MXPA00012459A - Absorbent articles having a stretch band and methods of making the same - Google Patents

Abstract

Disposable absorbent articles which include an outer cover, an absorbent chassis and a stretch band (64) and methods of making the same are described. The stretch band (64) is incorporated into the article by providing a waist panel which includes a pair of primary fasteners (62) attached to a first surface on opposed side margins of the waist panel. The stretch band (64) is attached to the second surface of the waist panel. The stretch band (64) includes a pair of secondary fasteners (66) on opposite end portions of the stretch band (64) which are releasably engaged with the second surface of the waist panel. The second surface of the waist panel may then be attached to an inner surface of the outer cover such that the stretch band (64) is slidably contained between the outer cover and the waist panel. The primary fasteners (62) on the waist panel and the secondary fasteners (66) on the stretch band (64) are configured to releasably engage an opposite waist region of the absorbent article to initially fasten the absorbent article on the wearer and further conform the waist regions to the wearer's body after the absorbent article has been initially placed on the wearer.

Description

ABSORBENT ITEMS THAT HAVE A STRETCHING BAND AND METHODS TO MAKE THEMSELVES Field of the Invention The present invention relates to disposable absorbent articles which are adapted to contain body exudates. More particularly, the present invention relates to absorbent articles which have stretched webs and methods for making same.

Background of the Invention It is desired that absorbent articles such as diapers, training pants or incontinence garments provide a comfortable and narrow fit around the wearer and contain body exudates. Furthermore, it is desirable that such absorbent articles, after being soiled, can be removed from the user in a convenient and clean manner without undesirably dirtying the caregiver or the surrounding area such as the wearer's clothing. In certain circumstances, it is also desirable that such absorbent articles be able to be pulled up or down over the user's hips to allow the user to the caregiver to easily pull the article and easily remove the article if it has become soiled. For example, such absorbent articles can assist in training for the children's toilet or toilet.

Conventional diapers have typically included a front waist portion and a back waist portion which are releasably connected around the user's hips during use by conventional fasteners such as tape fasteners or hook-type fasteners and fasteners. Curls For example, conventional fasteners have typically included a plurality of fasteners, such as adhesive tape appendages, located on the outermost corners of the diaper in the back waist region of the diaper and a complementary fastener, such as a fastening panel. taped, located on the outer surface of the outer cover of the diaper on the front waist portion of the diaper. In such a configuration, the diaper has been placed between the user's legs and the adhesive tape appendages are releasably attached to the tape panel to secure the back waist portion to the front waist portion of the diaper to secure the diaper around the diaper. waist of the user. Such conventional diapers can be easily fastened around the wearer and removed from the wearer after use without unwanted soiling of the caregiver.

However, such conventional diapers generally have a set of fasteners which must be disengaged and reattached to further conform the waist portions of the diaper to the wearer if the proper notch is not obtained with the first fastener. Such disengagement and resumption can be difficult to achieve when the user is active. In addition, such conventional diapers may not be provided in a presumed configuration and therefore are not configured to be pulled up or down over the user's hips when the fasteners are attached.

Various attempts have been made to provide absorbent articles which notch at the wearer's waist to effectively contain exudates from the body, and be capable of being pulled up or down on the wearer's hips and provide ease of cleaning and removal. after getting dirty. For example, some conventional absorbent articles have included more than one pair of fasteners to provide improved securing of the article around the wearer's waist. In addition, some conventional absorbent articles, such as the training underpants have included integral side panels which connect the front waist portion to the back waist portion of the absorbent article. The side panels have been made stretchable so that the waist opening of the absorbent article can be extended to allow the absorbent article to be raised or lowered onto the wearer's hips if desired. Such side panels have also been designed so that they can be torn to remove the user's training underpants after the latter has become soiled.

However, many such attempts have not been completely satisfactory. For example, absorbent articles which have had more than one pair of fasteners have not always provided a conformation of the waist portions of the article to the full waist of the wearer. Instead, many such items have been designed to conform only one of the waist regions or only the hip regions to the user's waist which may still result in gaps between the article and the wearer's waist and the other waist parts.

In addition, absorbent articles such as the training underpants have not always been able to achieve a conformal and closed notch to the wearer while at the same time they are still able to expand enough to rise and fall on the wearer's hips. Frequently such training underpants fit into the wearer's waist loosely which may undesirably result in run-off. As a result, many of the articles have not contained body exudates as effectively as conventional diaper-type articles which can be adjusted to achieve a more conformant fit to the wearer. In addition, the removal of soiled absorbent articles which have integral side panels, such as conventional training underpants, has not been completely satisfactory. For example, the side panels have been difficult to tear when attempting to remove the article from the user's waist instead of pulling the article down from the user's hips.

Therefore, despite attempts to develop improved absorbent articles, there is still a need for absorbent articles which provide complete conformation around the user's waist and the benefits of both conventional training underpants and conventional diapers. That is, there is still a need for absorbent articles which conform to the user to effectively contain the exudates of the body, which are able to be raised or lowered on the user's hips and buttocks without opening, and which are easily secured around the user and removed from it in a convenient and clean manner. There is also: a need for improved methods to reliably and consistently make such absorbent articles.

Synthesis of the Invention In response to the difficulties and problems discussed above, a new disposable absorbent article has been discovered which includes a stretch band fastening system and methods for making same. In one aspect, the present invention relates to a method for continuously making stretch band assemblies for use on disposable absorbent articles. The methods include providing two separate and spaced laterally and continuous tapes of the fastener material; joining the stretch bands between the straps of the fastener material at longitudinally spaced locations in a continuous stair type configuration; and selectively cutting the continuous web of stretch band assemblies into discrete stretch band assemblies. Each of the stretch band assemblies defines one of the stretch strips and a pair of laterally spaced fasteners attached to the opposite end portions of the stretch band. Each of the stretch band assemblies is configured to be attached to one of the absorbent articles so that the stretch band is desirably contained in the absorbent article.

In another aspect, the present invention relates to a method for making a disposable absorbent article which includes an outer cover and an absorbent frame. The method includes the steps of: a) providing a waist panel which includes a pair of primary fasteners attached to the opposite lateral margins of the waist panel; b) joining a stretch band which includes a pair of secondary fasteners on the opposite end portions thereof to the waist panel; c) joining the waist panel to the inner surface of the outer cover in the waist region of the absorbent article so that the stretch band is slidably contained in the outer cover and the waist panel; Y d) attaching the absorbent shell to the outer shell to provide the disposable absorbent article. Secondary fasteners on the stretch band are configured to releasably engage an opposite waist region of the absorbent article to further shape the waist regions to the wearer's body after the absorbent article has been placed on the wearer.

The disposable absorbent article can also be provided in a presumed configuration by folding the article around a fold line extending in a lateral direction through the crotch region of the article thereby placing the waist regions of the absorbent article in a Frere relation and releasably engaging the primary fasteners with an outer surface of the absorbent article in the opposite waist region of the absorbent article. In such a configuration, the secondary fasteners of the stretch band are configured to releasably engage the opposite waist region to conform the waist regions to the wearer's body after the presumed absorbent article has been pulled on the wearer's hips.

In a particular embodiment, the waist panel is provided by providing a continuous web of material; joining a belt of the primary fastener material along a longitudinal extension of the material web; cutting the continuous web of material and the tape along the longitudinal extension in a serpentine path to provide two continuous sections of material each defining a straight edge and a serpentine cutting edge which includes primary fasteners attached thereto; crossing the material sections one over the other to place the serpentine cutting edge of each of the material sections laterally out from the straight edge and to place the straight edges in an overlapping configuration; securing the straight edges together to provide a continuous web of tape panel material; and cutting the continuous web of the waist panel material in spaced apart locations to provide the individual waist panel.

In another particular embodiment, the stretch band is provided by integrating two laterally spaced and continuous webs of the primary fastener material; joining the band segments between the straps of the fastener material at longitudinally spaced locations e: a continuous stair type configuration to provide a continuous web of stretch band material; and selectively cutting the continuous web of the stretch band material to provide the stretch band. The two continuous tapes of the secondary fastening material can be provided by a continuous fabric of the secondary fastening material which is cut along a longitudinal extension in a serpentine path to provide the two tapes of the secondary fastening material each defining a serpentine cutting edge. and an opposite edge and crossing the tapes one over the other to place the serpentine cutting edge of each of the tapes laterally outwardly from the opposite edge of the respective tape before joining the band segments.

In still another aspect, the present invention relates to a disposable absorbent article which defines an absorbent, a front waist region, a posterior waist region, a crotch region which extends between waist regions and connects them, a lateral direction and a longitudinal direction. The absorbent article includes an outer cover, a waist panel located in a face relationship with the outer cover in one of the waist regions and a stretch band which is slidably located between the waist panel and the outer cover. The stretch band includes a pair of fasteners on the opposite end portions of the stretch band which are configured to releasably engage an outer surface of the opposite waist region of the article to conform the waist regions to the body of a wearer.

In still another aspect, the present invention relates to a disposable absorbent article which defines an absorbent, a front waist region, a posterior waist region, a crotch region which extends between the waist regions and connects them, a lateral direction and a longitudinal direction. The absorbent article includes an outer cover and a waist panel which is connected to the outer cover in the rear waist region of the absorbent article. The waist panel also defines the opposite lateral margins which extend laterally outwardly beyond the outer cover. The article also includes a pair of primary fasteners which are located on a first surface of the opposite side margins of the waist panel and which are configured to releasably engage an outer surface of the absorbent article of the front waist region.

The article further includes a stretch band which is slidably located between the waist panel and the outer cover. The stretch band includes a pair of secondary fasteners located on the opposite end portions of the stretch band. The secondary fasteners are configured to releasably engage the outer surface of the front waist region to further shape the waist regions to the body of a wearer after the primary fasteners have engaged releasably.

The present invention advantageously provides absorbent articles which include a bandc. of stretching for improved notch and performance and methods for making them. In particular, the present invention provides a method for fastening a stretch band to a disposable absorbent article in a reliable and consistent manner.

The absorbent article of the present invention may furthermore be capable of being reliably raised or lowered over the wearer's hips to assist in training or learning for the toilet or toilet of the wearer in a manner similar to conventional training underpants. After being raised on the wearer's hips, the stretch band of the absorbent article can be used to conform the waist of the article to the wearer's body for improved notch and flow control. In addition, similar to conventional diapers, the absorbent article of the present invention can be advantageously applied and removed from the user after the latter has been soiled with relative cleanliness and ease.

Brief Description of the Drawings The present invention will be more fully understood and the additional advantages will become more apparent when reference is made to the following detailed description of the invention and the accompanying drawings in which like numerals represent like elements. The drawings are merely representative and are not intended to limit the scope of; the attached claims.

Figure 1 representatively shows a schematic view of an example of a method for making a disposable absorbent article having a stretch band according to the present invention.

Figure 2 representatively shows a side view of an example of a disposable absorbent article according to the present invention.

Figure 3 representatively shows a side view of the disposable absorbent article of Figure 2 wherein the stretch band has been extended to conform the waist regions of the article to the wearer's waist.

Figure 4 representatively shows a plan view of the disposable absorbent article of Figure 2 in a condition not held, stretched and placed flat with the surface of the article contacting the user facing the observer; Y Fig. 5 representatively shows a plan view of a disposable absorbent article of Fig. 2 in an unclamped, stretched condition and placed flat with the surface of the article that makes contact with the wearer's clothing facing him.

Brief Description of the Invention The present invention relates to disposable absorbent articles which are configured to closely conform to the wearer's body to effectively contain body exudates and methods for making same. The absorbent articles can be provided in a presumed condition so that they can be raised or lowered onto the wearer's hips and buttocks and are configured to be easily secured to and removed from the wearer's waist. As such, the absorbent articles of the present invention can function in a manner similar to the training underpants when left in the presumed configuration or in a manner similar to conventional diapers when they are in an unattached configuration. Disposable absorbent articles are adapted to be worn on one side of a wearer's body to absorb and contain various exudates discharged from the body. As used he, the term "disposable" refers to articles which are intended to be discarded after limited use and which are not intended to be washed or otherwise restored to be reused.

The disposable absorbent articles of the present invention and methods for making them will be described in terms of a disposable diaper article which is adapted for use by infants around the lower torso. In particular, the absorbent articles will be described in terms of a disposable absorbent diaper; that has a stretch band. It is understood that the articles and methods of the present invention are equally adaptable to other types of absorbent articles such as adult incontinent products, training underpants, women's hygiene products, other personal care products or other garments for health care and the like.

Figure 1 representatively illustrates a schematic view of an example of a method for making a disposable diaper according to the present invention. Figures 2 and 3 representatively show an example of a disposable diaper, as generally indicated in item 20, which can be made according to the methods of the present invention. The figures 4 and 5 representatively show the diaper of Figure 2 in a configuration not held, stretched and placed flat. Cone is illustrated in Figures 2-5, diaper 20 defines a front waist region 22, a rear waist region 24, and a crotch region 26 which extends between and connects the front and rear waist regions 22 and 24. The diaper 20 further defines a pair of laterally opposite side edges 30, a pair of longitudinally opposite waist edges 32, an inner surface 34 which is configured to make contact with the wearer, an outer surface 36 opposite the surface interior 34, a longitudinal direction 38 and a lateral direction 40.

The front waist region 22 comprises the part of the diaper 20 which, when worn, is placed on the front of the wearer while the back waist region 24 comprises the part of the diaper 20 which, when worn, is placed over the back of the user. The crotch region 26 of the diaper 20 comprises the part of the diaper 20 which, when worn, is placed between the user's legs and covers the lower torso of the wearer. The laterally opposite side edges 30 of the diaper 20 generally define the leg openings which may be curvilinear. The waist edges 32 of the diaper 20 are configured to surround the wearer's waist when worn and provide a waist opening when fastened which defines a waist circumference dimension.

The illustrated diaper 20 includes an outer cover 42, an absorbent frame 44 and a fastening system 60. The absorbent frame 44 includes a lower sheet 46, a body facing liner 48 which is connected to the lower sheet 46 in an overlying relationship, and an absorbent core 50 which is located between the body side liner 48 and the lower sheet 46. The fastening system 60 includes a pair of primary fasteners 62, a stretch band 64, a pair of secondary fasteners 66 attached to the laterally opposite end portions of the stretch band 64 and a waist panel 70. The stretch band 64 is slidably contained between the waist panel 70 and the outer cover 42 of the diaper 20.

The absorbent frame 44 is configured to contain and / or absorb any exudates from the body discharged from the user. While, the outer cover 42, the primary fasteners 62, the stretch band 64 and the secondary fasteners 66 are configured to hold the diaper 20 around the wearer's waist, these at the same time hide the absorbent frame 44 from view, and provide a garment-like appearance. The diaper 20 may further include the leg elastics 52, the containment fins 54 and the waist elastics 56 as known; by those experts in art. It should be recognized that the individual components of the diaper 20 may optionally depend on the intended use of the diaper 20.

A suitable arrangement for some different components of the diaper of the present invention is also described in the patent application of the United States of America series number 08 / 907,585 entitled "A MULTIFUNCTIONAL CLASP FOR DISPOSABLE ABSORBENT ARTICLES" and filed on August 8, 1997 on behalf of J. Surprise, whose description is incorporated herein by reference.

The methods of the various aspects of the present invention are directed to reliably and consistently provide disposable absorbent articles having a stretch band 64, such as that representatively illustrated in Figures 2-5. A schematic view of an example of a method according to the present invention is illustrated in Figure 1. In general, the illustrated method includes a continuous web of stretch band assemblies 98 each of which may include a stretch band. 64 and a pair of secondary fasteners 66 attached to the laterally opposite end portions of the stretch band 64. The fabric of stretch band assemblies 98 is cut into discrete stretch band assemblies which are applied to a continuous stretch fabric. a waist panel material 116 which includes the primary fasteners 62 attached thereto. The waist panel material 116 is then selectively cut into individual waist panels 70 which are attached to a fabric of the outer cover material 126 at spaced locations so that the stretch band 64 is slidably contained between the outer cover 42 and the waist comb 70.

The multiple absorbent frame 44 as illustrated in Figures 4 and 5 are attached to the fabric of the outer cover material 126 at spaced apart locations to provide a continuous web of interconnected diapers (not shown). In such a configuration, the front waist region 22 of the diaper 20 can be connected to the rear waist region 24 of the training pant 20 to form the continuous web of interconnected diapers. Alternatively, the rear waist region 24 of the front diaper can be connected to the front waist region 22 of the training pant or the diapers can be arranged in a front-to-back / back-to-back relationship.

Additional components, such as the leg elastics 52, the containment fins 54 and the waist elastics 56 can also be connected to the continuously moving fabric of the cover material or the individual absorbent frames connected thereto to provide the diaper fabric. interconnected. The various components of the diaper 20 can be connected together by means known to those skilled in the art such as, for example, adhesive, thermal or ultrasonic bonding. Desirably, most of the components are connected using an ultrasonic joint for improved manufacturing efficiency and reduced material cost.

The continuous web of the stretch band assemblies 98 can be provided in a variety of ways. For example, as illustrated in Figure 1, a continuous fabric of a secondary fastener material 80 is unwound and passed through the die cutter 82 which selectively cuts the fabric of the secondary fastener material 80 along its longitudinal extent. in the direction of the machine in two laterally spaced tapes separated from the secondary fastening material 84. As used herein, the phrase "machine direction" refers to the direction in which the respective fabric of material moves continuously while the phrase "machine direction" refers to the direction perpendicular to the direction in which it moves. the fabric of respective material. The terms "longitudinal" and "late"ral" also refer generally to the direction of the machine and to the direction transverse to the machine respectively, For example, as illustrated in Figures 4 and 5, the longitudinal direction 38 and the lateral direction 40 of the diaper 20 correspond to the machine direction and cross machine direction, respectively, when the diapers are manufactured in an end-to-end or waist-to-waist relationship.

If it is desired to provide a non-linear edge over the secondary adjusters, the die cutter 82 can cut the secondary fastener material fabric 80 along a serpentine path thereby providing each belt 84 with a cutting edge 86 and an edge. opposite 88. In such a configuration, the discrete tapes of the secondary fastener material 84 are then crossed one over the other to place the cutting edge 86 of each tape 84 laterally outward from the opposite edge 88. As used herein, the term "outwardly" "refers to a distance in the direction transverse to the machine or laterally away from the longitudinal centerline of the respective moving fabric.

In the illustrated method, a continuous web of the stretch band material 90 is also unwound and passed through the cutter 92 which cuts the web of the stretch band 90 in the transverse direction to the machine in segments of individual stretch band 94. The opposite end portions of the discrete stretch band segments 94 are joined by a jointer 96 to the separate straps of the fastener material 84 to provide a continuous web of stretch band assemblies 98. The segments of Stretch band 94 is fastened to the straps of the fastener material 84 at spaced apart and longitudinally spaced locations. Therefore, as illustrated in Figure 1, the fabric of stretch band assemblies 98 can be provided in a ladder type configuration.

Desirably, at least a portion of the stretch band segments 94 include a latent elastic material which can be activated after the diaper is assembled so that the stretch bands 94 are in a pre-tensioned configuration in the diaper. 20. Alternatively, the stretch band segments 94 may be lengthened by at least about 10 percent and more desirably by at least about 25 percent before joining the straps of the fastener material 84 so that the bands of Stretch 94 are in a pretensioned configuration in diaper 20.

As representatively illustrated in Figure 1, the band of the stretch panel assemblies 98 is then cut into discrete stretch strips by the slide cutter 118. The discrete stretch strips are then joined at spaced apart locations for the fabric continuous of the waist panel material 116 using the joiner 120. The fabric of the waist panel material 116 includes multiple pairs of primary fasteners at spaced apart locations on the laterally opposite side edges of the fabric 116. In the embodiment illustrated, the primary fasteners are attached to a first surface of the waist panel material 116 and the discrete stretch bands are attached to the second surface of the waist panel material 116 opposite the first surface.

The primary fasteners may be attached to the waist panel material 116 by methods known to those skilled in the art. For example, as representatively illustrated in Figure 1, the waist panel material 116 can be provided by first providing a continuous web of base material 100 and fastening a web of primary grip material 102 along an extension. longitudinal of the fabric of the base material 100 using the jointer 104. The base material 100 is then passed through the die cutter 106 which cuts the base material 100 and the tape of the base material 100 and the tape of the primary fastener material 102 in the machine direction along its longitudinal extension in two continuous sections of the base material 108. If it is desired to provide non-linear edges over the primary fasteners, the die cutter 106 can cut the base material 100 and the tape of the primary fastening material 102 along a serpentine path thereby providing each section of the base material 108 with a straight edge 110 and a cutting edge 112. The discrete sections of the base material 108 are then crossed one envelope another to place the cutting edge 112 of each section 108 laterally outwardly from the straight edge 110. The straight edges 110 of each section 108 are placed in an overlap arrangement and are joined together by the joiner 114 to provide the continuous web of the material waist panel 116.

As illustrated in Figure 1, the continuous fabric of the waist panel material 116 with the discrete stretch bands intermittently attached to the mesh is selectively cut by the cutter 122 into discrete waist panels. The discrete waist panels can then be intermittently joined by the joiner 124 to the continuous fabric of the outer cover material 126 or to the absorbent articles interconnected in the spaced apart locations. The waist panels are attached so that the stretch band is slidably contained between the waist panels and the outer cover material or the absorbent article. For example, as illustrated in Figure 1, the outer cover material 126 having the waist panels attached thereto can be passed through the capture joiner 130 which joins the waist panels to the outer cover material 126 to a side of the stretching bands so that the stretching bands are slidably captured between the waist panel and the outer cover material 126.

The proper attachment equipment which can be used to provide the attachment of the different components of the diaper is well known to those skilled in the art. Desirably, the binders 96, 104, 114, 120, 124 and 130 are ultrasonic binders to provide improved cutting efficiency and efficiency. For example, as illustrated in FIG. 1, the joiner 96 may include one or more rotating ultrasonic horns and an anvil roller between which the individual ends of the stretch bands and the straps of fastener material 84 are passed to provide the type of ladder fabric of stretch band assemblies 98. Suitable rotary ultrasonic horns are described in U.S. Patent No. 5.11C.403 issued to Ehlert, the disclosure of which is incorporated herein by reference. Such rotating ultrasonic horns generally have a diameter of from about 5 to about 20 centimeters and a width of from about 2 to about 15 centimeters. Alternatively, the ultrasonic horn can; be a stationary ultrasonic horn as it is also known by those experts in the art. Other suitable ultrasonic horns and ultrasonic binders are commercially available from Branson Sonic Power Company, a business having offices in Danbury, Connecticut. The binders 96, 104, 114, 120, 124 and 130 may otherwise be thermal binders or adhesives as is well known.

The binders 96, 104, 114, 120, 124 and 130 can be configured to provide for the joining of different components in a variety of patterns and shapes or sizes. For example, the joints can be provided as dot patterns, circles, squares, triangles and the like which can be arranged in a linear or non-linear configuration. Such patterns can be located on the joint horn or the anvil roller :.

Suitable cutters for providing the die cutters 82 and 106 and the slide cutters 92, 118 and 122 for selectively cutting the fabrics of the method of the present invention are generally known to those skilled in the art. For example, the die cutter 82 may include the combination of a cutter roll and an anvil roll through which the fabric 80 is moved. The anvil roll may include a hardened steel rotating roll while the cutter roll may include one or more flexible hardened steel blades attached to another rotating roller. The pinch force between the blade and the cutter roller and the anvil roller creates the cut. The cutting roller may have one or more blades depending on the desired distance between the cuts. Slip cutters 92, 118 and 122 can further be configured to provide * a separation between the individual cut pieces after they are cut. Such spacing can be provided by transferring the cut pieces out of the cutter at a speed greater than the speed at which the fabric is provided to the cutter.

The continuous web of interconnected diapers provided by the above-mentioned methods can also be passed through another matrix cutter which selectively cuts the fabric into individual and discrete diapers. The discrete diapers can then be folded into a conventional blade bender around a lateral fold line in the crotch region of the diaper so that the waist regions of each diaper are placed in a facing relationship. If it is desired that the diapers be provided in a presumed configuration, the primary fasteners may further be bent over and engage releasably with the outer surface of the opposite waist region of each diaper. Such presumed diapers, as illustrated in FIG. 2, can then be raised or lowered in a manner similar to conventional training underpants articles.

The methods of the present invention, as representatively illustrated in Figure 1, can reliably and consistently provide absorbent articles that have a stretch band such as the diaper illustrated in Figure 2. In particular, the use of the panel arrangement The waistband having the stretch band assembly attached thereto provides an exact match and alignment to facilitate cutting and high speed application of the stretch bands and fasteners to the individual diapers. Thus, the methods can provide a uniform and consistent bonding of each stretch band to the diaper. The methods may also result in reduced waste through the use of a serpentine cut on nested pattern fabrics, such as the fabrics of the waist panel material and the stretch band material with the fastener material attached thereto, and crossing over the serpentine fabrics to provide shaped end portions on the waist panels and the stretch bands.

The different components of the absorbent articles made by the methods described above may include a variety of materials. For example, as representatively illustrated in Figures 2-5, the outer cover 42 of the diaper 20 may suitably be composed of a material which is either liquid permeable or liquid impervious. Since the absorbent frame 44 of the various aspects of the present invention is designed to contain the exudates from the body discharged from the user, it is not generally necessary that the outer cover 42 be impermeable to liquid. For example, the outer cover 42 may include various woven or non-woven materials such as the yarn-bound material, the meltblown material, the rayon material, the cotton material, or combinations thereof such as the material laminated joined with spin-blow with fusion-joined with hi.lado (SMS) The outer cover 42 may otherwise be at least partially impermeable to the liquid to further prevent any runoff of the body exudates. For example, a typical outer cover 42 can be manufactured from; a thin plastic film or other material impervious to flexible liquid, fibrous layers woven or non-woven, microporous "breathable" materials; the elastic materials and their combinations.

The absorbent frame 44 of the diaper 20 is suitably connected to the outer cover 42 to provide the disposable diaper 20. The absorbent frame 44 can be connected to the outer cover 42 in ways well known to those skilled in the art. For example, the absorbent frame 44 may be attached to the outer cover 42 using adhesive, thermal or ultrasonic bonding techniques known to those skilled in the art. Alternatively, the absorbent frame 44 can be connected to the outer cover 42 using conventional fasteners such as buttons, hook-and-loop type fasteners, adhesive tape fasteners, and the like. The other components of the diaper 20 can be suitably connected together using similar means.

Desirably, the absorbent frame 44 is connected to the outer cover 42 only on or one side of the waist edges 32 of the outer cover 42 thereby creating a front fastening part, a rear fastening part, and a non-bonded part. which extends between and connects the joined pairtes. The unattached part of the absorbent frame 44 remains essentially unattached to the outer cover 42 and is generally configured to fit between the user's legs and at least partially cover the lower torso of the user when in use. As a result of this, the unbonded part is generally the part of the absorbent frame 44 which is configured to initially receive exudates from the body from the user. Thus, the absorbent frame 44 is connected to the outer cover 42 in such a manner as to secure the frame 44 in place while not adversely restricting the movement of the outer cover 42 in use. Alternatively, the absorbent frame 44 may be attached to the outer cover 42 along the entire longitudinal extent of the absorbent frame 44 or any part thereof or along only the outer periphery of the absorbent frame 44.

As representatively illustrated in Figure 4, the absorbent frame 44 according to the present invention may include a backsheet 46, a side-to-body liner 48 which is connected to the backsheet 46 in an overlying relationship. and an absorbent core 50 which is located between the side-to-body liner 48 and the bottom sheet 46. In alternative configurations wherein the outer cover 42 is at least partially resistant to the flow of the liquids at through it, the lower sheet 46 can optionally be omitted from the absorbent frame 44.

The absorbent frame 44 is generally conformable and is capable of absorbing and retaining exudates from the body. Absorbent frame 44 can have any of a number of shapes and sizes. For example, as representatively illustrated in Figure 4, the absorbent frame 44 can be rectangular, I-shaped or T-shaped. The size and absorbent capacity of the absorbent frame 44 must be compatible with the size of the user. attempted and the fluid load imparted by the intended use of the diaper 20. Typically, it is desirable that the absorbent frame 44 have an absorbent capacity of at least about 300 grams of urine. It is generally preferred that the absorbent frame 44 be narrower in the crotch region 26 than in the waist regions 22 and 24. It has been found that the absorbent frame 44 of the present invention is particularly useful when the dimension of width in crotch region 26 is from about 2.5 to about 10.2 centimeters, desirably no more than about 7.6 centimeters and no more desirably more than about 5.1 centimeters. The narrow crotch width dimension of the absorbent frame 44 allows the absorbent frame 44 to better fit between the user's legs.

The body side liner 48 of the absorbent frame 44, as representatively illustrated in Figure 4 suitably presents a face surface to the body which is intended to be worn on one side of the wearer's body and to be docile, soft-feeling and not irritating to the user's skin. In addition, the body side liner 48 may be less hydrophilic than the absorbent core 50, to present a relatively dry surface to the user, and may be sufficiently porous to be permeable to the liquid, allowing it to easily penetrate the liquid through its thickness . A suitable side-up liner 48 can be manufactured from a wide selection of fabric materials, such as woven and non-woven fabrics, porous foams, cross-linked foams, perforated plastic films, natural fibers (e.g. algocon), synthetic fibers (for example, polyether or polypropylene fibers), or a combination of natural and synthetic fibers. The side-to-body liner 48 is suitably employed to help isolate the user's skin from; the fluids maintained in the absorbent core 50 of the absorbent frame 44.

The lower sheet 46 of the absorbent frame 44, as depicted representatively in Figure 4, may suitably be composed of a material which is either liquid permeable or liquid impervious. It is generally preferred that the bottom sheet 46 be formed of a material which is essentially fluid impermeable. A typical backing sheet can be made of a thin plastic film or other material impervious to flexible liquid. The back sheet 46 can also be constructed of a material which is similar to the material described as being suitable for the outer cover 42.

The body side liner 48 and the lower or back sheet 46 are generally adhered to one another to form a pocket in which the absorbent core 50 is located to provide the absorbent frame 44. The body side liner 48 and the backing sheet 46 can adhere directly to each other around the outer periphery * of the absorbent frame 44 by any means known to those skilled in the art such as adhesive bonds, sonic joints, or thermal bonds. For example, a continuous and uniform layer of adhesive, an adhesive pattern layer, a meltblown or meltblown pattern, or an array of lines, swirls, or spots of adhesive can be used to secure the side-to-body liner 48 to the lower sheet 46. It should be noted that both the side-to-body liner 48 and the lower sheet 46 do not require to be fully extended to the outer periphery of the absorbent frame 44. For example, the bottom sheet 46 may extend to the outer periphery of the absorbent frame 44 while the body side liner 48 can be attached to the lower sheet 46 inwardly of the outer periphery of the absorbent frame 44, or more toward the longitudinal centerline of the diaper 20. In alternative configurations, especially where the backing sheet 46 is omitted, the body side liner 48 can adhere properly and directly to the absorbent core 50 or the outer cover 42.

The absorbent core 50, as representatively illustrated in Figure 4, is positioned between the side-to-body liner 48 and the lower sheet 46 to form the absorbent frame 44. The absorbent core 50 is desirably conformable and is capable of absorbing and absorbing. retain exudates from the body. The absorbent core 50 can have any c.e a number of shapes and sizes. For example, the absorbent core may be rectangular, I-shaped or T-shaped. It is generally preferred that the absorbent core 50 be narrower in the crotch region 26. The size of the absorbent core 50 must be compatible with the size of the intended user and the desired absorbent capacity of the absorbent frame 44.

The absorbent core 50 of the absorbent frame 44 may suitably comprise various types of hydrophilic and wettable fibrous materials. Examples of suitable materials include naturally occurring organic fibers composed of an intrinsically wettable material, such as cellulosic fibers; synthetic fibers composed of cellulose or cellulose derivatives, such as rayon fibers; inorganic fibers composed of an inherently wettable material, such as glass fibers; synthetic fibers made of inherently wettable thermoplastic polymers, such as the particular polyamide and polyester fibers; and synthetic fibers composed of a non-wettable thermoplastic polymer, such as polypropylene fibers, which have been hydrophilized by appropriate means known to those skilled in the art. The absorbent core 50 can also comprise mixtures selected from the various types of fibers mentioned above.

In a particular aspect of the invention, the absorbent core 50 may include a matrix of hydrophilic fibers, such as a fabric of cellulosic fibers mixed with particles of a high-absorbency material such that it is commonly known as the superabsorbent material. How it is used here, the term "high absorbency material" refers to materials that are capable of absorbing at least 10 times their own weight in the liquid. In a particulate incorporation, the absorbent core 50 comprises a mixture of superabsorbent hydrogel forming particles and wood pulp fluff. The wood pulp fluff can be interchanged with synthetic, polymeric and meltblown fibers or with a combination of meltblown and natural fiber fibers. The high-absorbency material can be essentially mixed homogeneously with the hydrophilic fibers or it can not be mixed uniformly. The high-absorbency material can also be arranged in a generally discrete layer within the macronix of hydrophilic fibers. Alternatively, the absorbent core 50 may comprise a laminate of fibrous fabrics and a high absorbency material or other suitable means for maintaining a high absorbency material in a local area.ada As representatively illustrated in FIG. 4, the absorbent frame 44 of the disposable diaper 20 may include a pair of containment fins 54 which are configured to provide a barrier to lateral flow of body exudates. The containment fins 50 can be located along the laterally opposite side edges of the absorbent frame 44. Each containment fin 54 typically defines an unbonded edge which is configured to maintain a perpendicular and straight configuration in at least the region crotch 26 of the diaper 20 to form a seal against the user's body. The containment fins may extend longitudinally along the full extent of the absorbent frame 44 or may only extend partially along the length of the absorbent frame 44. When the containment fins 54 are shorter in length than the absorbent frame 44 , the containment fins 54 can be selectively positioned on either side along the side edges of the absorbent frame 44. In a particular aspect of the invention, the containment fins 54 extend along the entire length of the absorbent frame 44 to better contain body exudates.

Such containment fins 54 are generally known to those skilled in the art. For example, suitable constructions and arrangements for containment fins 54 are described in U.S. Patent No. 4,704,116 issued November 3, 1987, to K. Enloe, the disclosure of which is incorporated herein by reference. reference.

The disposable diaper 20 of the various aspects of the present invention may further include elastics at the waist edges 32 and at the side edges 30 of the diaper 20 to further prevent runoff of body exudates and hold the absorbent frame 44. For example as representatively illustrated in Figure 4, the diaper 20 of the present invention may include a pair of elastic leg members 52 which are connected to the laterally opposite side edges 30 of the crotch region 26 of the diaper 20 and a pair of elastic waist members 46 which are connected to the laterally opposite waist edges 32 of the diaper 20. The leg elastics 52 and the waist elastics 46 are generally adapted to fit around the legs and waist of a wearer in the use to maintain * a positive contact relationship with the user to effectively reduce or eliminate runoff from the you exudate from the body of the diaper 20.

Suitable materials for use as leg elastics 52 and waist elastics 56 are well known to those skilled in the art. Examples of such materials are sheets or threads or tapes of an elastomeric and polymeric material which adhere to the outer cover 42 in a stretched position, or which are attached to the outer cover 42 while the outer cover it is folded, so that the elastic constrictive forces are imparted to the outer cover 42. The pipe elastics can also include such materials as polyurethane, synthetic and natural rubber.

The absorbent article of the various aspects of the present invention further includes a multifunctional fastening system 60 for securing the absorbent article around the wearer's waist. The multifunctional fastening system includes fasteners located on one of the waist regions 22 and 24 of the diaper 20 which are configured to releasably engage the opposite waist region of the diaper 20 to hold the diaper around the wearer's waist. The use of the fasteners which are releasably attachable or engageable allows the ease of securing and removal of the diaper 20 from the wearer's waist.

As representatively illustrated in Figures 2-5, the multifunctional fastening system 60 of the present invention includes a pair of primary fasteners 62 which are located on the lateral edges 30 of the diaper 20 in the rear waist region 24 of the diaper 20. In such a configuration, the primary fasteners 62 are configured to surround the user's hips and engage the outer surface 36 of the front waist region 22 of the diaper 20 to maintain said diaper 20 on the wearer. Alternatively, the primary fasteners 62 can be located on the front waist region 22 and can be configured to releasably engage the outer surface 36 of the back cusp region 24 of the diaper 20.

Desirably, the primary fasteners 62 are releasably engageable directly with the exterior surface of the outer cover 42 of the diaper 20 to provide improved fastening ease. Alternatively, as representatively illustrated in Figures 2-5, the disposable diaper 20 of the present invention may further include a junction panel 68 located on the outer cover 42 of one of the waist regions 22 and 24 of the diaper 20 In such a configuration, the primary fasteners 62 are releasably engageable with the fastening panel 68 to hold the diaper 20 around the wearer's waist. When the primary fasteners 62 are releasably engaged, the side edges 30 of the diaper 20 define the leg openings which are configured to encircle the user's legs and the waist edges 32 define a waist opening which is configured to surround the waist of the user. As illustrated in Figure 5, the jointing panel 68 can include two separate panels located along the opposite side edges in one of the waist regions 22 and 24 of the cloth !. 20. Alternatively, the joining panel 68 may include a single piece of material which extends essentially through the respective waist edge 32 of the diaper 20.

In a particular embodiment, the primary fasteners 62 are configured to engage releasably with the outer surface of the opposite waist regions 22 and 24 of the diaper 20 before the diaper 20 is placed over the wearer to provide a presumed diaper. In such a configuration, the presumed diaper 20 can be raised or swung over the user's hips and legs. If the diaper 20 becomes soiled during use, the primary fasteners 62 can be disengaged to easily remove the diaper 20 from the wearer's waist with a reduced risk of undesirable soiling of the wearer's clothes or legs. Thus, in such a configuration, the diaper 20 of the different aspects of the present invention can be configured to be raised or lowered over the user's hips like conventional training pants and can be applied or removed by: fastening or unhooking fasteners similar to the conventional diaper articles.

The multifunctional fastening system 60 of the disposable diaper 20 of the present invention further includes a stretch band having a pair of secondary fasteners thereon to provide an improved securement to the diaper 20 around the wearer's waist after the primary fasteners 62 have been hooked releasably. The stretch band and secondary fasteners of the present invention are configured to additionally shape the waist regions 22 and 24 of the diaper 20 to the wearer's waist. For example, as representatively illustrated in Figures 2-5, the diaper 20 may include a stretch band 64 which includes a pair of secondary fasteners 66 located on the opposite end portions of the stretch band 64.

The stretch band 64 and the secondary clips 66 are located in one of the waist regions 22 and 24 of the diaper 20 and are configured to surround the wearer's hips and engage the outer surface 36 in the opposite waist regions 22 and 24 of the waistband. diaper 20. For example, the stretch band 64 and secondary clips 66 can be located along the waist edge 32 of the diaper 20 in the rear waist region 24 of the diaper 20. Er. such configuration, the stretch band 64 and the secondary fasteners 66 are configured to surround the posterior waist region 24 and the user's hips and engage the outer surface 36 of the front waist region 22 of the diaper 20 to hold the diaper over the UsuóLrio. Alternatively, the stretch band 64 and the secondary clips 66 can be located on the front waist region 22 and can be configured to releasably engage the outer surface 36 of the rear waist region 24 of the diaper 20.Desirably, the secondary fasteners 66 are releasably engageable directly with the outer surface of the outer cover 24 of the diaper 20 provided]: an improved fastening facility. Alternatively, as described above and representatively illustrated in Figure 5, the diaper 20 of the present invention may further include a bond panel 68 located on the outer cover 42 in one of the waist regions 22 and 24 of the diaper. 20. In such a configuration, the secondary fasteners 66 can be releasably engaged with the attachment panel 68 to hold the diaper 20 around the wearer's waist.

The use of such stretch band 64 cor. the secondary fasteners 66 have been found to be particularly desirable when the primary fasteners 62 are releasably engaged with the respective waist region of the diaper 20 to provide a presumed diaper which can be raised over the wearer's legs and hips. In such a configuration, the waist opening of the diaper 20 when the primary fasteners 62 are engaged should; be sufficient to allow the presumed diaper to climb on the wearer's hips. However, the circumference of the user's waist is typically less than the circumference around the wearer's hips. Therefore, the waist opening of the presumed diaper may not conform to the wearer's waist which may undesirably result in run-off. In such a configuration, the stretch band 64 and the secondary clips 66 of the diaper 20 of the present invention are configured to conform the waist regions of the diaper 20 to the wearer after the presumed diaper is raised over the wearer. Therefore, the caregiver does not require that the primary fasteners 62 be repositioned to conform the waist regions 22 and 24 to the wearer's waist. As a result of this, when the diaper 20 is to be removed from the user, the caregiver can simply unhook the secondary fasteners 66 if necessary and pull the diaper presujetado down on the user's hips and legs without having to reposition the primary fasteners 62.

In such configurations, the stretched band 64 and the secondary fasteners are intended to maintain the diaper 20 in a close conformal notch around the waist, of the wearer to reduce runoff of body exudates when in use. The primary fasteners 62 are intended to maintain the front and rear waist regions 22 and 24 of the diaper 20 connected in such a way that the diaper 20 can be raised or lowered from the wearer's hips after the secondary fasteners 66 have disengaged. Secondary fasteners 66 can also be selectively disengaged to facilitate inspection of diaper 20 to determine if it has been soiled. The primary fasteners 62 can also provide a "child proof function" by keeping the diaper 20 at least partially secured around the user's waist if the user disengages the secondary fasteners 66.

Suitable fasteners are well known to those skilled in the art and may include tape appendage fasteners, hook and loop fasteners, mushroom fasteners, boteroles, pins, bands and the like, and combinations thereof. same. For example, as representatively illustrated in Figures 2-5, primary fasteners 62 and secondary fasteners 66 can be hook-type fasteners and outer cover 42 or fastening panel 68 can be configured to function as a fastener of the type. of complementary curls. Desirably, the fasteners 62 and 66 are hook-type fasteners which are releasably engageable with the outer cover 42. Such an arrangement provides the ability to vary the size of the waist opening in very small increments over a wide range to fit in the waist of the user. The fasteners may have any shape and size that provides the desired fastening of the diaper 20 around the wearer's waist. It is also desirable that the outer cover of; Secondary fasteners 66 provide a visual cue to the caregiver as to their location. For example, in one embodiment, the secondary fasteners 66 are of a color different from that of the outer surface of the diaper 20 to allow the caregiver to easily determine the placement of the secondary fasteners 66.

Materials suitable for use as the stretch band 64 of the various aspects of the present invention may be similar to those materials described above as being suitable for the outer cover 42. Desirably, the stretch band 64 is made of an elastic material the which is capable of elongating at least about 50 percent, and more desirably at least about 100 percent to provide an improved notch around the wearer's waist. For example, the stretch band 64 may comprise a bonded and bonded laminate which includes a KRATON film material commercially available from the Dow Chemical Company, a business having offices located in Midland, Michigan. Alternatively, the stretch band 64 may include portions which include the elastic material and parts which include the inelastic material.

Desirably, the stretch band 64 is made of a latent elastic material which can be activated after the diaper 20 is manufactured. The use of such a latent elastic material eliminates the need to maintain the stretch band. 64 in a stressed condition when diapers are made. Such suitable latent elastic materials are known to those skilled in the art. For example, suitable latent elastic materials are commercially available from Exxon under the trade designation EXX601. Alternate latent elastic materials are described in United States Patent Application No. 08 / 854,934 filed March 13, 1997 and entitled "IMPROVED COMPOSITE ELASTIC MATERIAL AND PROCESS FOR PRODUCING THE SAME", the description of which is incorporated here for reference. The latent elastic material can be activated by a variety of methods known to those skilled in the art. For example, the latent elastic stretch bands can be activated by heating the diaper after it is made to cause the material to retract.

The primary fasteners 62, the stretch band 64 and the secondary fasteners 66 can be incorporated within the diaper 20 of the different aspects of the present invention in a variety of different ways known to those skilled in the art. For example, e. As illustrated above and as described above, diaper 20 may further include a waist panel 70 which defins a first surface, a second surface opposite the first surface and a pair of laterally opposite side margins 72. The primary fasteners 62 they are attached to the first super Eicie of the waist panel 70 along the side margins 72 and of the stretch band 64 and the secondary fasteners 66 are attached to the second surface of the waist panel 70. In such a configuration, the panel The waistband 70 can be located in the diaper 20 between the outer cover 42 and the absorbent frame 44 in one of the waist regions 22 and 24 and the stretch band 64 can be slidably contained between the waist panel 70 and the outer cover 42.

The primary fasteners 62 may adhere to the side margins 72 on the first surface of the waist panel 70 by any means known to those skilled in the art such as adhesive bonds, sonic joints or thermal joints. The secondary fasteners 66 can also be suitably connected to the end portions of the stretch band 64 using similar means. The stretch bands 64 with the secondary fasteners 66 are desirably joined to the second surface of the waist panel 70 by releasably engaging the secondary fasteners 66 with the second surface of the waist panel 70.

To provide the improved notch around the user's waist without adversely affecting the appearance of the outer cover 42 of the diaper 20, most of the length of the stretch band 64 will desirably be placed behind the outer cover 42 as illustrated in Figures 2-5. In such a configuration, the outer cover 42 defines a width in the lateral direction 40 which is less than a width of the waist panel 70 in the lateral direction so that the end portions of the stretch band 64 and the secondary clips are extend laterally beyond the side edge of the outer cover 42. Therefore, the width of the outer cover 42 must be less than the distance between the secondary clips 66 of the stretch band 64 on the waist panel 70 but sufficient to hide most of the stretch band 64 between the secondary fasteners 66 before the stretch band 64 has been extended to provide improved fastening. For example, as illustrated in Figure 5, the outer cover 42 defines a width 128 in the respective waist region where the stretch band 64 is located which is smaller than the distance between the secondary clips 66. Desirably, the The width 128 of the outer cover 42 at this location is from about 75 to about 99 percent of the distance between the secondary fasteners 66 when secured to the waist panel 70 before being extended for improved functionality and aesthetics.

As a result of this, the outer cover 42 and the waist panel 70 are configured to function as a single sleeve through which the stretch band 64 is slidably contained. Therefore, the outer portions of the stretch band 64 and the secondary clips 66 are located on the outer surface 36 of the honeycomb and the remaining portion of the stretch band 64 extends through and along the surface interior of the outer cover 42 between the outer cover 42 and the waist panel 70. Alternatively, the stretch band 64 may extend behind the outer cover 42 and be located between the outer cover 42 and the absorbent frame 44, between any of the layers of the absorbent frame 44 or between the absorbent frame 44 and the user. As illustrated, the secondary fasteners 66 are desirably configured to releasably engage the outer surface of the waist panel 70 between the side edges of the outer cover 42 and the primary fasteners 62 for improved control and ease of fastening.

A portion of the stretch band 64 between the side edges of the outer cover 42 can be secured to the other parts of the diaper 20 so that the inner surface of the outer cover 42 or the outer surface of the waist panel 70 provides a portion of joint 74 as illustrated in Figure 4. The bonded portion 74 of the stretch band 64 can be secured using methods known to those skilled in the art such as adhesive, sonic or thermal bonding. Desirably, the bonded portion 74 defines a joined length 76 as illustrated in FIG. 4, which is about 75 percent and more desirably less than about 50 percent of the total length of the stretch band 64. Such a joined length provides sufficient assurance of the stretch band to the diaper 20 without adversely affecting the ability of the stretch band to conform to the wearer's waist to provide the improved notch.

The stretch band 64 can define any length and width which provide improved fastening and notching around the wearer. For example, the stretch band 64 can define a length which is from about 7 to about 35 centimeters and a width which is from about 1 to about 10 centimeters. Desirably, the stretch band 64 defines a length which is slightly less than the width of the diaper 20 in the respective waist region so that the stretch band 64 is slightly elongated to pre-tension the waist region.

The waist panel 70 can suitably be attached to other parts of the diaper 20 using the joining methods described herein. For example, the waist panel 70 can be ultrasonically bonded to the outer cover 42. In a particular embodiment wherein the stretch band 64 is slidably enclosed between the waist panel 70 and the outer cover 42, the second surface of the panel 70 is attached to the inner surface of the outer cover 42 along and to one side of the stretch band 64 to provide a sleeve through which the stretch band is slidably contained.

Suitable materials to be used as the waist panel 70 of the different aspects of the present invention are similar to those materials described above as being suitable for the outer cover 42. Desirably, the waist panel 70 is made of a non-woven material. For example, the waist panel 70 can compress a material bonded to it which includes polypropylene. Alternatively, the waist panel 70 may include a stretchable material.

If it is desired that the absorbent article of the present invention be presujetado, the absorbent article of the present invention may further include a pair of releasable side links (not shown) to improve the reliability of holding the article in the presumed condition particularly when it is raised or lowered onto the wearer's hips. The absorbent articles including the releasable side seams are further described in the United States of America Patent Application entitled "Disposable ABSORBENT ARTICLES HAVING PASSIVE SIDE UNIONS AND ADJUSTABLE SEWING SYSTEMS" filed in the name of Elsberg on the same date as the present application. and who was given the Attorney Subject number, 13,611, the description of which is incorporated herein by reference. For example, the diaper 20 may include a pair of releasable side seams which releasably connect the side edges 30 of the diaper 20 in the front and back waist regions 22 and 24 of the diaper 20. In such a configuration, the releasable side seams they can assist the fastening system 60 in maintaining the diaper 20 in a presumed condition when the diaper 20 is raised or lowered over the wearer's hips. However, the releasable side links can prevent movement and change of the waist regions 22 and 24 in relation to one another for improved notch and function. The releasable side links can also prevent the winding or bending of the side edges 30 and of the waist edges 32 of the diaper 20 when it is raised on; the hips of the users.

The different aspects of the present invention advantageously provide disposable absorbent articles having a fastening system which includes a stretch band and methods for making the same. The fastening system can be presumed to engage releasably "; the front and back waist portions to allow the absorbent article to be raised or lowered over the user's hips such as conventional training pants. The fastener can be used to further shape the front and back waist portions * of the absorbent article to hold the absorbent article around the wearer's waist after the article has been placed on the wearer.

As a result of this, the absorbent article of the present invention is designed to conform to the wearer's waist and body to effectively contain body exudates while the body is still capable of being reliably raised or lowered over the wearer's hips to assist in training for the user's toilet. In addition, similarly to conventional diapers, the absorbent article of the present invention can be advantageously applied and removed from the user with relative ease and cleanliness.

Although the invention has been described in detail with respect to specific aspects thereof, it will be appreciated by those skilled in the art upon achieving an understanding of the foregoing, that alterations, variations and equivalents of these aspects can easily be conceived. Therefore, the scope of the present invention should be established as that of the appended claims and any equivalents thereof.

Claims (46)

R E I V I N D I C A C I O N S

1. A method for continuously making stretch band assemblies for use on disposable absorbent articles, said method comprising: a) providing two laterally spaced and continuous tapes of fastener material; b) joining the stretch bands between and the straps of the fastener material at spaced apart longitudinally spaced locations in a continuous stairway type configuration to provide a continuous web of stretch band assemblies; Y c) selectively cutting said continuous web of stretch band assemblies into discrete stretch band assemblies each of which defines one of; the stretching bands and a pair of laterally spaced and spaced fasteners attached to the opposite end portions of said stretch band wherein each of the discrete stretch band assemblies is configured to be attached to one of the absorbent articles in such a manner that said stretch band is slidably contained in the absorbent article.

2. The method as claimed in clause 1 characterized in that said fastening material straps are made of hook material of a hook-type and curl-type fastener.

3. The method as claimed in clause 1 characterized in that said tapes of the fastening material are provided by a process comprising: a) provide a continuous cloth of the fastener material; b) cutting said continuous web of the fastener material along a longitudinal length in a serpentine path to provide said two webs of the fastening material each defining a serpentine cutting edge and an opposite edge; Y c) crossing said ribbons one over the other to place the serpentine cutting edge of each of said ribs laterally outwardly from the opposite edge of the respective ribbon before the stretching bands are attached to said ribbons.

4. The method as claimed in clause 1 characterized in that the stretching bands are capable of elongating at least about 50 per cent.

5. The method as claimed in clause 1 characterized in that said stretch bands are attached to the straps of the fastener material using an ultrasonic joint.

6. The method as claimed in clause 1 characterized in that the stretch strips include a latent elastic material and further comprise activating said stretch strips for pretensioning said stretch strips.

7. The method as claimed in clause 1 further characterized because it comprises: a) providing a continuous web of the waist panel material which defines a first surface, a second surface and a pair of opposite lateral margins and which includes the primary fasteners attached to the first surface of said opposite lateral margins; b) joining each of the discrete stretch band assemblies to the second surface of the waist panel material at spaced apart locations; and c) cutting said waist panel material at spaced apart locations to provide the discrete waist panels wherein said second skin surface one of the waist panels is configured to be attached to the absorbent article so that the stretched web is slidably contained between the absorbent article and said waist panel.

8. The method as claimed in clause 7 characterized in that the continuous web of the waist panel material is provided by a process comprising: a) provide a continuous web of material; b) joining a tape of the primary fastening material along a longitudinal extension of the fabric of material; c) cutting said web of continuous material and said web along the longitudinal extension in a serpentine path to provide two continuous sections of material each defining a straight edge and a serpentine cutting edge which include discrete primary fasteners attached to the webs; same; d) crossing said continuous sections of material one over the other to place the straight edges in an overlapping configuration; Y e) securing the straight edges together to provide the continuous web of the waist panel material.

9. A method for making a disposable absorbent article which includes an outer cover and an absorbent frame, said method comprising the steps of: a) providing a waist panel which defines a first surface, a second surface and a pair of opposite side margins and which include a pair of primary fasteners attached to said first surface on the opposite side margins; b) attaching a stretched band to the second surface of the waist panel where said stretch band includes a pair of secondary fasteners on the opposite outer portions of said stretch band which are releasably engaged with said second surface of the belt. waist panel; c) attaching said second surface of said waist panel to an inner surface of the outer cover in a waist region of the absorbent article wherein said outer cover defines a width which is less than a distance between said secondary fasteners over said band of stretching and wherein said stretch band is slidably contained between the outer cover and the waist panel; Y d) attaching said absorbent frame to the outer cover to provide said absorbent article wherein said primary fasteners on said stretch band are configured to releasably engage an opposite waist region of the absorbent article to further shape said waist regions to the body of the absorbent article. user after the absorbent article has been placed on the user.

10. The method as claimed in clause 9 characterized in that said primary fasteners and the secondary fasteners are a hook material of a hook and loop type fastener.

11. The method as claimed in clause 9 characterized in that said stretch band includes a latent elastic material and said method further comprises activating said stretch band for pretensioning the stretch band.

12. The method as claimed in clause 9 characterized in that said waist panel is provided by a process comprising: a) provide a continuous material web; b) joining a belt of the primary fastening material along a longitudinal extension of the material web; c) cutting said continuous web of material and said belt along the longitudinal extension in a serpentine path to provide two continuous sections of material each defining a straight edge and a serpentine cutting edge including the primary fasteners attached to them. d) crossing said sections of material one over the other to place the serpentine cutting edge of each of; the material sections laterally outward from the straight edge and to place the straight edges in an overlapping configuration; e) securing said straight edges together to provide a continuous web of the waist panel material; Y f) cutting said continuous web of the waist panel material into spaced apart locations to provide said waist panel.

13. The method as claimed in clause 9 characterized in that said stretch band is provided by a process comprising: a) providing two laterally spaced and continuous tapes of the secondary fastening material; b) joining the web segments between and to the straps of the fastener material at longitudinally spaced locations in a continuous stair type configuration to provide a continuous web of stretch strips; Y c) selectively cutting said web of stretch strips to provide said stretch band by having the secondary clips on said end portions.

14. The method as claimed in clause 13 characterized in that said two continuous tapes of the primary fastening material are provided by a process comprising: • "< *, ¿^ a) provide a continuous web of the primary fastener material; b) cutting said continuous web of the secondary fastener material along a longitudinal extension in a serpentine path to provide said two tapes of the secondary fastener material each defining a serpentine cutting edge and an opposite edge; Y c) crossing said tapes one over the other to place the serpentine cutting edge of each of the tapes laterally outward from the opposite edge of the respective tape.

15. The method as claimed in clause 13 characterized in that said band segments are attached to the tapes of the secondary fastening material using ultrasonic linkage.

16. The method as claimed in clause 13 further characterized in that it comprises lengthening said web segments laterally by at least about 25 percent before joining said web segments to said tapes of the secondary fastener material.

17. The method as claimed in clause 9 characterized in that said step of joining the stretch band to the waist panel includes joining a part: of the band segment of said stretch band to said second surface of the waist panel.

18. The method as claimed in clause 17 characterized in that said joined portion of the band segment defines a joined length which is less than about 75 percent of the total length of said band segment.

19. The method as claimed in clause 17 characterized in that said joined portion of the band segment is located along a longitudinal centerline of the absorbent article.

20. A method for making a presumed disposable absorbent article which defines a front waist region, a back waist region, a crotch region which extends between and connects said waist regions, a pair of opposite side edges and a pair of opposite waist edges, said method comprises the steps of: a) providing a waist panel which defines a first surface, a second surface and a pair of opposite side margins and which include a pair of primary fasteners attached to said first surface on the opposite lateral margins; b) attaching a stretch band to said second surface of the waist panel wherein said stretch band includes a pair of secondary fasteners on; the opposite end portions of said stretch band which are releasably engaged with the second surface of the waist panel; c) joining said second surface of said waist panel to an outer cover of the absorbent article in the rear waist region of the absorbent article wherein said outer cover defines a width which is less than a distance between said secondary fasteners over said band of stretching and wherein said stretch band is slidably contained between said outer cover and the waist panel; d) attaching an absorbent frame to the outer cover to provide said disposable absorbent article; e) folding said absorbent article around a fold line extending in the lateral direction through the crotch region of said absorbent article thereby placing said waist regions of the absorbent article in a front relationship; Y f) releasably engaging said primary fasteners with an outer surface of the absorbent article in said front waist region of the absorbent article to provide said absorbent article presumed therein; the secondary fasteners on said stretch band are configured to releasably engage said front waist region to conform said waist regions to the wearer's body after the presumed absorbent article is raised on the wearer's hips.

21. The method as claimed in clause 20 characterized in that said primary fasteners and the secondary fasteners are a hook material of a hook and loop type fastener.

22. The method as claimed in clause 20 characterized in that said stretch band includes a latent elastic material and said method further comprises activating said stretch band for pretensioning the stretch band.

23. The method as claimed in clause 20 characterized in that said stretch band is provided by a process comprising: a) providing two laterally spaced and continuous tapes of the secondary fastening material; b) joining the web segments between and to said webs of fastener material at spaced apart longitudinally spaced locations in a continuous ladder type configuration to provide a continuous web of draw webs; Y c) selectively cutting said web of stretch bands to provide said stretch band having the secondary clips on the end portions.

24. The method as claimed in clause 23 characterized in that said web segments are attached to the tapes of the secondary fastening material using ultrasonic bonding.

25. The method as claimed in clause 23 further characterized in that it comprises elongating the web segments by at least about 25 per cent before joining the web segments to the webs of the fastener material.

26. The method as claimed in clause 23 characterized in that said step of joining the stretch band to the waist panel includes joining a part: of the band segment of the stretch band to said second surface of the waist panel.

27. The method as claimed in clause 26 characterized in that said joined portion of the band segment defines a joined length which is less than about 75 percent of the total length of the bandage segment.

28. A disposable absorbent article comprising an absorbent and a set of stretch bands made according to the method as claimed in clause 1.

29. An absorbent article made according to the method as claimed in clause 9.

30. A presujetado disposable absorbent article made according to the method as claimed in clause 20.

31. A disposable absorbent article which defines an absorbent, a front waist region, a posterior waist region, a crotch region which extends between said waist regions and connects them, a lateral direction and a longitudinal direction, said absorbent article includes: a) an outer cover; b) a waist panel located in a confronting relationship with said outer cover in one of said waist regions of said absorbent article; c) a stretch band which is slidably located between the waist panel and said outer cover and which defines a pair of laterally opposite end portions; Y d) a pair of fasteners which are located on the opposite end portions of said stretch band and which are configured to releasably engage an outer surface of the opposite waist region to conform said waist regions to the wearer's body .

32. The absorbent article as claimed in clause 31, characterized in that said fasteners are hook-type fasteners.

33. The absorbent article as claimed in clause 31 further characterized in that it comprises a junction panel which is located on said outer cover in said opposite waist region wherein said fasteners are configured to releasably engage the attachment panel.

34. The absorbent article as claimed in clause 31 characterized in that said fasteners are hook type fasteners which are configured to releasably engage said outer cover.

35. The absorbent article as claimed in clause 31 characterized in that said stretch band is capable of elongating at least about 50 percent.

36. The absorbent article as claimed in clause 31, characterized in that said stretch band is a latent elastic material which is activated to pretension the stretch band in said absorbent article.

37. The absorbent article as claimed in clause 31 characterized in that said waist panel is connected to said outer cover at spaced apart locations longitudinally to provide a sleeve through which said stretch band is slidably located.

38. The absorbent article as claimed in clause 31 characterized in that said waist panel does not extend into the waist region thereof.

39. The absorbent article as claimed in clause 31 characterized in that said waist panel defines lateral margins which extend laterally outwardly beyond the outer cover in said waist region.

40. A disposable absorbent article which defines an absorbent, a front waist region, a posterior waist region, a crotch region which extends between and connects said waist regions, a lateral direction and a longitudinal direction, said article Absorbent comprises: a) an outer cover; b) a waist panel which defines a first surface, a second surface which is connected to said outer cover in the rear waist region of said absorbent article and the opposite lateral margins which extend laterally outwardly beyond the external cover; c) a pair of primary fasteners which are located on said first surface on the opposite lateral margins of said waist panel and which are configured to releasably engage an outer surface of said absorbent article in said front waist region of the absorbent article; d) a stretch band which is slidably located between the waist panel and outer cover chicha and which defines a pair of laterally opposite end portions; Y e) a pair of secondary fasteners which are located on the opposite end portions of said waistband and which are configured to releasably engage said outer surface of the front waist region to further shape the waist regions to the body of the user after the primary fasteners are releasably engaged.

41. The absorbent article as claimed in clause 40 characterized in that said primary fasteners and secondary fasteners are hook-type fasteners.

42. The absorbent article as claimed in clause 40 further characterized in that it comprises at least one junction panel which is located on said outer cover in said front waist region wherein said primary fasteners are configured to releasably engage the fascia panel. Union.

43. The absorbent article as claimed in clause 40 characterized in that said primary and secondary fasteners are hook-type fasteners which are configured to releasably engage said outer cover.

44. The absorbent article such as eats is claimed in clause 40 characterized in that said stretch band is capable of elongating by about 50 percent.

45. The absorbent article such and as is claimed in clause 40 characterized in that each of; the secondary fasteners and each of the opposite end portions of said stretch band are configured to extend over the respective primary fasteners to releasably engage said front waist region of said absorbent article to conform said waist regions to the body of the wearer after that the primary fasteners are releasably hooked to the frontal waist region.

46. The absorbent article as claimed in clause 40 characterized in that said second surface of the waist panel is connected to the outer cover at longitudinally spaced locations to provide a sleeve through which the stretch band is slidably located. SUMMARY Disposable absorbent articles are described which include an outer cover, an absorbent frame and a stretch band and the methods for making the same. The stretch band is incorporated into the article by providing a waist panel which includes a pair of primary fasteners attached to a first surface on the opposite side margins of the waist panel. The stretch band is attached to the second surface of the waist panel. The stretch band includes a pair of secondary fasteners on the opposite end portions of the stretch band which are releasably engaged with the second surface of the waist panel. The second surface of the waist panel can then be attached to an inner surface of the outer cover so that the stretch band is slidably contained between the outer cover and the waist panel. The primary fasteners on the waist panel and the secondary fasteners on the stretch band are configured to releasably engage an opposite waist region of the absorbent article to initially hold the absorbent article on the wearer and further to conform the waist regions to the body of the absorbent article. user after the absorbent article has been initially placed on the user.