting layer of the disposable garment in a pattern which extends alongside but not in contact with a first elastic member maintained in tension atop said body contacting layer;
intermittently applying adhesive over said first elastic member so that said body contacting layer and said first elastic member adhere together at spaced locations therealong;
folding said body contacting layer on either side of said first elastic member upon itself to form a first barrier cuff which encloses said first elastic member;
releasing said tension on said first elastic member to form gathers along said first barrier cuff;
applying adhesive onto the body contacting layer of the disposable garment in a pattern which extends alongside but not in contact with a second elastic member maintained in tension atop said body contacting layer, said second elastic member being spaced from said firs-t elastic member:
: intermittently applying adhesive onto said second elastic member so that said body contacting layer and said second elastic member adhere together at spaced locations therealong;

folding said body contacting layer on either side of said second elastic member upon itself to form a second barrier cuff which encloses said second elastic member, said second barrier cuff being spaced from said first barrier cuff along said body contact-ing layer to form a waste containment pocket there-between;
releasing tension on said second elastic member to form gathers along said second barrier cuff.

2. The method of claim 1 in which said steps of applying adhesive onto said body contacting layer each comprises discharging an elongated adhesive fiber in a spiral motion from one of a pair of adhesive dispen-sers which are spaced above said body contacting layer of the disposable garment, said one adhesive dispenser of each of said pairs being positioned to apply the elongated adhesive fiber in a spiral pattern onto the body contacting layer along one side of one of said first and second elastic members but not in contact therewith.

., ,

3. The method of claim 2 in which said steps of intermittently applying adhesive over said first and second elastic members each comprises discharging an elongated adhesive fiber in a spiral motion from the other of said pair of adhesive dispensers, said other adhesive dispenser of each of said pairs being posi-tioned to apply the elongated adhesive fiber in a spiral pattern onto one of said first and second elastic members at spaced locations therealong.

4. The method of forming a waste containment pocket in a disposable garment, comprising:
forming a first barrier cuff and a second barrier cuff, each of said first and second barrier cuffs being formed by:
(i) applying adhesive onto a strip of material in a pattern which is alongside but not in contact with an elastic member maintained in tension atop said strip of material;
(ii) intermittently applying adhesive onto said elastic member so that said strip of material and said elastic member adhere together at spaced locations therealong;
(iii) folding said strip of material in half so that said elastic member is enclosed within the two halves of said strip of material and said halves are adhered together to form a barrier cuff;
(iv) releasing said tension on said elastic member to form gathers along said barrier cuff;
attaching said first barrier cuff and said second barrier cuff on opposite sides of the center of the body contacting layer of the disposable garment to form a waste containment pocket therebetween.

5. The method of claim 4 in which said step of applying adhesive onto a strip of material comprises discharging an elongated adhesive fiber in a spiral motion from one of a pair of adhesive dispensers which are spaced above said strip of material, said one adhesive dispenser being positioned to apply the elongated adhesive fiber in a spiral pattern onto the strip of material alongside but not in contact with the elastic member.

6. The method of claim 5 in which said steps of intermittently applying adhesive over said first and second elastic members each comprises discharging an elongated adhesive fiber in a spiral motion from the other of said pair of adhesive dispensers, said other adhesive dispenser of each of said pairs being posi-tioned to apply the elongated adhesive fiber in a spiral pattern onto one of said first and second elastic members at spaced locations therealong.