WO2000045764A1 - Vetement de type culotte jetable constitue par un non-tisse file-lie en copolymere de polypropylene/polyethylene - Google Patents

Vetement de type culotte jetable constitue par un non-tisse file-lie en copolymere de polypropylene/polyethylene Download PDF

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Publication number
WO2000045764A1
WO2000045764A1 PCT/US1999/002178 US9902178W WO0045764A1 WO 2000045764 A1 WO2000045764 A1 WO 2000045764A1 US 9902178 W US9902178 W US 9902178W WO 0045764 A1 WO0045764 A1 WO 0045764A1
Authority
WO
WIPO (PCT)
Prior art keywords
garment
chassis
facing surface
layer
region
Prior art date
Application number
PCT/US1999/002178
Other languages
English (en)
Inventor
Ebrahim Rezai
Jie Tao
Original Assignee
The Procter & Gamble Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by The Procter & Gamble Company filed Critical The Procter & Gamble Company
Priority to AU25735/99A priority Critical patent/AU2573599A/en
Priority to PCT/US1999/002178 priority patent/WO2000045764A1/fr
Priority to AT00913349T priority patent/ATE322376T1/de
Priority to DE60027137T priority patent/DE60027137T2/de
Priority to EP00913349A priority patent/EP1150833B1/fr
Priority to PCT/US2000/002770 priority patent/WO2000046023A2/fr
Priority to AU34815/00A priority patent/AU3481500A/en
Priority to JP2000597122A priority patent/JP2002540977A/ja
Publication of WO2000045764A1 publication Critical patent/WO2000045764A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/51121—Topsheet, i.e. the permeable cover or layer facing the skin characterised by the material
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
    • A61F13/51401—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
    • A61F13/51456—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties
    • A61F13/51464—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties being stretchable or elastomeric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/555—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving by ultrasonic heating
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00—Clothing

Definitions

  • the present invention relates to disposable pull-on garments. More specifically, the present invention relates to disposable pull-on garments which include a spunbonded nonwoven layer of a polypropylene/polyethylene copolymer. Examples of such disposable pull-on garments include disposable pull-on underwears, disposable pull-on diapers (adult and baby) including training pants, and disposable panties for menstrual use. BACKGROUND
  • Disposable pull-on garments such as disposable pull-on diapers to receive and contain urine and other body exudates.
  • Disposable pull-on garments having fixed sides which are also called “pant type” garments, have become popular for use on children able to walk and often who are toilet training.
  • These pull-on garments have side panels with edges that are seamed together to form two leg openings and a waist opening.
  • these pull-on garments need to fit snugly about the waist and legs of the wearer without drooping, sagging or sliding down from its position on the torso. Examples of these pull-on garments are disclosed, for example, in U.S. Patent No.
  • WO 98/22285 published on May 28, 1998 discloses such a seaming method.
  • the application of pressure and heat causes a melt of component sheet materials used in the side panels, in particular in the contacting surface materials of the side panels thereby forming a necessary bond between the side panels.
  • the difference of the melting points between the two contacting surface materials to be seamed is small.
  • the heating needs to be carefully adjusted and controlled in the seaming process. Otherwise, one of the materials which has a relatively lower melting point tends to be melt much more than the other material which has a relatively higher melting point.
  • the present invention is directed to a disposable pull-on garment having a front region, a back region and a crotch region between the front region and the back region.
  • the disposable pull-on garment comprises: a chassis provided in the front, back and crotch regions; one pair of front ear panels extending laterally outward from the chassis in the front region; and one pair of back ear panels extending laterally outward from the chassis in the back region.
  • Each of the ear panels has a body-facing surface and an outer-facing surface opposing the body-facing surface, and includes a first nonwoven layer provided on the body-facing surface on the ear panel, and a second nonwoven layer provided on the outer- facing surface on the ear panel.
  • One of the first and second nonwoven layers is a spunbonded nonwoven layer including first component fibers formed by a polypropylene/polyethylene copolymer, while the other of the first and second nonwoven layers includes second component fibers formed by a polypropylene based polymer.
  • the disposable pull-on garment further comprises seams each joining the corresponding front and back ear panels in an overlapping manner to form two leg openings and a waist opening.
  • Fig. 1 is a perspective view of one preferred embodiment of the disposable pull-on garment of the present invention in a typical in use configuration
  • Fig. 2 is a simplified plan view of the embodiment shown in Fig. 1 in its flat uncontracted condition showing the body-facing side the garment;
  • Fig. 3 is a cross-sectional view of a preferred embodiment taken along the section line 3-3 of Fig. 2;
  • Fig. 4 is a cross-sectional view of an elastic member of a preferred embodiment
  • Fig. 5 is a fragmentary enlarged perspective illustration of one preferred example of the elastomeric material layer.
  • pull-on garment refers to articles of wear which have a defined waist opening and a pair of leg openings and which are pulled onto the body of the wearer by inserting the legs into the leg openings and pulling the article up over the waist.
  • “disposable” describes garments which are not intended to be laundered or otherwise restored or reused as a garment (i.e., they are intended to be discarded after a single use and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner).
  • pull-on diaper refers to pull-on garments generally worn by infants and other incontinent individuals to absorb and contain urine and feces. It should be understood, however, that the present invention is also applicable to other pull-on garments such as training pants, incontinent briefs, feminine hygiene garments or panties, and the like.
  • panel denotes an area or element of the pull-on garment. (although a panel is typically a distinct area or element, a panel may coincide (functionally correspond) somewhat with an adjacent panel.)
  • layer does not necessarily limit the element to a single strata of material in that a layer may actually comprise laminates or combinations of sheets or webs of the requisite type of materials.
  • joind or “joining” encompasses configurations whereby an element is directly secured to another by affixing the element directly to the other element, and configurations whereby the element is indirectly secured to the other element by affixing the element to intermediate member(s) which in turn are affixed to the other element.
  • uncontracted state is used to describe states of pull-on garments in its unseamed (i.e., seams are removed), flat and relaxed condition wherein all elastic materials used are removed therefrom.
  • the present invention can be applied to a variety of disposable pull-on garments in need of ear panels to be seamed with an improved seam strength.
  • Preferred disposable pull- on garments include disposable pull-on underwears, disposable pull-on diapers (adult and baby) including training pants, and disposable panties for menstrual use.
  • the disposable pull-on garment of the present invention includes one pair of front ear panels extending laterally outward from the chassis in the front region; and one pair of back ear panels extending laterally outward from the chassis in the back region.
  • Each of the ear panels has a body-facing surface and an outer-facing surface opposing the body-facing surface, and includes a first nonwoven layer provided on the body-facing surface on the ear panel, and a second nonwoven layer provided on the outer-facing surface on the ear panel.
  • One of the first and second nonwoven layers is a spunbonded nonwoven layer including first component fibers formed by a polypropylene/polyethylene copolymer.
  • the other of the first and second nonwoven layers includes second component fibers formed by a polypropylene based polymer.
  • the polypropylene/polyethylene copolymer has a melting point range between about 100 °C and 165 °C. This and other preferred embodiments of the present invention will be described in detail hereinafter.
  • the nonwoven layer of polypropylene based polymer may be any type of nonwoven web that is formed by a homo-polypropylene, a propylene-segmental polymer, or a polymer mixture or alloy with a polypropylene.
  • a nonwoven layer may be formed by any nonwoven manufacture process known in the art such as a carding process, a spunbonding process, a meltblowing process, and the like.
  • the nonwoven layer of polypropylene based polymer is a carded or spunbonded nonwoven web formed by component fibers of about 100% by weight of polypropylene.
  • the spunbonded nonwoven layer of the present invention can be formed by any spunbonded nonwoven process known in the art, for example, U.S. Patent No. 3,692,618 issued to Dorschner et al. on September 19, 1972; U.S. Patent No. 3,338,992 issued to Kinney on August 29, 1967; U.S. Patent No. 3,341,394 issued to Kinney on September 12, 1967; U.S. Patent No. 3,502,538 issued to Petersen on March 24, 1970; U.S. Patent No.
  • the polypropylene/polyethylene copolymer which forms the component fibers can be produced by copolymerizing from about 0.5% to about 20% by weight of polyethylene in the backbone of a polypropylene.
  • the polypropylene copolymer is a block copolymer produced by copolymerizing the polyethylene by block in the backbone of polypropylene.
  • the polypropylene/polyethylene copolymer is a random copolymer produced by copolymerizing the polyethylene randomly in the backbone of polypropylene.
  • polyethylene is contained by copolymerization in the backbone of polypropylene.
  • a preferred polypropylene/polyethylene is produced when about 7% by weight of polyethylene is copolymerized with the polypropylene.
  • the polypropylene/polyethylene copolymer is less crystalline and thus has a broader melting point range than polypropylene itself.
  • the polypropylene/polyethylene copolymer has a melting point range between about 100 °C and 180 °C, more preferably between about 125 °C and 165 °C.
  • the broadened melting point range allows for seaming of the first and second nonwoven layers at a lower temperature and over a wider range of processing temperatures.
  • the difference in the melting points between the first and second nonwoven layers can be decreased due to the broadened melting point range of the polypropylene/polyethylene copolymer. Consequently, the first and second nonwoven layers can be seamed at a seaming temperature which is close to the melting points of the first and second nonwoven layers, as a result, the formation a hole(s) in the seamed portion and/or a hard portion of melted material after its solidification can be prevented.
  • the seamed ear panels can have an improved seaming strength, while preventing a graze on the wearer's skin or a red marking on the skin.
  • Any type of polyethylene can be employed in the copolymerization.
  • Preferred polyethylene includes a low density polyethylene (LDPE), a high density polyethylene
  • HDPE high density polyethylene
  • LLDPE linear low density polyethylene
  • the polyethylene has an ⁇ olefin structure such as 1- hexene, 1-butene and 1-octene.
  • the spunbonded nonwoven layer has a basis weight of
  • the spunbonded nonwoven layer has a basis weight of from about 15 g/m ⁇ to about 30 g/m ⁇ , more preferably from about 17 g/m ⁇ to about 25 g/m ⁇ , and an average fiber denier of less than about 1.9, and more preferably less than about 1.5.
  • the spunbonded nonwoven layer has an embossment pattern formed by a number of discrete bonding spots or areas. Any embossment process known in the art can be used for forming such an embossment pattern in spunbonded nonwoven layer.
  • a preferred embossment pattern is formed by feeding a spunbonded nonwoven web through two bonding rolls which have a raised pattern such as spots or grids on the surface of the bonding rolls. The bonding rolls are heated to a softening temperature of the material of the component fibers (i.e., the polypropylene/polyethylene copolymer).
  • the spunbonded nonwoven web passes between the heated bonding rolls so that the spunbonded nonwoven web can be compressed and heated by the bonding rolls in accordance with the pattern on the rolls, thereby forming an embossment pattern of discrete bonding spots or areas in the spunbonded nonwoven web.
  • the resulting spunbonded nonwoven web is preferably used as the spunbonded nonwoven layer.
  • the embossment holds the component fibers together and imparts an integrity to the nonwoven web or layer by bonding the component fibers within the nonwoven web or layer.
  • a preferred embossment pattern has lozenge shaped pin bonding areas wherein each pin has an average dimension of about 0.65 x 0.74 mm, a vertical spacing of about 1.23 mm between pins, and a horizontal spacing of about 1.26 mm between pins.
  • the embossment pattern has an embossment area (or a bonded area) ratio of less than about 25 %.
  • the embossment area ratio of the nonwoven web or layer is from about 5% to about 20%, and more preferably from about 10% to about 18%.
  • the spunbonded nonwoven layer has a Young's modulus of greater than about 4000 gf/inch (about 1575 gf7cm), preferably greater than about 5000 gf/inch (about 1969 gf/cm), and more preferably from about 5000 gf inch (about 1969 gf/cm) to about 12000 gf/inch (about 4724 gf/cm).
  • the spunbonded nonwoven layer has a stress of less than about 1000 gf7inch (about 394 gf cm) at peak in the Stress-Strain curve.
  • the spunbonded nonwoven layer has a stress of greater than about 600 gf inch (about 236 gf/cm), more preferably from about 700 gf/inch (about 276 gf/cm) to about 1000 gf/inch (about 394 gf/cm) at peak in the Stress-Strain curve.
  • a preferred spunbonded nonwoven web which is used for the spunbonded nonwoven layer of polypropylene/polyethylene copolymer is available from Mitsui Chemical Co., Ltd., Tokyo, Japan, under Code No. 23GSM.
  • This spunbonded nonwoven web includes component fibers formed by a random polypropylene/polyethylene copolymer which has about 7% by weight of polyethylene (LLPE) in the backbone of polypropylene.
  • This spunbonded nonwoven web has a basis weight of about 20 g/m , and includes component fibers having an average fiber denier of about 20.
  • This spunbonded nonwoven web has an average embossment ratio of about 18%.
  • the polypropylene/polyethylene copolymer of this spunbonded nonwoven web has a melting point range between about 105 °C and 170 °C.
  • This spunbonded nonwoven web has a Young's modulus of greater than about 4000 gf inch (about 1575 gf/cm), and also has a stress of less than about 1000 gf/inch (about 394 gf/cm) at peak in the Stress-Strain curve.
  • Fig. 1 shows one preferred embodiment of a disposable pull-on garment of the present invention (e.g., a unitary disposable pull-on diaper).
  • the disposable pull-on garment 120 has a front region 26; a back region 28 and a crotch region 30 between the front region 26 and the back region 28.
  • a chassis 41 is provided in the front, back and crotch regions 26, 28 and 30.
  • the chassis 41 includes a liquid pervious topsheet 24, a liquid impervious backsheet 22 associated with the topsheet 24, and an absorbent core 25 (not shown in Fig. 1) disposed between the topsheet 24 and the backsheet 22.
  • the chassis 41 has side edges 220 which form edge lines 222 in the front region 26.
  • the disposable pull-on garment 20 further includes a pair of front ear panels 46 each extending laterally outward from the corresponding sides of the chassis 41 in the front region 26, and a pair of extensible back ear panels 48 each extending laterally outward from the corresponding sides of the chassis 41 in the back region 28.
  • Each of the ear panels 46 and 48 has an outermost edge 240 which forms an outermost edge line 242.
  • At least one of the outermost edge lines 242 has a nonuniform lateral distance LD from the longitudinal center line 100 (not shown in Fig. 1 but in Fig. 2) in the uncontracted state of the garment 20.
  • the pull-on garment 20 further includes seams 32 each joining the front and back ear panels 46 and 48 along the corresponding edge lines 242 to form the two leg openings 34 and the waist opening 36.
  • the pull-on garment 20 includes a chassis layer 40 which generally determines the overall shape of the pull-on garment 20.
  • the chassis layer 40 is an outer cover nonwoven layer 74 which covers all of the outer-facing surface of the pull-on garment 20 to provide the feel and appearance of a cloth garment.
  • the outer cover nonwoven layer 74 is a continuous sheet or web formed by the spunbonded nonwoven of polypropylene/polyethylene copolymer of the present invention.
  • the continuous sheet i.e., the outer cover nonwoven layer 74
  • Each of the ear panels 46 and 48 includes a portion of the chassis layer 40.
  • Preferred pull-on garments which includes such a continuous sheet are disclosed in U.S. Patent No. 5,569,234 issued to Buell et al. on October 29, 1996.
  • At least one of, more preferably both of, the pairs of the ear panels 46 and 48 are elastically extensible in at least the lateral direction.
  • the ear panels 46 and 48 are elastically extensible both in the lateral and longitudinal directions.
  • extensible refers to materials that are capable of extending in at least one direction to a certain degree without undue rupture.
  • elasticity and “elastically extensible” refer to extensible materials that have the ability to return to approximately their original dimensions after the force that extended the material is removed.
  • any material or element described as “extensible” may also be elastically extensible unless otherwise provided.
  • the extensible ear panels 46 and 48 provide a more comfortable and contouring fit by initially conformably fitting the pull-on garment to the wearer and sustaining this fit throughout the time of wear well past when the pull-on garment has been loaded with exudates since the ear panels 46 and/or 48 allow the sides of the pull-on garment to expand and contract.
  • the ear panels 46 and 48 may be formed by unitary elements of the pull-on garment 20 (i.e., they are not separately manipulative elements secured to the pull-on garment 20, but rather are formed from and are extensions of one or more of the various layers of the pull-on garment).
  • the ear panels 46 and 48 include at least one unitary element or a continuous sheet (e.g. the chassis layer 40) that forms a part of the chassis 41 and continuously extends into the ear panels 46 and 48.
  • the ear panels 46 and 48 may only include discrete members (not shown in Figs.) which do not have any unitary element that also forms a part of the chassis 41.
  • Such an ear panel structure may be formed by joining the discrete members to the corresponding sides of the chassis 41.
  • the pull-on garment 20 further includes seam panels 66 each extending laterally outward from each of the ear panels 46 and 48; and tear open tabs 31 each extending laterally outward from the seam panel 66.
  • each of the seam panels 66 is an extension of the corresponding ear panels 46 and 48, or at least one of the component elements used therein (e.g., the chassis layer 40), or any other combination of the elements.
  • each of the tear open tabs 31 is also an extension of the corresponding seam panel 66 or at least one of its component elements used therein (e.g., the chassis layer 40), or any other combination of its elements.
  • the corresponding edge portions of the ear panels 46 and 48 are joined through the seam panels 66 in an overlapping manner to make an overlapped seam structure as shown in Fig. 1.
  • the front and ear panels 46 and 48 can be seamed in a butt seam manner (not shown in Figs.).
  • the bonding of the seams 32 can be performed by any suitable means known in the art appropriate for the specific materials employed in the chassis 41 and or the ear panels 46 and 48.
  • sonic sealing, heat sealing, pressure bonding, adhesive or cohesive bonding, sewing, autogeneous bonding, and the like may be appropriate techniques.
  • the seam panels 66 are joined by a predetermined pattern of heat/pressure or ultrasonic welds which withstands the forces and stresses generated on the garment 20 during wear.
  • a preferred method for making the seams is disclosed in WO 98/22285 (Schmitz) published on May 28, 1998.
  • a continuous belt 38 is formed by the ear panels 46 and 48, and a part of the chassis 41 about the waist opening 36 as shown in Fig. 1.
  • elasticized waist bands 50 are provided in both the front region 26 and the back region 28.
  • the continuous belt 38 acts to dynamically create fitment forces in the pull-on garment 20 when positioned on the wearer, to maintain the pull-on garment 20 on the wearer even when loaded with body exudates thus keeping the absorbent core 25 (not shown in Fig. 1) in close proximity to the wearer, and to distribute the forces dynamically generated during wear about the waist thereby providing supplemental support for the absorbent core 25 without binding or bunching the absorbent core 25.
  • Fig. 2 is a partially cut-away plan view of the pull-on garment 20 of Fig.
  • the pull-on garment 20 has the front region 26, the back region 28 opposed to the front region 26, the crotch region 30 positioned between the front region 26 and the back region 28, and a periphery which is defined by the outer perimeter or edges of the pull-on garment 20 in which the side edges are designated 115 and 240, and the end edges or waist edges are designated 152.
  • the topsheet 24 has the body-facing surface of the pull-on garment 20 which is positioned adjacent to the wearer's body during use.
  • the backsheet 22 has the outer-facing surface of the pull-on garment 20 which is positioned away from the wearer's body.
  • the pull-on garment 20 includes the chassis 41 including the liquid pervious topsheet 24, the liquid impervious backsheet 22 associated with the topsheet 24, and the absorbent core 25 positioned between the topsheet 24 and the backsheet 22.
  • the garment 20 further includes the front and back ear panels 46 and 48 extending laterally outward from the chassis 41, the elasticized leg cuffs 52, and the elasticized waistbands 50.
  • the topsheet 24 and the backsheet 22 have length and width dimensions generally larger than those of the absorbent core 25.
  • the topsheet 24 and the backsheet 22 extend beyond the edges of the absorbent core 25 to thereby form the side edges 115 and the waist edges 152 of the garment 20.
  • the liquid impervious backsheet 22 preferably includes a liquid impervious plastic film 68.
  • the pull-on garment 20 also has two centerlines, a longitudinal centerline 100 and a transverse centerline 110.
  • longitudinal refers to a line, axis, or direction in the plane of the pull-on garment 20 that is generally aligned with (e.g. approximately parallel with) a vertical plane which bisects a standing wearer into left and right halves when the pull-on garment 20 is worn.
  • transverse and lateral are interchangeable and refer to a line, axis or direction which lies within the plane of the pull-on garment that is generally perpendicular to the longitudinal direction (which divides the wearer into front and back body halves).
  • the pull-on garment 20 and component materials thereof also have a body-facing surface which faces the skin of wearer in use and an outer-facing surface which is the opposite surface to the body-facing surface.
  • topsheet 24, the backsheet 22, and the absorbent core 25 may be assembled in a variety of well known configurations, exemplary chassis configurations are described generally in U.S. Patent 3,860,003 entitled “Contractible Side Portions for Disposable Diaper” which issued to Kenneth B. Buell on January 14, 1975; and U.S. Patent 5,151,092 entitled “Absorbent Article With Dynamic Elastic Waist Feature Having A Predisposed Resilient Flexural Hinge" which issued to Kenneth B. Buell et al., on September 29, 1992.
  • Fig. 3 is a cross-sectional view of a preferred embodiment taken along the section line 3-3 of Fig. 2.
  • the pull-on garment 20 includes the chassis 41 including the liquid pervious topsheet 24, the liquid impervious backsheet 22 associated with the topsheet 24, and the absorbent core 25 positioned between the topsheet 24 and the backsheet 22.
  • the pull-on garment further includes the front ear panels 46 each extending laterally outward from the chassis 41, and an inner barrier cuffs 54.
  • Fig. 3 depicts only the structure of the front ear panel 46 and the chassis 41 in the front region 26, preferably a similar structure is also provided in the back region 28.
  • each of the front ear panels 46 is formed by a lamination of an extended part 72 of the barrier flap 56, an elastic member 70 and the outer cover nonwoven layer 74.
  • the flap nonwoven web 72 is formed by a polypropylene based polymer.
  • the flap nonwoven web 72 is a spunbonded nonwoven web including component fibers of about 100% of polypropylene.
  • a preferred spunbonded nonwoven web which is suitably applied to the flap nonwoven web 72 is available as Code No. DAPP-35GSM from Fiberweb France, Inc. (Ziest, France).
  • the outer cover nonwoven layer 74 is the spunbonded nonwoven of polypropylene/polyethylene copolymer of the present invention.
  • the flap nonwoven web 72 and the outer cover nonwoven layer 74 can be seamed at a seaming temperature which is close to the melting points of the flap nonwoven web 72 and the outer cover nonwoven layer 74, the formation a hole(s) in the seamed portion and/or a hard portion of melted material after its solidification can be prevented.
  • the elastic member 70 includes a plane elastomeric material layer 124 (not shown in Fig. 3).
  • plane elastomeric material refers to elastomeric materials which continuously extend in two dimensional directions.
  • Preferred plane elastomeric materials include a scrim, a perforated (or apertures formed) film, an elastomeric woven or nonwoven, an elastomeric foam and the like.
  • the plane elastomeric material layer 124 includes at least a portion that has a nonuniform lateral width.
  • the absorbent core 25 can be any absorbent member which is generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquids such as urine and other certain body exudates.
  • the absorbent core 25 may be manufactured in a wide variety of sizes and shapes (e.g., rectangular, hourglass, "T"-shaped, asymmetric, etc.) and from a wide variety of liquid-absorbent materials commonly used in disposable pull-on garments and other absorbent articles such as comminuted wood pulp which is generally referred to as airfelt.
  • absorbent materials examples include creped cellulose wadding; meltblown polymers including coform; chemically stiffened, modified or cross-linked cellulosic fibers; tissue including tissue wraps and tissue laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling materials; or any equivalent material or combinations of materials.
  • the configuration and construction of the absorbent core 25 may vary (e.g., the absorbent core 25 may have varying caliper zones, a hydrophilic gradient, a superabsorbent gradient, or lower average density and lower average basis weight acquisition zones; or may include one or more layers or structures). Further, the size and absorbent capacity of the absorbent core 25 may also be varied to accommodate wearers ranging from infants through adults. However, the total absorbent capacity of the absorbent core 25 should be compatible with the design loading and the intended use of the garment 20.
  • a preferred embodiment of the garment 20 has an asymmetric, modified hourglass- shaped absorbent core 25 having ears in the front and back waist regions 26 and 28.
  • Other exemplary absorbent structures for use as the absorbent core 25 that have achieved wide acceptance and commercial success are described in U.S. Patent No. 4,610,678 entitled “High-Density Absorbent Structures” issued to Weisman et al. on September 9, 1986; U.S. Patent No. 4,673,402 entitled “Absorbent Articles With Dual-Layered Cores” issued to Weisman et al. on June 16, 1987; U.S. Patent No. 4,888,231 entitled “Absorbent Core Having A Dusting Layer” issued to Angstadt on December 19, 1989; and U.S. Patent No. 4,834,735, entitled “High Density Absorbent Members Having Lower Density and Lower Basis Weight Acquisition Zones", issued to Alemany et al. on May 30, 1989.
  • the chassis 41 may further include an acquisition/distribution core 84 of chemically stiffened fibers positioned over the absorbent core 25, thereby forming a dual core system.
  • the fibers are hydrophilic chemically stiffened cellulosic fibers.
  • chemically stiffened fibers means any fibers which have been stiffened by chemical means to increase stiffness of the fibers under both dry and aqueous conditions. Such means include the addition of chemical stiffening agents which, for example, coat and or impregnate the fibers. Such means also include the stiffening of the fibers by altering the chemical structure of the fibers themselves, e.g., by cross-linking polymer chains.
  • the fibers utilized in the acquisition/distribution core 84 can also be stiffened by means of chemical reaction.
  • crosslinking agents can be applied to the fibers which, subsequent to application, are caused to chemically form intrafiber crosslink bonds. These crosslink bonds can increase stiffness of the fibers.
  • intrafiber crosslink bonds to chemically stiffen the fibers is preferred, it is not meant to exclude other types of reactions for chemical stiffening of the fibers.
  • chemical processing includes intrafiber crosslinking with crosslinking agents while such fibers are in a relatively dehydrated, defibrated (i.e. individualized), twisted, curled condition.
  • Suitable chemical stiffening agents include monomeric crosslinking agents including, but not limited to, C 2 -C 8 dialdehydes and C 2 -C 8 monoaldehydes having an acid functionality can be employed to form the cosslinking solution. These compounds are capable of reacting with at least two hydroxyl groups in a single cellulose chain or on proximately located cellulose chains in a single fiber.
  • Such crosslinking agents contemplated for use in preparing the stiffened cellulose fibers include, but are not limited to, glutaraldehyde, glyoxal, formaldehyde, and glyoxylic acid.
  • Other suitable stiffening agents are polycarboxylates, such as citric acid.
  • the polycarboxylic stiffening agents and a process for making stiffened fibers from them are described in U.S. Patent No. 5,190,563, entitled "Process for Preparing Individualized, Polycarboxylic Acid crosslinked Fibers" issued to Herron, on March 2, 1993. The effect of crosslinking under these conditions is to form fibers which are stiffened and which tend to retain their twisted, curled configuration during use in the absorbent articles herein.
  • Such fibers, and processes for making them are cited in the above incorporated patents.
  • the acquisition/distribution core 84 includes chemically treated stiffened cellulosic fiber material, available from Weyerhaeuser Co. (U.S.A.) under the trade designation of "CMC".
  • the acquisition/distribution core 84 has a basis weight of from about 40 g/m ⁇ to about 400 g/ ⁇ .2, more preferably from about 75 g/m ⁇ to about 300 g/m ⁇ .
  • the chassis 22 further includes an acquisition/distribution layer 82 between the topsheet 24 and the acquisition/distribution core 84 as shown in Fig. 3.
  • the acquisition/distribution layer 82 is provided to help reduce the tendency for surface wetness of the topsheet 24.
  • the acquisition/distribution layer 82 preferably includes carded, resin bonded hiloft nonwoven materials such as, for example, available as Code No. FT-6860 from Polymer Group, Inc., North America (Landisiville, New Jersey, U.S.A.), which is made of polyethylene telephthalate fibers of 6 dtex, and has a basis weight of about 43 g/m ⁇ .
  • a preferable example for the acquisition/distribution layer 82 and the acquisition/distribution core 84 is disclosed in EP 0797968A1 (Kurt et al.) published on October 1, 1997.
  • the topsheet 24 is preferably compliant, soft feeling, and non-irritating to the wearer's skin. Further, the topsheet 24 is liquid pervious permitting liquids (e.g., urine) to readily penetrate through its thickness.
  • a suitable topsheet 24 may be manufactured from a wide range of materials such as woven and nonwoven materials; polymeric materials such as apertured formed thermoplastic films, apertured plastic films, and hydroformed thermoplastic films; porous foams; reticulated foams; reticulated thermoplastic films; and thermoplastic scrims.
  • Suitable woven and nonwoven materials can be included of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polymeric fibers such as polyester, polypropylene, or polyethylene fibers) or from a combination of natural and synthetic fibers.
  • the topsheet 24 is preferably made of a hydrophobic material to isolate the wearer's skin from liquids which have passed through the topsheet 24 and are contained in the absorbent core 25 (i.e., to prevent rewet). If the topsheet 24 is made of a hydrophobic material, at least the upper surface of the topsheet 24 is treated to be hydrophilic so that liquids will transfer through the topsheet more rapidly.
  • the topsheet 24 can be rendered hydrophilic by treating it with a surfactant. Suitable methods for treating the topsheet 24 with a surfactant include spraying the topsheet 24 material with the surfactant and immersing the material into the surfactant. A more detailed discussion of such a treatment and hydrophilicity is contained in U.S. Patent No. 4,988,344 entitled "Absorbent Articles with Multiple Layer Absorbent Layers" issued to Reising, et al. on January 29, 1991 and U.S. Patent No.
  • the topsheet 24 is a nonwoven web that can provide reduced tendency for surface wetness; and consequently facilitate maintaining urine absorbed by the core 25 away from the user's skin, after wetting.
  • One of the preferred topsheet materials is a thermobonded carded web which is available as Code No. P-8 from Fiberweb North America, Inc. (Simpsonville, South Carolina, U.S.A.).
  • Another preferred topsheet material is available as Code No. S-2355 from Havix Co., Japan.
  • This material is a bi-layer composite material, and made of two kinds of synthetic surfactant treated bicomponent fibers by using carding and air-through technologies.
  • Yet another preferred topsheet material is a thermobonded carded web which is available as Code No. Profleece Style 040018007 from Amoco Fabrics, Inc. (Gronau, Germany).
  • Another preferred topsheet 24 includes an apertured formed film. Apertured formed films are preferred for the topsheet 24 because they are pervious to body exudates and yet non-absorbent and have a reduced tendency to allow liquids to pass back through and rewet the wearer's skin. Thus, the surface of the formed film which is in contact with the body remains dry, thereby reducing body soiling and creating a more comfortable feel for the wearer.
  • the backsheet 22 includes the liquid impervious film 68 as shown in, for example, Fig. 3.
  • the liquid impervious film 68 longitudinally extends in the front, back and crotch regions 26, 28 and 30. More preferably, the liquid impervious film 68 does not laterally extend into the at least one of the ear panels 46 or 48.
  • the liquid impervious film 68 has a body-facing surface 79 and an outer-facing surface 77 opposing the body-facing surface 79.
  • the liquid impervious film 68 is impervious to liquids (e.g., urine) and is preferably manufactured from a thin plastic film. However, more preferably the plastic film permits vapors to escape from the garment 20.
  • a microporous polyethylene film is used for the liquid impervious film 68.
  • a suitable microporous polyethylene film is manufactured by Mitsui Toatsu Chemicals, Inc., Nagoya, Japan and marketed in the trade as PG-P.
  • a disposable tape (not shown in Figs.) is additionally joined to the outer surface of the backsheet 22 to provide a convenient disposal after soiling.
  • a preferred disposal tape (or device) for pull-on garments is disclosed in International Publication No. WO 94/09736 (Rollag et al.) published on May 11, 1994.
  • a suitable material for the liquid impervious film 68 is a thermoplastic film having a thickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils), preferably including polyethylene or polypropylene.
  • the liquid impervious film has a basis weight of from about 5 g/ ⁇ _2 to about 35 g/m ⁇ .
  • other flexible liquid impervious materials may be used.
  • the backsheet 22 further includes the outer cover nonwoven layer 74 (i.e., the chassis layer 40) which is joined with the outer-facing surface 77 of the liquid impervious film 68 to form a laminate.
  • the outer cover nonwoven layer 74 is formed by the spunbonded nonwoven layer of the polypropylene/polyethylene copolymer of the present invention.
  • the outer cover nonwoven layer 74 preferably covers all of the outer-facing surface of the pull-on garment 20 to provide the feel and appearance of a cloth garment.
  • the outer cover nonwoven layer 74 may be joined to the liquid impervious film 68 by any suitable attachment means known in the art.
  • the outer cover nonwoven layer 74 may be secured to the liquid impervious film 68 by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines, spirals, or spots of adhesive.
  • Suitable adhesives include a hotmelt adhesive obtainable from Nitta Findley Co., Ltd., Osaka, Japan as H-2128, and a hotmelt adhesive obtainable from H.B. Fuller Japan Co., Ltd., Osaka, Japan as JM-6064.
  • the outer cover nonwoven layer 74 is a spunbonded nonwoven web of polypropylene/polyethylene copolymer, for example, obtainable from Mitsui Chemical Co., Ltd., Tokyo, Japan, under Code No. 23GSM.
  • the outer cover nonwoven layer 74 is formed from component fibers of the polypropylene/polyethylene copolymer.
  • the backsheet 22 is positioned adjacent the outer-facing surface of the absorbent core 25 and is preferably joined thereto by any suitable attachment means known in the art.
  • the body-facing surface 79 of the liquid impervious film 68 may be secured to the absorbent core 25 by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines, spirals, or spots of adhesive.
  • Adhesives which have been found to be satisfactory are manufactured by H. B. Fuller Company of St. Paul, Minnesota, U.S.A., and marketed as HL-1358J.
  • An example of a suitable attachment means including an open pattern network of filaments of adhesive is disclosed in U.S. Patent No.
  • attachment means including several lines of adhesive filaments swirled into a spiral pattern is illustrated by the apparatus and methods shown in U.S. Patent No. 3,911,173 issued to Sprague, Jr. on October 7, 1975; U.S. Patent No. 4,785,996 issued to Ziecker, et al. on November 22, 1978; and U.S. Patent No. 4,842,666 issued to Werenicz on June 27, 1989.
  • the attachment means may include heat bonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitable attachment means or combinations of these attachment means as are known in the art.
  • the absorbent core 25 is not joined to the backsheet 22, and/or the topsheet 24 in order to provide greater extensibility in the front region 26 and the back region 28.
  • the pull-on garment 20 preferably further includes elasticized leg cuffs 52 for providing improved containment of liquids and other body exudates.
  • the elasticized leg cuffs 52 may include several different embodiments for reducing the leakage of body exudates in the leg regions.
  • the leg cuffs can be and are sometimes also referred to as leg bands, side flaps, barrier cuffs, elastic cuffs or gasketing cuffs.
  • the pull-on garment 20 preferably further includes an elasticized waistband 50 that provides improved fit and containment.
  • the elasticized waistband 50 is that portion or zone of the pull-on garment 20 which is intended to elastically expand and contract to dynamically fit the wearer's waist.
  • the elasticized waistband 50 preferably extends longitudinally outwardly from the waist edge of the pull-on garment 20 toward the waist edge of the absorbent core 25.
  • the pull-on garment 20 has two elasticized waistbands 50, one positioned in the back region 28 and one positioned in the front region 26, although other pull-on garment embodiments can be constructed with a single elasticized waistband.
  • the elasticized waistband 50 may be constructed in a number of different configurations including those described in U.S. Patent 4,515,595 entitled "Disposable Diapers with Elastically Contractible Waistbands" issued to Kievit et al. on May 7, 1985 and the above referenced U.S. Patent 5,151,092 issued to Buell.
  • the waistbands 50 may include materials that have been "prestrained” or “mechanically prestrained” (i.e., subjected to some degree of localized pattern mechanical stretching to permanently elongate the material).
  • the materials may be prestrained using deep embossing techniques as are known in the art.
  • the materials may be prestrained by directing the material through an incremental mechanical stretching system as described in U.S. Patent No. 5,330,458 entitled “Absorbent Article With Elastic Feature Having A Portion Mechanically Prestrained” issued to Buell et al., on July 19, 1994.
  • the materials are then allowed to return to their substantially untensioned condition, thus forming a "zero strain” stretch laminate that is extensible, at least up to the point of initial stretching. Examples of “zero strain” laminate are described hereinafter.
  • At least one pair of the ear panels 46 and 48 includes the elastic member 70 as shown in Fig. 3.
  • the elastic member 70 of the front ear panels 46 includes an elastomeric material layer 124 (not shown in Fig. 3) which preferably extends laterally outward from the chassis 41 to provide good fitness by generating the optimal retention (or sustained) force at the waist and side areas of the wearer.
  • the elastomeric material layer 124 is extensible in at least one direction, preferably in the lateral direction to generate a retention (or sustained) force that is optimal to prevent the pull-on garment 20 from drooping, sagging, or sliding down from its position on the torso without causing the red marking on the skin of the wearer.
  • each of the ear panels 46 and 48 includes the elastomeric material layer 124.
  • the elastic member 70 is operatively joined to the outer cover nonwoven layer 74 and preferably the nonwoven webs 72 in the ear panels 46 and 48 to form a laminate.
  • the elastic member 70 is operatively joined to the nonwoven webs 72 and 74 by securing them to at least one, preferably both of the nonwoven webs 72 and 74 while in a substantially untensioned (zero strain) condition.
  • the elastic member 70 can be operatively joined to the nonwoven webs 72 and 74, by using either an intermittent bonding configuration or a substantially continuous bonding configuration.
  • intermittently bonded laminate web means a laminate web wherein the plies are initially bonded to one another at discrete spaced apart points or a laminate web wherein the plies are substantially unbonded to one another at discrete spaced apart areas.
  • substantially continuously bonded laminate web means a laminate web wherein the plies are initially bonded substantially continuously to one another throughout the areas of interface.
  • the stretch laminate be bonded over all or a significant portion of the stretch laminate so that the inelastic webs (i.e., the nonwoven webs 72 and 74) elongate or draw without causing rupture, and the layers of the stretch laminates are preferably bonded in a configuration that maintains all of the layers of the stretch laminate in relatively close adherence to one another after the incremental mechanical stretching operation. Consequently, the elastic panel members and the other plies of the stretch laminate are preferably substantially continuously bonded together using an adhesive.
  • the adhesive selected is applied with a control coat spray pattern at a basis weight of about 7.0 grams/m ⁇ .
  • the adhesive pattern width is about 6.0 cm.
  • the adhesive is preferably an adhesive such as is available from Nitta Findley Co., Ltd., Osaka, Japan, under the designation H2085F.
  • the elastic panel member and any other components of the stretch laminates may be intermittently or continuously bonded to one another using heat bonding, pressure bonding, ultrasonic bonding, dynamic mechanical bonding, or any other method as is known in the art.
  • the elastic member 70 is operatively joined to the nonwoven webs 72 and 74, at least a portion of the resultant composite stretch laminate is then subjected to mechanical stretching sufficient to permanently elongate the non-elastic components which are, for example, the nonwoven webs 72 and 74.
  • the composite stretch laminate is then allowed to return to its substantially untensioned condition. At least one pair of, preferably both of the ear panels 46 and 48 is thus formed into "zero strain" stretch laminates. This configuration allows the ear panels 46 and 48 to be elastically extensible in at least the lateral direction.
  • a “zero strain” stretch laminate is one type of elastic laminate which is preferably used for such disposable products.
  • methods for making "zero strain” stretch laminate webs are disclosed in U.S. Patent No. 5,167,897 issued to Weber et al. on December 1, 1992; U.S. Patent No. 5,156,793 issued to Buell et al. on October 20, 1990; and U.S. Patent No. 5,143,679 issued to Weber et al. on September 1, 1992.
  • an elastomeric material is operatively joined to at least one non-elastic component material in a substantially untensioned (zero strain) condition.
  • At least a portion of the resultant non-elastic composite stretch laminate is then subjected to mechanical stretching sufficient to permanently elongate the non-elastic component material.
  • the composite stretch laminate is then allowed to return to its substantially untensioned condition.
  • the elastic laminate is formed into a "zero strain" stretch laminate.
  • zero strain stretch laminate refers to a laminate comprised of at least two plies of material which are secured to one another along at least a portion of their coextensive surfaces while in a substantially untensioned (“zero strain") condition; one of the plies comprising a material which is stretchable and elastomeric (i.e., will return substantially to its untensioned dimensions after an applied tensile force has been released) and a second ply which is elongatable (but not necessarily elastomeric) so that upon stretching the second ply will be, at least to a degree, permanently elongated so that upon release of the applied tensile forces, it will not fully return to its original undeformed configuration.
  • the resulting stretch laminate is thereby rendered elastically extensible, at least up to the point of initial stretching, in the direction of initial stretching.
  • the elastic member 70 is preferably joined to, more preferably directly secured to the respective edges 78 of the liquid impervious film (i.e., the liquid impervious film 68) through an adhesive 76 as shown in Fig. 3.
  • liquid impervious film 68 longitudinally extends in the front, back and crotch regions 26, 28 and 30, it does not laterally extend into at least one of, preferably each of the extensible ear panels 46 and 48.
  • the elastic member 70 is joined to the respective edges 78 of the liquid impervious film 68 at the outer-facing surface 77 as shown in Fig. 3.
  • the elastic member 70 may be joined to the respective edges 78 of the liquid impervious film 68 at the body-facing surface 79 (not shown in Figs.).
  • the adhesive 76 is applied in a spiral glue pattern.
  • the adhesive 76 is a flexible adhesive with an amorphous and crystallizing component.
  • Such a preferred adhesive is made by Nitta Findley Co., Ltd., Osaka, Japan, under the designation H2085F.
  • the elastic member 70 may be joined to the respective edges 78 of the liquid impervious film 68 by any other bonding means known in the art which include heat bonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or combinations of these attachment means.
  • the elastic member 70 includes the elastomeric material layer 124 having a first surface 150 and a second surface 152 opposing the first surface 150, and a first coverstock layer 122 which is joined to the first surface 150 of the elastomeric material layer 124.
  • the first coverstock layer 122 is joined to the first surface 150 of the elastomeric material layer 124 by an adhesive (not shown in Fig. 4).
  • the elastic member 70 further includes a second coverstock layer 126 which is joined to the second surface 152 of the elastomeric material layer 124 by an adhesive (not shown in Fig. 4).
  • the elastic member 70 is joined to the respective edges 78 of the liquid impervious film 68 at the outer-facing surface 77 as shown in Fig. 3.
  • the elastic member 70 may be joined to the respective edges 78 of the liquid impervious film 68 at the body-facing surface 79 (not shown in Figs.).
  • the elastomeric material layer 124 may be formed in a wide variety of sizes, forms and shapes.
  • the elastomeric material layer 124 is in the form of a continuous plane layer.
  • Preferred forms of continuous plane layer include a scrim, a perforated (or apertures formed) film, an elastomeric woven or nonwoven, and the like.
  • the continuous plane layer may take any shape which can be suitably provided in the ear panels.
  • Preferred shapes of continuous plane layer include a quadrilateral including a rectangle and a square, a trapezoid, and the other polygons.
  • the elastomeric material layer 124 is in the form of discrete strands (or strings) which are not connected each other.
  • Elastomeric materials which have been found to be especially suitable for the elastomeric material layer 124 are styrenic block copolymer based scrim materials, perforated (or apertured) elastic films, preferably with a thickness of from about 0.05 mm to about 1.0 mm (0.002 inch - 0.039 inch).
  • Other suitable elastomeric materials for the elastomeric material layer 124 include "live" synthetic or natural rubber, other synthetic or natural rubber foams, elastomeric films (including heat shrinkable elastomeric films), elastomeric woven or nonwoven webs, elastomeric composites, or the like.
  • the elastomeric scrim 124 has a plurality of first strands 125 and a plurality of second strands 127.
  • the plurality of first strands 125 intersect the plurality of second strands 127 at nodes 130 at a predetermined angle ⁇ , forming a net-like open structure having a plurality of apertures 132.
  • Each aperture 132 is defined by at least two adjacent first strands and at least two adjacent second strands, so that the apertures 132 are substantially rectangular in shape.
  • Other configurations of the apertures 132 such as parallelograms, squares, or circular arc segments, can also be provided.
  • the first and second strands 125 and 127 are substantially straight and substantially parallel to one another.
  • the first strands 125 intersect the second strands 127 at nodes 130 such that the angle ⁇ is about 90 degrees.
  • the first and second strands 125 and 127 are preferably joined or bonded at nodes 90.
  • a preferred elastomeric scrim 124 is manufactured by the Conwed Plastics Company (Minneapolis, Minn., U.S.A.) under the designation XO2514. This material has about 12 elastic strands per inch in the structural direction B (i.e., the first strands 125) and about 7 elastic strands per inch in the structural direction D (i.e., the second strands 127).
  • the elastomeric material layer 124 is a porous, macroscopically-expanded, three-dimensional elastomeric web.
  • the porous, macroscopically-expanded, three-dimensional elastomeric web 172 has a continuous first surface 174 and a discontinuous second surface 176 opposing the first surface 174.
  • the elastomeric web 172 preferably comprises a formed film interconnecting member 186 including at least two polymeric layers 178 and 182.
  • the first layer 178 is substantially elastic and the second layer 182 is substantially less elastic than the first layer 178.
  • At least one of the two polymeric layers 178 and 182 is formed from a polystyrene thermoplastic elastomer.
  • the elastomeric web 172 exhibits a multiplicity of primary apertures 184 in the first surface 174 of the web 172.
  • the primary apertures 184 are defined in the plane of the first surface 174 by a continuous network of the interconnecting member 186.
  • the interconnecting member 186 exhibits an upwardly concave-shaped cross-section along its length.
  • the interconnecting member 186 also forms secondary apertures 188 in the plane of the second surface 176 of the web 172.
  • the apertures 184 and 188 may take any shape.
  • a preferred elastomeric web is disclosed in International Publication No. WO 98/3716 (Curro et al.), published on August 27, 1998.
  • a preferred porous elastomeric material for the elastomeric material layer is available from Tredegar Film Products under the designation X-25007.
  • the elastic member 70 includes first and second coverstock layers 122 and 126, and elastomeric material layer 124 disposed in the first and second coverstock layers 122 and 126.
  • the first coverstock layer 122 has an inner surface 142 and an outer surface 144.
  • the inner surface 142 of the first coverstock layer 122 is the surface that is positioned facing the elastomeric material layer 124.
  • the second coverstock layer 126 also has an inner surface 146 and an outer surface 148.
  • the inner surface 146 of the second coverstock layer 126 is the surface that is positioned facing the elastomeric material layer 124.
  • the elastomeric material layer 124 also has two planar surfaces, first surface 150 and second surface 152, each of which is substantially parallel with the planes of the first and second coverstock layers 122 and 126.
  • the first surface 150 is that planar surface of the elastomeric material layer 124 that is most closely adjacent with the inner surface 142 of first coverstock layer 122.
  • the second surface 152 is that planar surface of elastomeric material layer 124 that is most closely adjacent to the inner surface 146 of the second coverstock layer 126.
  • the first and second coverstock layers 122 and 126 need to have a relatively high elongation at breaking, and are more preferably stretchable or elongatable, yet more preferably drawable (but not necessarily elastomeric), without undue (and preferably without any), tearing or ripping. Further, the first and second coverstock layers 122 and 126 are preferably compliant, soft feeling, and non-irritating to the wearer's skin and give the article the feel and comfort of a cloth garment.
  • An exemplary preferred nonwoven material for the first and second coverstock layers 122 and 126 is a consolidated nonwoven material available from the Fiberweb North America, Inc.
  • consolidated nonwoven material means a nonwoven material that has been gathered or necked under mechanical tension in the structural direction D so that the material can elongate in the structural direction D under low force.
  • This material has a basis weight of 25 g/m 2 before consolidation and a basis weight of about 63g/m2 after consolidation.
  • the spunbonded nonwoven of polypropylene/polyethylene copolymer of the present invention may be used for the first and second coverstock layers 122 and 126.
  • the elastomeric material layer 124 and the first and second coverstock layers 122 and 126 are joined together, preferably by using an adhesive, to form the elastic member 70.
  • a preferred method for making the elastic member 70 is described in International Publication No. WO 98/55298 (Langdon et al.) published on December 10, 1998.

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  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Vascular Medicine (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Epidemiology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Dermatology (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)
  • Absorbent Articles And Supports Therefor (AREA)

Abstract

Cette invention se rapporte à un vêtement de type culotte jetable comportant une partie avant, une partie arrière et une partie d'entrejambe située entre la partie avant et la partie arrière. Ce vêtement de type culotte jetable comprend: une structure située dans les parties avant, arrière et d'entrejambe; une paire de rabats latéraux dans la partie avant qui s'étendent latéralement vers l'extérieur depuis la structure dans la partie avant; et une paire de rabats latéraux dans la partie arrière qui s'étendent latéralement vers l'extérieur depuis la structure dans la partie arrière. Chacun des rabats latéraux possède une surface orientée vers le corps de l'utilisateur et une surface orientée vers l'extérieur opposée à la surface orientée vers le corps de l'utilisateur, chacun de ces rabats latéraux étant constitué par une première couche de non-tissé placée sur la surface du rabat latéral orientée vers le corps de l'utilisateur, et par une seconde couche de non-tissé placée sur la surface du rabat latéral orientée vers l'extérieur. L'une de ces première et seconde couches de non-tissé est constituée par une couche de non-tissé filé-lié contenant des premières fibres à composantes formées par un copolymère de polypropylène/polyéthylène, alors que l'autre de ces deux couches de non-tissé contient des secondes fibres à composantes formées par un polymère à base de polypropylène. Ce vêtement de type culotte jetable comprend en outre des jointures joignant chacune les rabats latéraux avant et arrière correspondants de façon à ce qu'ils se chevauchent, afin de former deux ouvertures pour les jambes et une ouverture pour la taille.
PCT/US1999/002178 1999-02-02 1999-02-02 Vetement de type culotte jetable constitue par un non-tisse file-lie en copolymere de polypropylene/polyethylene WO2000045764A1 (fr)

Priority Applications (8)

Application Number Priority Date Filing Date Title
AU25735/99A AU2573599A (en) 1999-02-02 1999-02-02 Disposable pull-on garment including spunbonded nonwoven of polypropylene/polyethylene copolymer
PCT/US1999/002178 WO2000045764A1 (fr) 1999-02-02 1999-02-02 Vetement de type culotte jetable constitue par un non-tisse file-lie en copolymere de polypropylene/polyethylene
AT00913349T ATE322376T1 (de) 1999-02-02 2000-02-02 Elastisches laminat und wegwerfartikel, die einen spinnvliesstoff aus polyethylen/polypropylen copolymerisaten enthalten
DE60027137T DE60027137T2 (de) 1999-02-02 2000-02-02 Elastisches laminat und wegwerfartikel, die einen spinnvliesstoff aus polyethylen/polypropylen copolymerisaten enthalten
EP00913349A EP1150833B1 (fr) 1999-02-02 2000-02-02 Stratifie elastique et article jetable comprenant un non-tisse file-lie en copolymere de polypropylene/polyethylene
PCT/US2000/002770 WO2000046023A2 (fr) 1999-02-02 2000-02-02 Stratifie elastique et article jetable comprenant un non-tisse file-lie en copolymere de polypropylene/polyethylene
AU34815/00A AU3481500A (en) 1999-02-02 2000-02-02 Elastic laminate and disposable article including spunbonded nonwoven of polypropylene/polyethylene copolymer
JP2000597122A JP2002540977A (ja) 1999-02-02 2000-02-02 ポリプロピレン／ポリエチレン共重合体のスパンボンド不織層を有する弾性積層品及び使い捨て物品

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1999/002178 WO2000045764A1 (fr) 1999-02-02 1999-02-02 Vetement de type culotte jetable constitue par un non-tisse file-lie en copolymere de polypropylene/polyethylene

Publications (1)

Publication Number Publication Date
WO2000045764A1 true WO2000045764A1 (fr) 2000-08-10

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WO2007141744A1 (fr) * 2006-06-09 2007-12-13 The Procter & Gamble Company Stratifié étirable, son procédé de fabrication et article absorbant
WO2008060204A1 (fr) * 2006-11-13 2008-05-22 Sca Hygiene Products Ab Stratifié élastique et article absorbant comprenant le stratifié
US7806884B2 (en) 2004-06-22 2010-10-05 Sca Hygiene Products Ab Absorbent article comprising an elastic laminate
US8052665B2 (en) 2004-06-22 2011-11-08 Sca Hygiene Products Ab Absorbent article comprising an elastic laminate
US8109916B2 (en) 2006-11-13 2012-02-07 Sca Hygiene Products Ab Absorbent article comprising an elastic laminate
US8303561B2 (en) 2007-11-14 2012-11-06 Sca Hygiene Products Ab Method of producing an absorbent garment, and an absorbent garment produced according to the method
US8545654B2 (en) 2006-05-12 2013-10-01 Sca Hygiene Products Ab Pant-type absorbent article and a method for producing pant-type absorbent articles
US8741083B2 (en) 2006-05-12 2014-06-03 Sca Hygiene Products Ab Elastic laminate and a method for producing an elastic laminate
US9102132B2 (en) 2006-11-13 2015-08-11 Sca Hygiene Products Ab Absorbent article comprising an elastic laminate material
US9271880B2 (en) 2004-10-04 2016-03-01 Sca Hygiene Products Ab Absorbent article comprising an elastic web material
US9456934B2 (en) 2007-11-14 2016-10-04 Sca Hygiene Products Ab Method of producing an absorbent garment, and an absorbent garment produced according to the method
US9475264B2 (en) 2005-03-02 2016-10-25 Sca Hygiene Products Ab Underwear article comprising an elastic laminate

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WO1996031176A1 (fr) 1995-04-05 1996-10-10 The Procter & Gamble Company Application localisee de fibres de denier fin sur un voile de file-lie pour l'optimisation des proprietes hydrophobes des bandes enserrant les cuisses dans les couches et les serviettes hygieniques
US5569234A (en) 1995-04-03 1996-10-29 The Procter & Gamble Company Disposable pull-on pant
US5626571A (en) * 1995-11-30 1997-05-06 The Procter & Gamble Company Absorbent articles having soft, strong nonwoven component

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US4610681A (en) 1985-05-31 1986-09-09 Kimberly-Clark Corporation Disposable underpants having discrete outer seals
US4940464A (en) 1987-12-16 1990-07-10 Kimberly-Clark Corporation Disposable incontinence garment or training pant
US5171239A (en) 1989-08-10 1992-12-15 Uni-Charm Corporation Disposable garments
US5236430A (en) * 1991-11-21 1993-08-17 The Procter & Gamble Company Disposable training pant having fusion-slit side seams
US5246433A (en) 1991-11-21 1993-09-21 The Procter & Gamble Company Elasticized disposable training pant and method of making the same
US5569234A (en) 1995-04-03 1996-10-29 The Procter & Gamble Company Disposable pull-on pant
US5769838A (en) * 1995-04-03 1998-06-23 The Procter & Gamble Company Disposable pull-on pant
WO1996031176A1 (fr) 1995-04-05 1996-10-10 The Procter & Gamble Company Application localisee de fibres de denier fin sur un voile de file-lie pour l'optimisation des proprietes hydrophobes des bandes enserrant les cuisses dans les couches et les serviettes hygieniques
US5626571A (en) * 1995-11-30 1997-05-06 The Procter & Gamble Company Absorbent articles having soft, strong nonwoven component

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8052665B2 (en) 2004-06-22 2011-11-08 Sca Hygiene Products Ab Absorbent article comprising an elastic laminate
US7806884B2 (en) 2004-06-22 2010-10-05 Sca Hygiene Products Ab Absorbent article comprising an elastic laminate
US9271880B2 (en) 2004-10-04 2016-03-01 Sca Hygiene Products Ab Absorbent article comprising an elastic web material
US9475264B2 (en) 2005-03-02 2016-10-25 Sca Hygiene Products Ab Underwear article comprising an elastic laminate
US8741083B2 (en) 2006-05-12 2014-06-03 Sca Hygiene Products Ab Elastic laminate and a method for producing an elastic laminate
US8852372B2 (en) 2006-05-12 2014-10-07 Sca Hygiene Products Ab Pant-type absorbent article and a method for producing pant-type absorbent articles
US8545654B2 (en) 2006-05-12 2013-10-01 Sca Hygiene Products Ab Pant-type absorbent article and a method for producing pant-type absorbent articles
US8603059B2 (en) 2006-06-09 2013-12-10 The Procter & Gamble Company Stretch laminate, method of making, and absorbent article
US8177766B2 (en) 2006-06-09 2012-05-15 The Procter & Gamble Company Stretch laminate, method of making, and absorbent article
EP2202062A3 (fr) * 2006-06-09 2011-03-23 The Procter & Gamble Company Elastisches Laminat, Herstellungsverfahren und saugfähiger Artikel
WO2007141744A1 (fr) * 2006-06-09 2007-12-13 The Procter & Gamble Company Stratifié étirable, son procédé de fabrication et article absorbant
US9102132B2 (en) 2006-11-13 2015-08-11 Sca Hygiene Products Ab Absorbent article comprising an elastic laminate material
CN101534778B (zh) * 2006-11-13 2013-05-01 Sca卫生用品公司 弹性叠片和包括该弹性叠片的吸收物品
US8109916B2 (en) 2006-11-13 2012-02-07 Sca Hygiene Products Ab Absorbent article comprising an elastic laminate
US8298205B2 (en) 2006-11-13 2012-10-30 Sca Hygiene Products Ab Elastic laminate and absorbent article comprising the laminate
WO2008060204A1 (fr) * 2006-11-13 2008-05-22 Sca Hygiene Products Ab Stratifié élastique et article absorbant comprenant le stratifié
US8303561B2 (en) 2007-11-14 2012-11-06 Sca Hygiene Products Ab Method of producing an absorbent garment, and an absorbent garment produced according to the method
US9456934B2 (en) 2007-11-14 2016-10-04 Sca Hygiene Products Ab Method of producing an absorbent garment, and an absorbent garment produced according to the method

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