CA2130245A1 - Gradated containment flaps in a disposable absorbent child's training pant - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

A disposable absorbent article includes a waste containment assembly that has a liner, outer cover, and an absorbent composite between the liner and outer cover, and a pair of gradated containment flaps operatively joined to the waste containment assembly. Methods are provided for making the absorbent article.

Description

- 213~2~5 PATENT

GRADATED CONTAINMENT FLAPS IN A DISPOSABLE ABSORBENT
CHILD'S TRAINING PANT

Backaround of the Invention S ~his invention pertains to dlsposable absorbent artlcles, and more partlcularly to a chlld's trainlng pant having improved containment flaps for provid1ng improved containment and absorbency of waste matter.
~ , Currently, disposable absorbent articles find widespread use in the areas of adult care, infant care, and child care, and have generally replaced reusable cloth articles. Disposable diapers, for example, have met a part~cular need and have become very popular. However, once a child reaches an age of about 15 to 30 months, a parent or caretaker generally deslres to start tollet tralnlng so the chlld can become independent of the parent or caretaker. A tralning pant is used for toilet training when the child has reached an age at which he or she is ready to graduate to underpants as a replacement for disposable diapers. A suitable disposable traln~ng pant is an article having closed sldes so that a child can raise and lower the pant without requiring any assistance. A child puts the training pant on by placing his or her feet through the waist and leg openings , .. ,,. r t , . , ,., ~ "",, ~ ".. , ";,,~",.",, ., ~ .,.,."~" , .

-- 213~5 and pulling the pant upwardly to fit snugly at the crotch. This is significantly different from the way a diaper is fitted.

Although it is desired by the parent that the child not have an ~
5 accident while wearing a training pant, accidents will occur and, -~ ~-during those times when the pant cannot be replaced, multiple ~-accidents can occur that exceed the containment capacity of current training pants. Thus, there is a need to provide a chlld's train1ng pant with improved containment.
: ' Summarv of the Invention ;~
In one embodiment of the present invention there is provided a ~ ~
disposable absorbent article having a waste containment assembly ~;; ;including an outer cover and an absorbent composite on the outer cover. A pair of containment flaps are Joined to the waste contalnment assembly. Each contalnment flap has a prox1mal edge and a gradatet distal edge with an apex. The apexes of the distal edges are in contact w1th each other when the containment flaps are in a stretched, flat cond1tlon.
In another embodlment of the present lnvent10n there is provided a dlsposable absorbent article having a waste containment assembly including side panels, a waist opening, and a pair of leg openings.
A pair of gradated containment flaps are ~oined to the waste containment assembly.
. - .
In still another embodiment of the present invention there is provlded a method of maklng a disposable absorbent article comprising ' - -` 21~2~

the steps of providing a waste containment assembly, supplying a pair of containment flaps having distal edges with apexes, placing the ~ ~
containment flaps with the waste containment assembly so that $he ~ ; apexes are in contact when stretched flat, and joining the containment flaps to the waste containment assembly.

Brief DescriDtion of the Drawinas ~he above-mentioned and other features of the present invention and the manner of attaining them wilt become more apparent, and the invention itself will be better understood by reference to the following description of the invent1On, taken in con~unction with the accompanying drawings, wherein:

Fig. 1 is a top plan view of a diaper having conventional containment flaps;

Fig. 2 is a cross-sectional view through the crotch area of the diaper in Fig. 1 with the containment flaps vertically oriented;

Fig. 3 is a perspective view illustrating a step in fitting the diaper of Fig. 1 on an infant;

Fig. 4 is an elevational, part~ally broken-away view of a training pant at an intermed1ate point of its being pulled on and having the same type of containment flaps as the diaper of Fig. l;

- - ` 2 ~ 3 ~

Fig. 5 ;s an eleYational, part;ally broken-away view at the crotch area typifying an embodiment of the present invention fitted on a child;

Fig. 6 is a stretched-flat top plan view of the embodiment in Fig. 5 typifying two different configurations of a containment flap in a flat state;

Fig. 7 is a cross-secttonal view of Fig. 6 taken along line 7-7 and viewed in the direction of the arrows;

Fig. 8 is a cross-sectional view of Fig. 6 taken along line 8-8 and viewed in the direction of the arrows with the containment flaps in a generally uprlght orientation;
Fig. 9 is an exploded, fragmentary view similar to the view of Fig. 8, but with containment flaps in a flat state; and Flg. 10 typ~f1es one method of maklng a conta~nment flap of the present 1nvention.

pefinitions ~ithin the context of this specification, each term or phrase below will include the following meaning or meanings:
~ ~-(a) ~SBL~ means a stretch bonded laminate that is at least a ~ -two-layered composite in which one layer is a gatherable layer and the other layer is an elast1c layer. The layers are Joined 2~ 3~2~5 together when the elastic layer is in a stretched condition so that, upon relaxing the layers, the gatherable layer is gathered.

(b) ~Two-dimensional~ refers to a garment, such as a diaper, that can be opened and laid in a flat condition without destructively tearing any structure. This type of garment does not have continuous leg and waist openings when opened and laid flat, and requires a fasten~ng device, such as adheslve tapes, to attach the garment about the wearer.

(c) ~Three-dimensional~ refers to a finished garment similar to shorts or pants ln that they have continuous leg and waist open~ngs that are bounded by the material of which the garment is made. This type of garment can be opened and laid flat only by destructively tearing it. This type of garment may or may not have manually tearable seams.

(d) ~ember~ when used ~n the singular can have the dual meaning of a single element or a plural1ty of elements.

(e) ~Operatively ~olned~ with reference to the attachment of an g elast1c member to another element means that the elastic member when attached to or connected to or treated with heat with the element gives that element elast1c properties. With reference to the attachment of a non-elast1c member to another element, it means that the member and element can be attached in any suitable manner that permits or allows them to perform the 2 1 3 ~ 2 '~
, intended or described function of the joinder. The joining, attaching, connecting or the like can be either directly, such as joining either member directly to an element, or can be indirectly by means of another member or element disposed ~-s between the first member and the first element.
''~,.'-' ~f) ~Disposed~, ~disposed onn, ~disposed with", "disposed at", ~disposed near~, and variations thereof are intended to mean -that one element can be 1ntegral or un1tary with another element, or that one element can be a separate structure ~oined to or connected to or placed with or placed near another element. ~ `;

(g) ~Disposable~ includes being disposed of after use, and not intended to be washed and reused.

.
(h) ~Gradated~, ~gradat10n~, and ~gradating" includes to curve, slope, deflect, 1ncl1ne, step, or the like, in gradual, successive stages or degrees.
(1) ~Force~ 1ncludes a phys1cal 1nfluence exerted by one body on another wh1ch produces acceleration of bod1es that are free to move and deformat10n of bodies that are not free to move. Force ls expressed in grams-force. ;~
~ -;
Tension~ includes a uniaxial force tending to cause the extens~on of a body or the balancing force with1n that body res1sting the extension. -~

~` 21 3~ r~

(k) "Extensionn, "extend", and "extended" include the change in length of a material due to stretching. Extension is expressed in units of length.

(1) ~Elongation~ includes the ratio of the extension of a material to the length of a material prior to the extension. Elongation is e~pressed in percent.

0 (m) ~RuptureH includes the breaking or tearing apart of a material;
in tensile testing, rupture refers to the total separation of a material into two parts either all at once or in stages, or the development of a hole in some materials.
S (n) ~Ultimate elongation~ includes the elongation at the point of rupture.

(o) ~Elasticity~ and ~elast~c~ include that property of a mater~al by virtue of whtch it tends to recover 1ts origlnal slze and shape after removal of a force causing the deformat1On.

~hese definitions are not ~ntended to be limiting, and these terms may be defined with additional language in the remaining portion of the specif~cation.
pescriDt~on of a Preferred Embodiment Referring primarily to Figs. 1-3, a disposable, two-dimensional garment such as diaper 10 comprises front waist section 12 including ~ ~, - 7 - ~ ~

. ~. ~ .. , . , .. .. , ~. i .. . .

2 ~ 3 ~ 2 !~ ~
oppositely disposed front ear sections l4, back waist section 16 including adhesive tapes 18 on respective oppositely disposed back ear sections 20, and crotch section 21 between front waist section 12 and back waist section 16. Diaper 10 further comprises a backsheet 22, a liner 24, and an absorbent pad 26 disposed between backsheet 22 and liner 24. Extensions of backsheet 22 and liner 24 beyond the longitudinal edges or absorbent sides 38 of absorbent pad 26 form oppositely disposed side sections 28. Sections 28 individually include an elastic member 30 adhesively attached between backsheet 22 and liner 24. Disposed with each side section 28 is a containment flap 32 having elastic members 34 attached thereto. Each containment flap 32 can be one or more layers of desired material that encloses elastic members 34 in any suitable manner known in the art. Elastic members 30 and elastic members 34 are attached in diaper 10 while 1n an extended condition in order to provide an elastic effect at side sections 28 and at the distal ends 40 of conta1nment flaps 32, respect1vely. A more detailed description of the structure of a typical diaper lO, its process of manufacture, and method of use are containet in U.S. Pat. No. 4,704,116, wh1ch is ass19ned to the ass1gnee of the present 1nvent10n.

Referring specifically to Fig. 2, crotch width WD is measured between oppos1te proximal ends 41 of containment flaps 32 and along a line transverse, i.e., perpendicular, to the longitudinal direction of centerline CL. Each flap 32 has a height HD measured between distal end 40 and proximal end 41~at which flap 32 is joined or adhered to liner 24. A proximal end is identified as that line or point of ~3~2~

attachment or joining that is closest to its respective distal end.
For example, if a containment flap is attached or adhered by three parallel lines of adhesive beads, then the proximal end is coincident with or starts at the adhesive bead closest to the distal end.
Similarly, .f the containment flap is adhered by a ribbon of adhesive, then the proximal end is coincident with or starts at the edge of the adhesive ribbon closest to the distal end. Height HD is much less in dimension than the width WD 1n diaper lO; the significance of th~s relat~onship w~ll be descr~bed hereafter.
Referring now to Fig. 3, torso 36 of an infant has been placed upon back waist section 16 of diaper lO in preparation of fitting and attaching diaper 10 to torso 36. Legs 44 of the infant are spread far apart so that front section 12 can be easily folded upwardly over the front of torso 36 in a manner that snugly fits crotch section 21 aga~nst the infant. Thereafter, adhesive tapes 18 are attached to the outermost surface of respective front ear sections 14. Because of the wide crotch dimension of diaper 10, wh1ch generally is about 6 to about 8 1nches, the narrow crotch d~mens1On of the infant, which generally 1s about 2 to about 4 1nches, and the large d~stance between conta1nment flaps 32, flaps 32 contact lnitially the inner leg surfaces 52 of the thighs when diaper 10 1s folded upwardly to fit between the legs. Containment flaps 32, upon contacting the inner leg surfaces 52 can bend or turn outwardly away from the center of the diaper. This is not the desired position or shape of flaps 32 for optimum waste containment. In order for containment flaps 32 to perform optimally, it is important they do not turn or bend ~ :. ' , .. . ~, . ... . .
g 2 1 3 ~ 7 !~ ~
outwardly, since urine can wick along flaps 32, out of the confines of diaper 10, and along the legs of the wearer.

Turning now to Fig. 4, a disposable, three-dimensional garment such as training pant 46 is partially fitted, i.e., not pulled fully upwardly to the waist, on a child's torso 48. Torso 48 includes legs 50 that have respective inner surfaces 52. Training pant 46 can be made or constructed in a variety of ways, one of which is described in U.S. Pat. Application Serial No. 043,132 filed on March 25, 1993, which is incorporated by reference herein. Other training pant designs are described in U.S. Pat. Nos. 4,938,757, 4,747,846, and 4,940,464 Training pant 46 generally comprises waste containment section 54 and side panels 56, which may or may not have elastic characterlstics.
Side panels 56, which can be rendered elastic by elastic members 55, are ultrasonically bonded to form manually tearable, non-refastenable seams 58. Elast~c ~embers 55 (Fig. 6) can be a layer of elastic mater~al or an SBL. Tra1n~ng pant 46 ~urther 1ncludes front end portion 49, back end portion 5l, and crotch area 53 between end port1cns 49 and 51. Waste containment section 54 includes the containment n aps 32 earlier described with reference to diaper 10, -~
backsheet 22, liner 24, absorbent pad 26, and side sections 28.
Containment flaps 32 have respective distal ends 40.

Several differences, both structural and functional, exist between a diaper, su.h as diaper 10, and a training pant, such as training pant - 10 - '' - ~13Q2~

46. One of the differences is in the method of fitting a diaper on a baby and a training pant on a child. As described above, diaper l0, which is a two-dimensional article, is fitted on an infant by placing the infant on back waist section 16 ( Fig. 3) and then folding front waist section 12 upwardly to be joined with back waist section 16 by adhesive tapes 18. In contrast, training pant 46, which is a three-dimensional article, is not fitted in the same manner.
Training pant 46 is fitted by inserting the child's feet through waist opening 60 and respective leg openings 62 (Fig. 4J, then grasping training pant 46 near waist opening 60, and pulling upwardly along the legs until crotch area 53 is snugly fit against the crotch. ~-During the travel of training pant 46 upwardly along legs 50 and - `
their inner surfaces 52, distal ends 40 of flaps 32 begin to turn or bend outwardly away from each other and then bend downwardly due to 15 the sliding contact or friction between legs 50 and flaps 32. This `
position of flaps 32 is undesirable since urine can wick or transfer along and over contatnment flaps 32 and beyond side sections 28, thereby soiling the child's clothes.
, ~,."

20 It has been discovQred that a mechanism causing this outward turning ~
or bend1ng of containment flaps 32 as they move upwardly along inner ~ -~ . ....:.. . -leg surfaces 52 is the relatively very short height dimension HD
(Fig. 2) of containment flaps 32 in relation to width dimension WD, and the elastic1ty and tension provided by the flap elastics.
Referring now to Fig. 6, another disposable, three-dimensional garment such as training pant 47 is shown with two configurations or designs of gradated containment flaps 64, 64' of the present ... ...

., . ~
': :

2 ~ ~ ~ 2 ~

invention operatively joined therewith. Hereafter, the description will refer at ti~es collectively to flaps 64, 64', but it should be understood that these two different configurations or designs generally would not be used together. Rather, reference to flaps 64, 64' collectively is tG be interpreted and understood that the flap configuration or design can be, in one example, a pair of containment flaps 64 or, in another example, a pair of containment flaps 64'.
Waste containment assembly 61 includes liner 66, absorbent compos~te 70, and outer cover 88. Alternatively, waste conta~nment assembly 61 can include absorbent composite 70 and outer cover 88 without liner 66. ~aste conta~nment assembly 61 also can include structures such ~ ~
as a surge management or other type of layer (not shown). Training ~ ~;
pant 47 also comprises side panels 56 joined by seams 58 to form waist opening 60 and leg openings 62 (Fig. 5). Side panels 56 can be extensions of outer cover 88 and/or liner 66, or separate elements, and may be elasticized by, for example, elastic members 55.

Conta~nment flap 64 is ~llustrated on the left side of centerline C/L
1n F~g. 6t and contalnment flap 64' is illustrated on the right s1de of centerl1nQ C/L. Conta1nmQnt flap 64', on the right side of centerl1ne C/L of Fig. 6, is similar in construction to containment n ap 64 except that d1stal edge 65' has a different gradation than that of distal edge 65. At front end portion 71', distal edge 65' is generally parallel to proximal edge 63' or centerline C/L.
Sim11arly, back end portion 73' of containment flap 64' is generally parallel to proximal edge 63' or centerline C/L.
'~ ~ . ,:

2~ 332~

Training pant 47 has each containment flap 64, 64' attached to waste containment assembly 61, and although flaps 64, 64' can be attached to outer cover 88 or any other structure of training pant 47, they are desirably attached to the top surface 68 of liner 66. Each containment flap 64, 64' has proximal edge 63, 63' adhesively attached to top surface 68. Flap elastics 67, 67' are integrated, while ~n an extended condition, at respective gradated distal edges 65, 65' of flaps 64, 64'. Elastics 67, 67' can be attached in any suitable manner known in the art so that ~ntermediate port~ons of flaps 64, 64' are gathered. Pant 47 further includes front end portion 49, back end portion 51, pant back edge 72, and pant front edge 74. ~he distance between edges 72, 74 define the length of training pant 47.

In Fig. 6, training pant 47 is in a flat state prior to being folded to form seams 58 (Fig. 5), which result in the flnished tralning pant 47 havlng wa1st open1ng 60 and leg openings 62. The term ~f1nished training pant' means a three-dimensional training pant that can be used for ~ts intended purpose. Fig. 8 shows the generally upr19ht poslt10n containment flaps 64, 64' assume when pant 47 1s be1ng pulled on and worn. It is understood that, although waste containment assembly 61 is illustrated here as being flat for ease of understand1ng, waste contalnment assembly 61 in fact assumes a bowed-or bucket like shape in the crotch as illustrated in Fig. 5.
Referring to Figs. 6, 7, and 8, each containment flap 64, 64' can extend the longitudinal length of train1ng pant 47 between back edge ~-72 and front edge 74, and is attached to liner 66 at proximal edges 63, 63'. Each containment flap 64, 64' has a front end portion 71, 2 ~ 3 ~

71' and a back end portion 73, 73' adhered to liner 66 such that corresponding end portions of distal edges 65, 65' are adhered to liner 66. Front end portions 71, 71' and back end portions 73, 73' can be adhered or otherwise attached in any suitable manner known in the art. One specific method of attachment is described in U.S.
Patent Application Serial No. 054,508 filed April 26, 1993 and assigned to the assignee of this application.

Referring to Fig. 6, a description of conta1nment flap 64, which is the containment flap on the left side of the centerline C/L, will be made. Containment flap 64 extends the full length of training pant 47 between front edge 74 and back edge 72. Containment flap 64 comprises a generally straight proximal,edge 63 that is generally parallel to the centerline C/L of the training pant 47 and is desirably attached along its length to liner 66 by means of flap seam adhesive 124 (Fig. 9). Containment flap 64 further includes a gradated d1stal edge 65 having an apex 75 and a flap elastic 67 attached therein while in an extended state, so that upon relaxing flap elast1c 67, elast1c 67 will gather distal edge 65. F1g. 6 illustrates containment flap 64 in a flat state to show that distal edge 65 is gradated in a convex-manner relative to the centerline.
Gradated distal edge 65 can be formed or configured in any curvilinear or non-curvilinear fashion so as to adjust the longitudinal location of apex 75 relative to front edge 74 and back edge 72. For example, a girl's training pant 47 can have apex 75 located generally a~ the widway point between front edge 74 and back edge 72. For boys, apex 75 can be located closer to front edge 74.

- 213~2~S
The gradation of flaps 64 can be accomplished in at least two ways.
A first way is to cut the material, of which a flap 64 is made, to form distal edge 65 with the desired gradation, and then attach flap elastic 67 to distal edge 65. A second way is to cut the material in a generally rectangular form, and then attach flap elast~c 67 in a gradated manner to provide a gradation to the tension provided by the -attached flap elastic 67.

Unique to the present invention is that apex 75 can contact or overlap the centerline C/L and thus contact or overlap with a corresponding apex 75 of a similar containment flap 64 attached to the right side of centerline C/L, when the flaps 64 are stretched flat as illustrated in Fig. 6. If apexes 75 overlap, it is desired that they overlap less than about 1 centimeter. In accordance with the present ~nvention, flap elastics 67 have a tension sufflcient to gather or draw the corresponding contacting or overlapping apexes 75 apart so that they do not contact or overlap in use.
.
As described, each dlstal edge 65, 65' has been formed or conf~gured to be gradated such that the front end portions 71, 71' and back end portions 73, 73' of flaps 64, 64' and/or flap elastlcs 67, 67' diverge or curve away from centerline C/L as illustrated in Fig. 6. ~-- ;
Each containment flap 64, 64' has a flap height HP (Fig. 8) that is measured between apex 75, 75' and proximal edge 63, 63' along a line 25 transverse, i.e., perpendicular, to centerline C/L. Each proximal ~-edge 63, 63' is identified as that line or point of attachment or joining that is closest to its respective distal edge 65, 65'.

' ~, .. . .

" . - . ., , . .. ., ,.- , , ., . ,..... , .-. ;.. , , .. ~, . . .

213~2~:~
As mentioned above, apexes 75, 75' can contact or overlap as illustrated in Fig. 6, and with proper selection of tension on flap elastics 67, 67', distal edges 65, 65' are gathered and drawn away from each other so as not to overlap when training pant 47 is in use.
S This permits a pair of containment flaps 64, 64' to assume a higher or taller upright orientation (Figs. 5 and 8) to assist in containing urine and liquid bowel movements until absorbent composite 70 can fully absorb these wastes. This is important since absorbent compas1te 70 of training pant 47 has a w~dth that ls between about 2 inches to about 4 inches ln crotch area 53, as compared to a width of about 6 to about 8 inches for a typical diaper absorbent.

In Fig. 8, each containment flap 64, 64' has a flap height HP
measured between apexes 75, 75' of respective distal edges 65, 65' and respective proximal edges 63, 63', and a flap width WP measured between proximal edges 63, 63' along a line perpend1cular to the longitudinal centerline C/L of training pant 47. Flap height HP has a range between about 25 mm to about 76 mm, and a desired range of about 31 mm to about 51 mm. Flap width WP has a range between about S0 mm to about 102 mm, and a des~red range of about 76 mm to about 90 mm. Overall product length is measured between back edge 72 and front edge 74, and the length is between about 432 mm to about 1,067 m~.

Continuing to refer to Figs. 6-8, flap elastics 67, 67', which may be a single ribbon of elastic material or a plurality of strands of elastic material, have a predetermined elongation and tension in order to assist in properly positioning containment flaps 64, 64', r 2 1 ~ 5 and especially apexes 75, 75', at the crotch of the wearer. In order for containment flaps 64, 64' to assume a desired upright orientation, as shown in Fig. 8, to contact and seal against inner surfaces 52 of legs 50 (Fig. 5), each flap elastic 67, 67' desirably has a minimum of about 90 percent elongation when incorporated into flap 64, 64' of a finished training pant 47. A desired range of elongation is between about 90 percent to about 150 percent stretch. ;~
A desired tension range for each flap elastic 67, 67' is between about 90 grams-force to about 200 grams-force at 90 percent of ultimate elongation.

Flap height HP, flap width ~P, and the elastic characteristics of f~ap elastics 67, 67' determine the anatomical location of distal edges 65, 65' and well 86 at the crotch of the wearer. If the elastic characteristics of flap elastics 67, 67' are not within the desired ranges, there ~s inconsistency in proper or correct flap positioning at the crotch of the wearer. For example, distal edges 65, 65' can shift too close together such that flaps 64, 64' form a tent over absorbent compos1te 70, thereby prevent~ng absorptlon of 29 ur1ne or other waste matter. ~ ~
:.
The present invention provides consistent containment flap positioning within the crotch of the wearer as shown in Fig. 5.
Additionally, because of the relatively large dimension of flap height HP, when absorbent composite 70 becomes heavier due to the absorption of waste matter and begins to sag downwardly, containment -~
flaps 64, 64' will extend to maintain their seal, thereby containing 2~3~2~;~
liquid and other waste matter in well 86 until absorbent composite 70 has time to fully absorb the waste matter.
~ ~' Anotner unique feature of the present invention is a containment flap 5 softness quality measured as the average actual drape value. The ~-materials of which containment flaps 64 are made desirably have an average actual drape value less than about 1.83. This softness reduces red marking, irritation, and other effects at the sensitive crotch area. The test procedure for determ1ning the average actual drape value 1s ASTM Standard D-1388 entltled ~Stlffness of Fabrlcs~
and Method 5206 Federal Test Methods Standard #19lA. Equipment used was a Cantilever Bend1ng Tester, Model 79-10 ava~lable from Testing Machines Inc., 400 Bayview Avenue, Amityville, New York. l170l; a 30~ x 30~ precis1On paper cutter with sample holder; and a cutting press with l/2~ x 6~ rectangular cutting d~e. In performing this test, 5 products were selected and, prior to perform1ng the test, each of the conta1nment flaps were 1dentified as the "left~ and ~r1ght~ conta~nment flap. The conta1nment flaps were then removed from the 5 products to g1ve a total of 10 conta1nment flaps, wh1ch were cut 1nto str1ps hav1ng a length of 6 1nches and a wldth of l/2 1nch. ~hese str1ps d1d not 1nclude the flap elast1cs. Each str1p was moved at a rate of 4 3/4 1nches per minute in a direction parallel to its long dimens1On, so that its lead1ng edge pro~ected from the edge of a horizontal surface. The length of the overhang was measured when the t1p of the strip depressed under 1ts own we19ht to a point where the line ~oining the tip to the edge of the platform made an angle of 41.5 degrees w~th the horizontal. Once a strip depressed to the angle of 41.5 degrees, its length was measured, and .- . ,, , .. ~ ., ,., ., .,, . , . .. ;. * ., .. . ,.", .. .. .. .......

``,,- - ,p:
213~2~;) the actual drape value was calculated by dividing the measured length in inches by 2. After performing this test on each of the l0 flaps from the 5 products, the 10 actual drape values were averaged to determine the average actual drape value.
~ ~
In use, the child will position his or her feet through waist opening ;~ ~-60 and leg openings 62 and then grasp pant 47 and pull upwardly along legs 50. As pant 47 moves upwardly, there is an increase in the sliding contact pressure or frlct~on between containment flaps 64, 10 64' and inner surfaces 52 of legs 50. However, because of the above-described features of the containment flaps of the present invention, flaps 64, 64' w~ll maintain their upright orientation ~ ~
while pant 47 is pulled snugly into the ch11d's crotch. Containment ~ ;
flaps 64, 64' will then be properly posltioned, as shown in Fig. 5, in order to form well 86. As absorbent composite 70 becomes heavier due to lts absorbing waste, absorbent composite 70 will tend to sag or move downwardly, away from the crotch. However, containment flaps 64, 64' wlll be able to extend in he19ht, as shown in Fig. S, to ma1ntaln ~he seal agalnst the crotch.
Fig. 9 shows outer cover 88, which desirably is a two-layer composite 1nclud1ng liquid permeable nonwoven layer 90 and liquid impermeable f~lm layer 92 suitably ~olned together by adhesive 94. Outer cover 88 can also be a single layer compris~ng film layer 92, nonwoven layer 951 or any other suitable liquid permeable or liquid imper~eable material. Carrier sheet 98 has 3 strands of leg elastic 96 adhesively attached thereto, while in a stretched condition, in ~ -~
any su~table manner known in the art. Carrier sheet 98, with leg ,,, ' "
- 19- ., ' ''13~2'~;~

elastics 96 attached thereto in a stretched condition, is adhesively attached to fi~m layer 92 by leg adhesive 100. Absorbent composite 70 comprises a mixture of cellulosic pulp fluff and superabsorbent materials that are wrapped in tissue wrap 102 to provide integrity to : .
the fluff/superabsorbent material mixture. Absorbent composite 70 can comprise only cellulosic pulp fluff, only superabsorbent materials, or a combination of both with other absorbent or non-absorbent materials. Absorbent composite 70 ~s adhes~vely attached to f11m layer 92 by absorbent construction adhes~ve 104.
Liner 66 is adhesively attached to absorbent compos~te 70 and fllm layer 92 by liner adhesive 108, and by adhesive bead 110 to carrier sheet 98.

Referring specifically to a single containment flap 64, flap elast~cs 67, which are 3 strands of elastic material, are adhesively attached, while in an extended condition, to nonwoven layer 112 by elastic adhesive 114. Flap adhesive 116 is applied in any suitable manner to nonwoven layer 112, and f11m layer 118 ~s attached to nonwoven layer 112 by flap adhesive 116. Nonwoven layer 112, at ~ts end near flap elast1cs 67, 1s folded over flap elastics 67 and film layer 118, and attached to film layer 118 by flap fold adhesive 120. Flap 64 is then attached to liner 66 by means of flap seam adhesive 124, which runs the full length of containment flap 64. The end portions of flap 64 adjacent back edge 72 and front edge 74 are adhered to l~ner 66 by flap end adhesive 126 to provide attachment of that corresponding portion of distal edge 65 and flap elastic 67, thereby anchoring elastic 67 in place so that its remaining portion that is unattached to liner 66 gathers flap 64.

.: X ; ` ~ s ~ :~`3 - ` ., 13~2~5 The materials of which training pant 47 are made, including co~tainment flaps 64, 64', can be any materials specifically desired by the user or manufacturer. Numerous examples of materials used in 5 constructing training pant 47 are described in the aforementioned ;
U.S. patents and patent applications.

~ .'';

In one embodiment, elastic members 55 can be a stretch bonded laminate comprising an inner layer of a prestretched elastic meltblown core sandwiched between and attached to a pair of spunbond polypropylene nonwoven webs having a basis weight of about 0.4 oz/yd (13.6 gsm). Elastic wembers 55 can be incorporated with or into ;
training pant 47 in any suitable manner, such as those described in ~ :15 the aforement1cned U.S. patents and patent applications. Suitable ~
elastic polymers can be purchased from the Shell Chemical Company of `
Houston, ~exas under the trade name Kraton. Suitable adhesives can be obtained from Findley Adheslves, Inc. of Wauwatosa, Wisconsin.
,, Flap elast~cs 67, 67' ~n containment flaps 64, 64' are strands of Lycra ~151 940 decitex elastic which can be obtained from E. I. du Pont de Nemours Co., ~ilmington, Oelaware. Nonwoven layer 112 is a spunbond polypropylene nonwoven web having a basis weight of about 0.7 oz/yd2 (23.7 gsm), and film layer 118 is a 0.6 mil polyethylene film which can be obtained from Filmtech Corp. of Easton, Pennsylvania. It is desired that nonwoven layer 112 be liquid . ..
permeable, and that film layer 118 be liquid impermeable. Film layer -~
118 may also be vapor permeable, liquid impermeable, and film layer 213~2~5 118 may have portions thereof that are liquid impermeable with the other remaining portions being liquid permeable.

Bodyside liner 66 is liquid permeable and is a spunbonded polypropylene nonwoven web having a basis weight of about 0.75 oz/yd2 (25.4 gsm). Outer cover nonwoven layer 90 is a spunbonded polypropylene nonwaven web having a basis weight of about 0.8 oz/yd2 (27.2 gsm), and outer cover film layer 92 ~s a 1.0 mil polyethylene film obta~nable from Edison Plastlcs Co. of South Pla~nfleld, New Jersey.

Carr1er sheet 98 ~s a 0.75 mil polypropylene film which is liquid ~mpermeable and can be obta~ned from Edison Plastics Co. of South Plainf1eld, New Jersey, and leg elast~cs 96 are 3 strands of bycra T151 940 dec1tex elast1c which can be obta~ned from E. I. du Pont de Nemours, ~llm1ngton, Delaware.

F19. 10 typ1f~es one way of mak1ng conta1nment flaps 64. A
cont~nuously movlng web 78 has parallel flap elastlcs 67 stretched and selecttvely attached thereto 1n a des1red gradated conf~guratton or des19n. After flap elast~cs 67 have been attached, web 78 can be cut between flap elast~cs 67 along cut~line 128, and transversely cut along cut-l~nes 130 to form separate gradated conta1nment flaps 64.

~hile thls invent~on has been described as having a preferred embodlment, it w1ll be understood that it 1s capable of further mod1f~cat~ons. This appl1cat~on is thereby 1ntended to cover any - -var1ations, equ~valents, uses, or adaptat~ons of the ~nvention 21302~5 following the general principles thereof, and including such departures from the present disclosure as come within known or ;~;
customary practice in the art to which this invention pertains and -~:
fall within the limits of the appended claims. ` .:.

~"' ' ~'."'' ..,,''. .,' '.';
- 23 - .:.

Claims (23)

1. A disposable absorbent article, comprising:
a waste containment assembly comprising an outer cover and an absorbent composite on said outer cover, and a pair of containment flaps operatively joined to said waste containment assembly, each said containment flap comprising a proximal edge and a gradated distal edge having an apex, said apexes of said distal edges being in contact when said containment flaps are in a stretched, flat condition.

2. The article of claim 1 wherein said apexes overlap.

3. The article of claim 1 wherein each said containment flap has a flap height between about 25 mm to about 76 mm.

4. The article of claim 1 wherein each said containment flap has an average actual drape value less than about 1.83.

5. The article of claim 1 further comprising a flap elastic in each said containment flap, said flap elastic having an elongation between about 90 percent to about 150 percent.

6. The article of claim 5 wherein said flap elastic has a tension range between about 90 grams-force to about 200 grams-force at about 90 percent of ultimate elongation.

7. The article of claim 1 wherein said absorbent composite has a crotch width between about 50 mm to about 102 mm.

8. The article of claim 1 wherein each said containment flap has a flap width between about 50 mm to about 102 mm.

9. A disposable absorbent, three-dimensional article, comprising:
a waste containment assembly comprising sides panels, a waist opening, and a pair of leg openings, and a pair of gradated containment flaps operatively joined to said waste containment assembly.

10. The article of claim 9 wherein each said containment flap has an average actual drape value less than about 1.83.

11. The article of claim 9 wherein each said containment flap has a flap height between about 25 mm to about 76 mm.

12. The article of claim 9 wherein each said containment flap has an apex, said apexes of said containment flaps being in contact when said containment flaps are in a stretched, flat condition.

13. The article of claim 12 wherein said apexes overlap.

14. The article of claim g further comprising a flap elastic in each said containment flap, said flap elastic having an elongation between about 90 percent to about 150 percent.

15. The article of claim 9 wherein said flap elastic has a tension range between about 90 grams-force to about 200 grams-force at about so percent of ultimate elongation.

16. The article of claim 9 wherein said absorbent composite has a crotch width between about 76 mm to about 102 mm.

17. The article of claim 9 wherein each said containment flap has a flap width between about 50 mm to about 102 mm.

18. The article of claim 9 further comprising an elastic member operatively joined to each said side panel.

19. A method of making a disposable absorbent article, comprising the steps of:
providing a waste containment assembly, supplying a pair of containment flaps having respective distal edges with apexes, placing the containment flaps with the waste containment assembly so that the apexes are in contact when stretched flat, and joining the containment flaps to the waste containment assembly.

20. The method of claim 19 further comprising the step of attaching portions of the waste containment assembly together to form a waist opening and a pair of leg openings.

21. The method of claim 19 wherein the step of placing includes overlapping the apexes.

22. The method of claim 20 further comprising the step of elasticizing the portions of the waste containment assembly.

23. The method of claim 19 wherein the step of supplying comprises supplying containment flaps having an average actual drape value less than about 1.83.