WO2016122558A1

WO2016122558A1 - Absorbent article with pocket having a first material component and a second material component and method of manufacturing thereof

Info

Publication number: WO2016122558A1
Application number: PCT/US2015/013666
Authority: WO
Inventors: Paul A. Weber; Joseph D. Coenen; Jeffrey A. DEBROUX; Nicole J. BARNA; David F. Bishop
Original assignee: Kimberly-Clark Worldwide, Inc.
Priority date: 2015-01-30
Filing date: 2015-01-30
Publication date: 2016-08-04

Abstract

An absorbent article (10) can include a pocket (60) disposed in the front waist region (12). The pocket (60) can include a first material component (64) and a second material component (66). The first material component (64) can be bonded to the chassis (9) to form a first side edge (70) and a second side edge (72) of the pocket (60). The second material component (66) can be bonded to the first material component (64) and the chassis (9) to form an upper lateral edge (74) of the pocket (60). The pocket (60) can be closed with respect to the chassis (9) at the first side edge (70), the second side edge (72), and the upper lateral edge (74), and can be open with respect to a bottom surface (78) of the pocket (60) at the lower lateral edge (76).

Description

ABSORBENT ARTICLE WITH POCKET HAVING A FIRST MATERIAL COMPONENT AND A SECOND MATERIAL COMPONENT AND METHOD OF MANUFACTURING THEREOF

TECHNICAL FIELD

The present invention relates to absorbent articles. BACKGROUND OF THE DISCLOSURE

When absorbent articles become soiled with exudates and are changed from the wearer, it is common for the lower abdomen and/or crotch region of the wearer to become soiled by urine, fecal matter, and/or other bodily discharges. Prior to replacing the soiled absorbent article and replacing it with a new, clean absorbent article, the skin of the wearer is cleansed. This cleaning of the skin can be done in a variety of ways and using a variety of different materials, but caregivers commonly use wet wipes or cloths to clean the wearer's skin. In some circumstances, caregivers may choose to use a clean portion of an inner layer of the soiled absorbent article to provide a first wipe to cleanse the wearer's skin in the lower abdomen or crotch region prior to using wet wipes, cloths, or tissues.

To perform this initial wipe, a caregiver may attempt to pinch or gather the front waist region of the absorbent article to obtain a grip on the absorbent article to use the inner layer of the absorbent article in a wiping fashion. However, pinching or gathering the front waist region of the absorbent article can reduce the effective area of the inner layer of the absorbent article that is intended to wipe the wearer's skin in the soiled area as well as create an uneven inner surface of the absorbent article that is not as conducive to wiping as the initial flat surface. Pinching or gathering the front waist region of the absorbent article in this fashion may also expose a caregiver's fingers or hand to the exudates remaining on the wearer's skin, as the gathered material in the front waist region may fold over due to pinching or gathering of the absorbent article near the front waist edge of the absorbent article where the absorbent article may have less structural integrity and/or due to the wiping motion the caregiver employs with the absorbent article. Additionally, gripping the front waist region of the absorbent article in such a fashion may prove to be difficult altogether as the outer cover materials may have a low coefficient of friction, resulting in the gathered or pinched area of the front waist region slipping out of the caregiver's hands while trying to wipe the soiled area. While some of these issues have been recognized in prior documents, no effective solution has been provided to date to adequately address these issues.

Previous attempts to provide a solution have typically involved providing a pocket on the front of the absorbent article, but these solutions can be difficult to manufacture. Thus, there is a need for an absorbent article that includes a pocket providing a caregiver the ability to utilize the absorbent article as a first wipe to cleanse the wearer's skin and protects the caregiver's hand from

contamination while at the same time simplifying the manufacturing process to provide such a pocket.

SUMMARY OF THE DISCLOSURE

In one embodiment, an absorbent article can include a front waist region including a front waist edge, a rear waist region including a rear waist edge, and a crotch region. The absorbent article can further include a longitudinal axis and a lateral axis. The absorbent article can also include a chassis including an outer surface and a pocket disposed on the outer surface of the chassis in the front waist region. The pocket can include a first side edge, a second side edge opposite from the first side edge, an upper lateral edge, a lower lateral edge, and a bottom surface. The pocket can be closed with respect to the chassis at the first side edge, the second side edge, and the upper lateral edge. The pocket can be open with respect to the bottom surface at the lower lateral edge. The pocket can include a first material component and a second material component. The first material component can include an uppermost edge, a lowermost edge, and two opposing side edges. The second material component can include a top edge, a bottom edge, and two opposing side edges. The second material component can be bonded to the first material component and the chassis to form the upper lateral edge of the pocket.

In another embodiment, an absorbent article can include a front waist region including a front waist edge, a rear waist region including a rear waist edge, and a crotch region. The absorbent article can further include a longitudinal axis and a lateral axis. The absorbent article can also include a chassis including an outer surface and a pocket disposed on the outer surface of the chassis in the front waist region. The pocket can include a first side edge, a second side edge opposite from the first side edge, an upper lateral edge, a lower lateral edge, and a bottom surface. The pocket can be closed with respect to the chassis at the first side edge, the second side edge, and the upper lateral edge. The pocket can be open with respect to the bottom surface at the lower lateral edge. The pocket can include a first material component and a second material component. The first material component can include an uppermost edge, a lowermost edge, and two opposing side edges. The second material component can include a top edge, a bottom edge, and two opposing side edges. The second material component can be bonded to the first material component and to the outer surface of the chassis such that the lowermost edge of the first material component is closer to the lateral axis than is the bottom edge of the second material component.

In yet another embodiment, a method of manufacturing an absorbent article is disclosed. The absorbent article can include a front waist region including a front waist edge, a rear waist region including a rear waist edge, and a crotch region. The absorbent article can further include a longitudinal axis, a lateral axis, and a pocket in the front waist region. The method can include providing a chassis including an outer surface and providing a continuous web of a first material. The method can further include cutting the continuous web of the first material to form a first material component. The method can additionally include bonding the first material component to the outer surface of the chassis near opposing side edges of the first material component to form a first side edge and a second side edge of the pocket. Additionally, the method can include providing a continuous web of a second material and cutting the continuous web of the second material to form a second material component. Furthermore, the method can include bonding a first portion of the second material component to the first material component. Another aspect of the method can be bonding a second portion of the second material component to the outer surface of the chassis.

Bonding the second portion of the second material component to the outer surface of the chassis can form an upper lateral edge of the pocket, and the pocket can be open with respect to the chassis at a lower lateral edge of the pocket.

BRIEF DESCRIPTION OF DRAWINGS

A full and enabling disclosure thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended figures in which:

FIG. 1 is a perspective view of an exemplary embodiment of an absorbent article including a pocket, with a caregiver's hand accessing the pocket.

FIG. 2 is a top plan view of the absorbent article of FIG. 1 in a stretched, laid flat configuration, with the outer cover facing the viewer.

FIG. 3 is a cross-sectional view taken along line 3-3 from FIG. 2.

FIG. 4 is a process schematic depicting an exemplary embodiment of a method of manufacturing an absorbent article including a pocket.

FIG. 5 is process schematic depicting an exemplary method of bonding the first material component and the second material component of the pocket to a web of outer cover from the method of manufacturing an absorbent article of FIG. 4.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the disclosure. DETAILED DESCRIPTION OF THE DISLOSURE

In an embodiment, the present disclosure is generally directed towards an absorbent article having a pocket disposed on the outer surface of the absorbent article and a method of manufacturing the same. The pocket can aid a caregiver with providing an initial cleaning of the wearer after the article is soiled by the wearer and prior to changing the absorbent article. Each example is provided by way of explanation and is not meant as a limitation. For example, features illustrated or described as part of one embodiment or figure can be used on another embodiment or figure to yield yet another embodiment. It is intended that the present disclosure include such modifications and variations.

When introducing elements of the present disclosure or the preferred embodiment(s) thereof, the articles "a", "an", "the" and "said" are intended to mean that there are one or more of the elements. The terms "comprising", "including" and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements. Many modifications and variations of the present disclosure can be made without departing from the spirit and scope thereof. Therefore, the exemplary embodiments described above should not be used to limit the scope of the invention.

Definitions:

The term "absorbent article" refers herein to an article which may be placed against or in proximity to the body (i.e., contiguous with the body) of the wearer to absorb and contain various liquid, solid, and semi-solid exudates discharged from the body. Such absorbent articles, as described herein, are intended to be discarded after a limited period of use instead of being laundered or otherwise restored for reuse. It is to be understood that the present disclosure is applicable to various disposable absorbent articles, including, but not limited to, diapers, training pants, youth pants, swim pants, feminine hygiene products, including, but not limited to, menstrual pads, incontinence products, medical garments, surgical pads and bandages, other personal care or health care garments, and the like without departing from the scope of the present disclosure.

The term "acquisition layer" refers herein to a layer capable of accepting and temporarily holding liquid body exudates to decelerate and diffuse a surge or gush of the liquid body exudates and to subsequently release the liquid body exudates therefrom into another layer or layers of the absorbent article.

The term "bonded" or "coupled" refers herein to the joining, adhering, connecting, attaching, or the like, of two elements. Two elements will be considered bonded or coupled together when they are joined, adhered, connected, attached, or the like, directly to one another or indirectly to one another, such as when each is directly bonded to intermediate elements. The bonding or coupling of one element to another can occur via continuous or intermittent bonds.

The term "carded web" refers herein to a web containing natural or synthetic staple length fibers typically having fiber lengths less than about 100 mm. Bales of staple fibers can undergo an opening process to separate the fibers which are then sent to a carding process which separates and combs the fibers to align them in the machine direction after which the fibers are deposited onto a moving wire for further processing. Such webs are usually subjected to some type of bonding process such as thermal bonding using heat and/or pressure. In addition to or in lieu thereof, the fibers may be subject to adhesive processes to bind the fibers together such as by the use of powder adhesives. The carded web may be subjected to fluid entangling, such as hydroentangling, to further intertwine the fibers and thereby improve the integrity of the carded web. Carded webs, due to the fiber alignment in the machine direction, once bonded, will typically have more machine direction strength than cross machine direction strength.

The term "film" refers herein to a thermoplastic film made using an extrusion and/or forming process, such as a cast film or blown film extrusion process. The term includes apertured films, slit films, and other porous films which constitute liquid transfer films, as well as films which do not transfer fluids, such as, but not limited to, barrier films, filled films, breathable films, and oriented films.

The term "gsm" refers herein to grams per square meter.

The term "hydrophilic" refers herein to fibers or the surfaces of fibers which are wetted by aqueous liquids in contact with the fibers. The degree of wetting of the materials can, in turn, be described in terms of the contact angles and the surface tensions of the liquids and materials involved. Equipment and techniques suitable for measuring the wettability of particular fiber materials or blends of fiber materials can be provided by Cahn SFA-222 Surface Force Analyzer System, or a substantially equivalent system. When measured with this system, fibers having contact angles less than 90 are designated "wettable" or hydrophilic, and fibers having contact angles greater than 90 are designated "nonwettable" or hydrophobic.

The term "liquid impermeable" refers herein to a layer or multi-layer laminate in which liquid body exudates, such as urine, will not pass through the layer or laminate, under ordinary use conditions, in a direction generally perpendicular to the plane of the layer or laminate at the point of liquid contact.

The term "liquid permeable" refers herein to any material that is not liquid impermeable. The term "meltblown" refers herein to fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity heated gas (e.g., air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which can be a microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,241 to Butin et al., which is incorporated herein by reference. Meltblown fibers are microfibers which may be continuous or discontinuous, are generally smaller than about 0.6 denier, and may be tacky and self-bonding when deposited onto a collecting surface. The term "nonwoven" refers herein to materials and webs of material which are formed without the aid of a textile weaving or knitting process. The materials and webs of materials can have a structure of individual fibers, filaments, or threads (collectively referred to as "fibers") which can be interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven materials or webs can be formed from many processes such as, but not limited to, meltblowing processes, spunbonding processes, carded web processes, etc.

The term "pliable" refers herein to materials which are compliant and which will readily conform to the general shape and contours of the wearer's body.

The term "spunbond" refers herein to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinnerette having a circular or other configuration, with the diameter of the extruded filaments then being rapidly reduced by a conventional process such as, for example, eductive drawing, and processes that are described in U.S. Patent No. 4,340,563 to Appel et al., U.S. Patent No. 3,692,618 to Dorschner et al., U.S. Patent No. 3,802,817 to Matsuki et al., U.S. Patent Nos. 3,338,992 and 3,341 ,394 to Kinney, U.S. Patent No. 3,502,763 to Hartmann, U.S. Patent No. 3,502,538 to Peterson, and U.S. Patent No. 3,542,615 to Dobo et al., each of which is incorporated herein in its entirety by reference. Spunbond fibers are generally continuous and often have average deniers larger than about 0.3, and in an embodiment, between about 0.6, 5 and 10 and about 15, 20 and 40. Spunbond fibers are generally not tacky when they are deposited on a collecting surface.

The term "superabsorbent" refers herein to a water-swellable, water-insoluble organic or inorganic material capable, under the most favorable conditions, of absorbing at least about 15 times its weight and, in an embodiment, at least about 30 times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride. The superabsorbent materials can be natural, synthetic and modified natural polymers and materials. In addition, the superabsorbent materials can be inorganic materials, such as silica gels, or organic compounds, such as cross-linked polymers.

The term "thermoplastic" refers herein to a material which softens and which can be shaped when exposed to heat and which substantially returns to a non-softened condition when cooled.

The term "user" or "caregiver" refers herein to one who fits an absorbent article, such as, but not limited to, a diaper, training pant, youth pant, incontinent product, or other absorbent article about the wearer of one of these absorbent articles. A user and a wearer can be one and the same person.

Absorbent Article:

Referring to FIGS. 1 -3, a non-limiting illustration of an absorbent article 10, for example, a diaper, is illustrated. Other embodiments of the absorbent article could include training pants, youth pants, adult incontinence garments, and feminine hygiene articles. While the embodiments and illustrations described herein may generally apply to absorbent articles manufactured in the product longitudinal direction, which is hereinafter called the machine direction manufacturing of a product, it should be noted that one of ordinary skill in the art could apply the information herein to absorbent articles manufactured in the latitudinal direction of the product, which hereinafter is called the cross direction manufacturing of a product, without departing from the spirit and scope of the disclosure.

The absorbent article 10 illustrated in FIGS. 1 and 2 includes a chassis 9 including a front waist region 12, a rear waist region 14, and a crotch region 16 disposed between the front waist region 12 and the rear waist region 14 and interconnecting the front and rear waist regions, 12, 14, respectively. The front waist region 12 can be referred to as the front end region, the rear waist region 14 can be referred to as the rear end region, and the crotch region 16 can be referred to as the intermediate region. The absorbent article 10 has a pair of longitudinal side edges, 18, 20, and a pair of opposite waist edges, respectively designated front waist edge 22 and rear waist edge 24. The front waist region 12 can be contiguous with the front waist edge 22 and the rear waist region 14 can be contiguous with the rear waist edge 24. The longitudinal side edges 18, 20 can extend from the front waist edge 22 to the rear waist edge 24.

The front waist region 12 can include the portion of the absorbent article 10 that, when worn, is positioned at least in part on the front of the wearer. The rear waist region 14 can include the portion of the absorbent article 10 that, when worn, is positioned at least in part on the back of the wearer. The crotch region 16 of the absorbent article 10 can include the portion of the absorbent article 10, that, when worn, is positioned between the legs of the wearer and can partially cover the lower torso of the wearer. The waist edges, 22 and 24, of the absorbent article 10 are configured to encircle the waist of the wearer and together define a central waist opening 23 for the waist of the wearer, as shown in FIG. 1. Portions of the longitudinal side edges, 18 and 20, in the crotch region 16 can generally define leg openings for the legs of the wearer when the absorbent article 10 is worn.

The absorbent article 10 can include a chassis 9 including an outer cover 26 and a bodyside liner 28, the bodyside liner 28 being depicted in the cut-away portion of FIG. 2. In an embodiment, the bodyside liner 28 can be bonded to the outer cover 26 in a superposed relation by any suitable means such as, but not limited to, adhesives, ultrasonic bonds, thermal bonds, pressure bonds, or other conventional techniques. The outer cover 26 can define a length in a longitudinal direction 30, and a width in the lateral direction 32, which, in the illustrated embodiment, can coincide with the length and width of the absorbent article 10. As illustrated in FIG. 2, the absorbent article 10 can have a longitudinal axis 29 extending in the longitudinal direction 30 and a lateral axis 31 extending in the lateral direction 32. The longitudinal axis 29 and the lateral axis 31 can define a horizontal plane. As depicted in FIG. 2, the longitudinal axis 29 is disposed midway between the longitudinal side edges 18, 20 of the absorbent article 10 and the lateral axis 31 is disposed midway between the front waist edge 22 and the rear waist edge 24 of the absorbent article 10.

As shown in FIGS. 2 and 3, the chassis 9 of the absorbent article 10 can further include an absorbent body 34. The absorbent body 34 can be disposed between the outer cover 26 and the bodyside liner 28. In an embodiment, the absorbent body 34 can have a length and width that are the same as or less than the length and width of the absorbent article 10. The bodyside liner 28, the outer cover 26, and the absorbent body 34 can form part of an absorbent assembly 36. The absorbent assembly 36 can also include other components such as a fluid transfer layer 38 and a fluid acquisition layer 39, as are known in the art.

The absorbent article 10 can be configured to contain and/or absorb liquid, solid, and semisolid body exudates discharged from the wearer. For example, containment flaps 40, 42 (shown in FIG. 1 ), which are known in the art, can be configured to provide a barrier to the lateral flow of body exudates. To further enhance containment and/or absorption of body exudates, in some embodiments the absorbent article 10 can suitably include a waist elastic member, such as a rear waist elastic member 44. In some embodiments, the absorbent article 10 can include a front waist elastic member, although one is not depicted in the figures herein. The absorbent article 10 can further include leg elastic members, 46 and 48, as depicted in FIGS. 1 and 2 and as are known to those skilled in the art. The rear waist elastic member 44 can be attached to the outer cover 26 and/or the bodyside liner 28 proximate the rear waist edge 24 and can extend over part or all of the rear waist edge 24. In an embodiment shown in FIGS. 1 and 2, the rear waist elastic member 44 is attached to the bodyside liner 28. The leg elastic members, 46 and 48, can be attached to the outer cover 26 and/or the bodyside liner 28 proximate the opposite longitudinal side edges, 18 and 20, and positioned in the crotch region 16 of the absorbent article 10. The leg elastic members, 46 and 48, can be curved as shown in FIG. 2, or can be parallel to the longitudinal axis 29 as is known in the art.

The absorbent article 10 can also include a fastening system that can be used to put the absorbent article 10 in a fastened configuration. In some embodiments, the fastening system can include a primary fastening system 47 and a secondary fastening system 49. The primary fastening system 47 can include at least one primary first fastening component 52 and at least one primary second fastening component 54. The secondary fastening system 49 can include at least one secondary first fastening component 51 and at least one secondary second fastening component 53.

Additional details regarding each of these elements of the absorbent article 10 described herein can be found below and with reference to the Figures 1 through 5.

Outer cover:

The outer cover 26 and/or portions thereof can be breathable and/or liquid impermeable. The outer cover 26 and/or portions thereof can be elastic, stretchable, or non-stretchable. The outer cover 26 may be constructed of a single layer, multiple layers, laminates, spunbond fabrics, films, meltblown fabrics, elastic netting, microporous webs, bonded-carded webs or foams provided by elastomeric or polymeric materials. In an embodiment, for example, the outer cover 26 can be constructed of a microporous polymeric film, such as polyethylene or polypropylene.

In an embodiment, the outer cover 26 can be a single layer of a liquid impermeable material, such as a polymeric film. In an embodiment, the outer cover 26 can be suitably stretchable, and more suitably elastic, in at least the lateral direction 32 of the absorbent article 10. In an embodiment, the outer cover 26 can be stretchable, and more suitably elastic, in both the lateral 32 and the longitudinal 30 directions. In an embodiment, the outer cover 26 can be a multi-layered laminate in which at least one of the layers is liquid impermeable. In an embodiment, the outer cover 26 can be a two layer construction, including an outer layer material and an inner layer material (not shown) which can be bonded together such as by a laminate adhesive. Suitable laminate adhesives can be applied continuously or intermittently as beads, a spray, parallel swirls, or the like, but it is to be understood that the inner layer can be bonded to the outer layer by other bonding methods, including, but not limited to, ultrasonic bonds, thermal bonds, pressure bonds, or the like.

The outer layer of the outer cover 26 can be any suitable material and may be one that provides a generally cloth-like texture or appearance to the wearer. An example of such material can be a 100% polypropylene bonded-carded web with a diamond bond pattern available from Sandler A.G., Germany, such as 30 gsm Sawabond 4185® or equivalent. Another example of material suitable for use as an outer layer of an outer cover 26 can be a 20 gsm spunbond polypropylene non- woven web. The outer layer may also be constructed of the same materials from which the bodyside liner 28 can be constructed as described herein.

The liquid impermeable inner layer of the outer cover 26 (or the liquid impermeable outer cover 26 where the outer cover 26 is of a single-layer construction) can be either vapor permeable (i.e., "breathable") or vapor impermeable. The liquid impermeable inner layer (or the liquid impermeable outer cover 26 where the outer cover 26 is of a single-layer construction) can be manufactured from a thin plastic film. The liquid impermeable inner layer (or the liquid impermeable outer cover 26 where the outer cover 26 is of a single-layer construction) can inhibit liquid body exudates from leaking out of the absorbent article 10 and wetting articles, such as bed sheets and clothing, as well as the wearer and caregiver.

Where the outer cover 26 is of a single layer construction, it can be embossed and/or matte finished to provide a more cloth-like texture or appearance. The outer cover 26 can permit vapors to escape from the absorbent article 10 while preventing liquids from passing through. A suitable liquid impermeable, vapor permeable material can be composed of a microporous polymer film or a non- woven material which has been coated or otherwise treated to impart a desired level of liquid impermeability. As shown in FIGS. 1 -3, the absorbent article 10 can include a pocket 60. The pocket 60 can be disposed in the front waist region 12 of the absorbent article 10 and can be disposed on an outer surface 7 of the chassis 9. In some embodiments, the pocket 60 can be disposed in the front waist region 12 and can extend into the crotch region 16 of the absorbent article 10. The pocket 60 can include a pocket longitudinal axis 62, as shown in FIG. 2. Preferably, the pocket longitudinal axis 62 substantially aligns with the longitudinal axis 29 of the absorbent article 10. In some embodiments, the pocket 60 can be formed from a first material component 64 and a second material component 66. The pocket 60 can include a first side edge 70, a second side edge 72, an upper lateral edge 74 and a lower lateral edge 76. Although the first side edge 70, the second side edge 72, the upper lateral edge 74, and the lower lateral edge 76 are depicted as being linear segments, the first side edge 70, the second side edge 72, the upper lateral edge 74, and/or the lower lateral edge 76 can be configured to be arcuate in shape, or in any other suitable shape.

The pocket 60 can include a bottom surface 78 and a top surface 79. In some embodiments, such as the embodiment shown in FIGS. 1 -3, the bottom surface 78 of the pocket 60 can be formed by a garment facing surface 27 of the outer cover 26. In other embodiments, the bottom surface 78 of the pocket 60 can be formed by another component (not shown) coupled to the outer cover 26. In some embodiments, such as the embodiment shown in FIGS. 1-3, the top surface 79 of the pocket 60 can be formed by the first material component 64. The pocket 60 can be closed with respect to the absorbent assembly 36 at least at the first side edge 70 and the second side edge 72. In some embodiments, the pocket 60 can be closed with respect to the chassis 9 at the upper lateral edge 74 as well.

The first material component 64 and the second material component 66 can together define the pocket 60 of the absorbent article 10. As illustrated in FIG. 2, the first material component 64 can include an uppermost edge 64a, a lowermost edge 64b, and two opposing side edges 64c and 64d. The second material component 66 can include a top edge 66a, a bottom edge 66b, and two opposing side edges 66c and 66d. A pocket 60 formed by a first material component 64 and a second material component 66 can have increased rigidity in the lateral direction 32 as compared to a pocket 60 being formed by a single material. The increased rigidity can provide the caregiver with easier access to the pocket 60 and/or improved functionality of the pocket 60.

In one embodiment, the first material component 64 can be bonded to the outer surface 7 of the chassis 9. In one embodiment, the first material component 64 can be bonded to the absorbent assembly 36 to form a first side edge 70 of the pocket 60 and the second side edge 72 of the pocket 60. For example, in some embodiments, as illustrated in FIGS. 2 and 3, the outer surface 7 of the chassis 9 can be the outer surface 37 of absorbent assembly 36, and in some embodiments, the garment facing surface 27 of the outer cover 26. The first material component 64 can be bonded to the garment facing surface 27 of the outer cover 26 by an adhesive 68 near each of the opposing side edges 64c and 64d of the first material component 64 to form the first and second side edges 70, 72 of the pocket 60. In some embodiments, the adhesive 68 can bond the first material component 64 directly to the garment facing surface 27 of the outer cover 26.

As noted above, the first side edge 70 and the second side edge 72 can be configured to be arcuate in shape as opposed to the linear segments depicted in the embodiments illustrated herein. As an example, such a configuration could be accomplished by modifying the adhesive 68 that bonds the first material component 64 to the outer surface 7 of the chassis 9. Additionally or alternatively, one or more of the opposing side edges 64c, 64d of the first material component 64 could be arcuate in shape, or any other suitable shape, to provide a first side edge 70 and/or second side edge 72 of the pocket 60 with an alternative shape to a linear segment as shown herein. In some embodiments, the second material component 66 can be bonded to the first material component 64 and to the outer surface 7 of the chassis 9 to form an upper lateral edge 74 of the pocket 60. In some embodiments, the second material component 66 can be bonded to the outer surface 7 of the chassis 9 by being bonded to the outer surface 37 of the absorbent assembly 36 to form an upper lateral edge 74 of the pocket 60. As illustrated in FIG. 2, the top edge 66a of the second material component 66 can be closer to the front waist edge 22 than is the uppermost edge 64a of the first material component 64. Such a configuration can provide for the second material component 66 to bond to the outer surface 7 of the chassis 9, such as the garment facing surface 27 of the outer cover 26, to form the upper lateral edge 74 of the pocket 60. In some embodiments, as illustrated in FIGS. 2 and 3, the second material component 66 can be bonded to the first material component 64 and the outer surface 37 of the absorbent assembly 36 by an adhesive 69 to form the upper lateral edge 74 (labeled in FIG. 2) of the pocket 60. In some embodiments, the adhesive 69 can bond the second material component 66 directly to the garment facing surface 27 of the outer cover 26 to bond the second material component 66 to the outer surface 37 of the absorbent assembly 36, which forms the outer surface 7 of the chassis 9. As illustrated in FIGS. 2 and 3, in some

embodiments the adhesive 69 can substantially cover the body facing side 66e of the second material component 66, extending from the top edge 66a to the bottom edge 66b and nearly from side edge 66c to opposing side edge 66d. It can be appreciated that the adhesive 69 can be applied intermittently or in any other suitable fashion. As noted above, the upper lateral edge 74 of the pocket 60 can be configured to be of a different shape than the linear segment that is shown in the figures herein. As but one example, the upper lateral edge 74 could be configured to be arcuate in shape. Such a configuration could be accomplished by adjusting the shape of the uppermost edge 64a of the first material component 64 to be arcuate and/or adjusting the adhesive 69 that bonds the second material component 66 to the outer surface 7 of the chassis 9 to be in an arcuate fashion. It is contemplated that the upper lateral edge 74 can have shapes other than linear segments or arcuate segments.

It is to be appreciated that, in other embodiments, the upper lateral edge 74 of the pocket 60 can be formed by bonding the first material component 64 to the outer surface 7 of the chassis 9, for example, by use of an adhesive (not shown) near the uppermost edge 64a of the first material component 64. Additionally, in some embodiments the upper lateral edge 74 of the pocket 60 can be open with respect to the chassis 9. Such a configuration can be accomplished by not having the top edge 66a of the second material component 66 be disposed closer to the front waist edge 22 than is the uppermost edge 64a of the first material component 64 such that the second material component 66 does not form the upper lateral edge 74 of the pocket 60 by being bonded to the outer surface 7 of the chassis 9 above the uppermost edge 64a of the first material component 64. Alternatively, such a configuration could be accomplished by adjusting the adhesive 69 such that the second material component 66 extends above the uppermost edge 64a of the first material component 64, but is not bonded to the chassis 9 above the uppermost edge 64a of the first material component 64.

In some embodiments, as illustrated in FIG. 2, the second material component 66 can be bonded to the first material component 64 and to the outer surface 7 of the chassis 9 such that the lowermost edge 64b of the first material component 64 is closer to the lateral axis 31 than is the bottom edge 66b of the second material component 66. In other words, the first material component 64 and the second material component 66 can be disposed such that a portion of the first material component 64 is not covered by the second material component 66. Such a configuration of the pocket 60 can help indicate the presence of the pocket 60 to a caregiver.

The second material component 66 can be wider than the first material component 64 in a direction parallel to the lateral axis 31 in some embodiments. For example, as illustrated in FIGS. 2 and 3, the side edge 66c of the second material component 66 is disposed closer to the longitudinal side edge 18 of the absorbent article 10 than is the side edge 64c of the first material component 64 and the side edge 66d of the second material component 66 is disposed closer to the longitudinal side edge 20 of the absorbent article 10 than is the side edge 64d of the first material component 64. Configuring the second material component 66 to be wider than the first material component 64 can help ensure that the second material component 66 can seal and form the upper lateral edge 74 of the pocket 60.

It is contemplated, however, that in some embodiments the second material component 66 can be the same width as the first material component 64 in a direction parallel to the lateral axis 31 , or more narrow in width than the first material component 64 in a direction parallel to the lateral axis 31. In embodiments where the second material component 66 is bonded to the outer surface 7 of the chassis 9 to form the upper lateral edge 74 of the pocket 60, it is preferred to have the second material component 66 be substantially the same width or wider than the width of the first material component 64 in a direction parallel to the lateral axis 31.

Of course, it is to be appreciated that while adhesives 68, 69 are disclosed in the

embodiments depicted in FIGS. 1 -3 to bond the first material component 64 to the chassis 9 and the second material component 66 to the first material component 64 and the chassis 9, other known means of bonding can be used, including but not limited to, pressure bonding, ultrasonic bonding, thermal bonding, etc. It is also contemplated that while the first material component 64 can be directly bonded to the outer cover 26 in some embodiments to bond the first material component 64 to the outer surface 7 of the chassis 9, the first material component 64 could be indirectly bonded to the outer surface 7 of the chassis 9. For example, the first material component 64 could be directly bonded to another component (not shown) which in turn is directly bonded to the outer surface 7 of the chassis 9.

Similarly, it is contemplated that while the second material component 66 can be directly bonded to the first material component 64 and directly bonded to the outer surface 7 of the chassis 9 (e.g., the garment facing surface 27 of the outer cover 26) in some embodiments to bond the second material component 66 to the first material component 64 and the outer surface 7 of the chassis 9, the second material component 66 could be indirectly bonded to the first material component 64 and/or indirectly bonded to the outer surface 7 of the chassis 9. For example, the second material component 66 could be directly bonded to one or more other components (not shown) which in turn are directly bonded to the first material component 64 and/or the outer surface 7 of the chassis 9.

The first material component 64 and the second material component 66 can be comprised of the same material or different materials from one another. In one preferred embodiment, the first material component 64 can comprise a spunbond-meltblown-spunbond ("SMS") material and the second material component 66 can comprise a point unbonded ("PUB") non-woven material. In some embodiments, the second material component 66 can comprise a portion of the fastening system of the absorbent article 10. For example, the second material component 66 can form or can include the primary second fastening component 54 for the primary fastening system 47 of the absorbent article 10. Thus, the second material component 66 can provide the advantage of dual functionality of not only forming a portion of the pocket 60, but also forming a portion of the fastening system.

In some embodiments, the first material component 64 can provide extendable and/or elastic properties. In some embodiments, the second material component 66 can provide extendable and/or elastic properties. In some embodiments, both the first material component 64 and the second material component 66 can provide extendable and/or elastic properties. The first and/or second material components 64, 66, respectively, can provide extendable properties due to their material composition or by coupling them to one or more extendable and/or elastic materials.

As illustrated in FIG. 2, the pocket 60 can include a width 80 and a length 82. The length 82 can be measured in the longitudinal direction 30 from the upper lateral edge 74 to the lower lateral edge 76. In preferred embodiments, the length 82 of the pocket 60 can be between about 1.25 inches and about 3.75 inches. The width 80 can be measured in the lateral direction 32 from the first side edge 70 to the second side edge 72. In preferred embodiments, the width 80 of the pocket 60 can be between about 3.00 inches and about 6.00 inches.

Turning now to FIGS. 4 and 5, an exemplary method 1 10 of manufacturing an absorbent article 10 including a pocket 60 as illustrated in FIGS. 1-3 will now be disclosed. The method 110 can include providing a chassis 9 including an outer surface 7. The chassis 9 can include an absorbent assembly 36 including a bodyside liner 28, an outer cover 26, and an absorbent body 34 disposed between the bodyside liner 28 and the outer cover 26. The chassis 9 can be provided in a form configuring a discrete absorbent article 10 including the bodyside liner 28, outer cover 26, and absorbent body 34, such as shown in FIGS. 1-3, or can be provided in partial form, such as in the form of a chassis web 109, as is illustrated in FIGS. 4 and 5. In some embodiments, the chassis web 109 can include an outer cover web 126, such as shown in FIGS. 4 and 5, which can then later be combined with a bodyside liner 28 and absorbent body 34 (in web form) and cut into discrete absorbent articles 10. As shown in FIGS. 4 and 5, the chassis web 109 can include an outer surface 107 and outer cover web 126 can include a garment facing surface 127.

As shown in both FIGS. 4 and 5, the method 110 can include providing a continuous web 164 of a first material and providing a continuous web 166 of a second material. The continuous webs 164, 166 can pass over idlers 156 and/or other web control mechanisms as are known in the art. The method 110 can also include cutting the continuous web 164 of the first material to form a first material component 64. The method 110 can also include bonding the first material component 64 to the outer surface 107 of the chassis web 109 (e.g., garment facing surface 127 of outer cover web 126).

Similarly, the method 1 10 can also include cutting the continuous web 166 of the second material to form a second material component 66 and bonding the second material component 66 to the first material component 64 and the outer surface 107 of the chassis web 109 (e.g., garment facing surface 127 of outer cover web 126). An exemplary method of cutting the web 164 of the first material to form a first material component 64 and bonding the first material component 64 to the outer surface 107 of the chassis web 109 and cutting the web 166 of the second material to form a second material component 66 and bonding the second material component 66 to the first material component 64 and the outer surface 107 of the chassis web 109 will now be discussed.

In some embodiments, the continuous webs 164, 166 of the first material and the second material, respectively, can be transferred and cut by employing a knife roll 184 and an anvil roll 186, as depicted in FIG. 4. As is known in the art, the anvil roll 186 can be supplied with a source of vacuum (e.g., a vacuum pump, vacuum chamber, etc.) that is capable of selectively applying vacuum pressure (i.e., negative pressure) through one or more holes (not shown) in the outer surface 187 of the anvil roll 186 as is known in the art. By communicating a vacuum to the outer surface 187 of the anvil roll 186, the continuous webs 164, 166 of the first material and the second material, respectively, can be generally drawn to and secured against the outer surface 187 of their respective anvil roll 186. In some embodiments, the vacuum source may be capable of applying a vacuum in the range of 1 to 20 inches of water, and more preferably in the range of 3 to 10 inches of water, and even more preferably in the range of 4 to 7 inches of water.

In the method 1 10 depicted in FIG. 4, the continuous webs 164, 166 of the first material and the second material, respectively, can be delivered to their respective anvil rolls 186 at a slower linear speed than the surface speed of their respective anvil roll 186. In other words, the surface speed of the anvil rolls 186 is greater than the speed at which the incoming continuous webs 164, 166 of the first material and the second material, respectively, are fed to their respective anvil roll 186. It is understood that the incoming continuous webs 164, 166 of the first and second material can be fed to their respective anvil roll 186 at any suitable rate. As illustrated in FIG. 4, adhesive unit 188a can apply an adhesive 68 to the continuous web 164 of the first material and adhesive unit 188b can apply adhesive 69 to the continuous web 166 of the second material, as will be discussed in further detail below.

To cut the continuous web 164 of the first material and the continuous web 166 of the second material the knife rolls 184 can include one or more knife edges 185 (one knife 185 is shown for each knife roll 184 in FIG. 4). The knife edge 185 can be configured to cut material provided on the outer surface 187 of the respective anvil roll 186 when the knife edge 185 comes into contact with the outer surface 187 of the respective anvil roll 186. Thus, as illustrated in FIG. 4, when the continuous web 164 of the first material is fed to the anvil roll 186 depicted on the left side of FIG. 4, the knife edge 185 on the respective knife roll 184 can cut the continuous web 164 of the first material in a transverse or cross-machine direction when the knife edge 185 comes into contact with the outer surface 187 of that anvil roll 186, thereby forming a first material component 64. Similarly, when the continuous web 166 of the second material is fed to the anvil roll 186 depicted on the right side of FIG. 4, the knife edge 185 on the respective knife roll 184 can cut the continuous web 166 of the second material in a transverse or cross-machine direction when the knife edge 185 comes into contact with the outer surface 187 of that anvil roll 186, thereby forming a second material component 66.

Once the first material component 64 has been cut from the continuous web 164 of the first material by knife roll 184 and the second material component 66 has been cut from the continuous web 166 of the second material by knife roll 184, the first material component 64 and the second material component 66 will be transported at the surface speed of the respective anvil roll 186 on which they are located and held to the outer surface 187. As discussed above, the first material component 64 and the second material component 66 can be held on the outer surface 187 of the respective anvil roll 186 by vacuum.

Turning now to FIG. 5, the application of the adhesive 68 to the continuous web 164 of the first material and the application of the adhesive 69 to the continuous web 166 of the second web material is illustrated for a preferred embodiment. The adhesive 68 from the adhesive unit 188a (shown in FIG. 4) can be applied adjacent to longitudinal side edges 164c, 164d of the continuous web 164 of the first material prior to the cutting of the continuous web 164 of the first material to form the first material component 64. The adhesive 69 from the adhesive unit 188b (shown in FIG. 4) can be applied to a first surface 167 of the continuous web 166 of the second material prior to the cutting of the continuous web 166 of the second material to form the second material component 66.

As illustrated in FIGS. 4 and 5, once the continuous web 164 of the first material is cut to form the first material component 64 by the knife roll 184 and the anvil roll 186, as discussed above, the first material component 64 can be bonded to the outer surface 107 of the chassis web 109 (e.g., garment facing surface 127 of outer cover web 126). As illustrated in the exemplary embodiment of FIG. 5, the first material component 64 can be bonded to the garment facing surface 127 of outer cover web 126 to form a first side edge 70 and a second side edge 72 of the pocket 60. The adhesive 68 that was applied adjacent the longitudinal side edges 164c, 164d of the continuous web 164 of the first material provides the bonding of the first material component 64 to the garment facing surface 127 of outer cover web 126 to form the first side edge 70 and the second side edge 72 of the pocket 60 by bonding the first material component 64 to the outer cover web 126 near the side edges 64c, 64d of the first material component 64.

Furthermore, once the continuous web 166 of the second material is cut to form the second material component 66 by the respective knife roll 184 and the anvil roll 186, as discussed above, the second material component 66 can be bonded to the first material component 64 and the outer surface 107 of the chassis web 109 (e.g., garment facing surface 127 of outer cover web 126). As depicted in FIG. 5, the second material component 66 can partially overlap the first material component 64 such that a first portion 67a of the second material component 66 is bonded to the first material component 64 and a second portion 67b of the second material component 66 is bonded to the outer surface 107 of the chassis web 109 (e.g., garment facing surface 127 of outer cover web 126). The adhesive 69 applied to the first surface 167 of the continuous web 166 of the second material provides the bonding of both the first portion 67a of the second material component 66 to the first material component 64 and the bonding of the second portion 67b of the second material component 66 to the outer surface 107 of the chassis web 109. As previously noted, the adhesive 69 could be applied in various fashions, intermittent, spray, slot-coat, etc, without departing from this disclosure.

As illustrated in FIG. 5, the bonding of the second portion 67b of the second material component 66 to the outer surface 107 of the chassis web 109 (e.g., garment facing surface 127 of outer cover web 126) can form the upper lateral edge 74 of the pocket 60, with the pocket 60 being open with respect to the outer surface 107 of the chassis web 109 (e.g., garment facing surface 127 of outer cover web 126) at the lower lateral edge 76 of the pocket 60. As illustrated in FIGS. 4 and 5, the first material component 64 and the second portion 67b of the second material component 66 can each be directly bonded to the garment facing surface 127 of the outer cover web 126. The first material component 64 and the second material component 66 can be registered with respect to the chassis web 109 (e.g., outer cover web 126) such that the pocket 60 formed by the first material component 64 and the second material component 66 will be located in the front waist region 12 of the absorbent article 10 once the chassis web 109 is cut to form discrete absorbent articles 10.

As illustrated in this embodiment, the method 110 can include bonding the first portion 67a of the second material component 66 to the first material component 64 after the first material component 64 is bonded to the outer surface 107 of the chassis web 109 (such as the garment facing surface 127 of outer cover web 126). However, in some embodiments, it is contemplated that the first portion 67a of the second material component 66 can be bonded to the first material component 64 prior to bonding the first material component 64 to the outer surface 107 of the chassis web 109 (such as the garment facing surface 127 of outer cover web 126).

As previously described and as illustrated in FIGS. 2 and 5, the first material component 64 can include an uppermost edge 64a and a lowermost edge 64b, and two opposing side edges 64c and 64d. The second material component 66 can include a top edge 66a, a bottom edge 66b, and two opposing side edges 66c and 66d. In some embodiments, the first material component 64 and the second material component 66 can be bonded to the outer surface 107 of the chassis web 109 (e.g., garment facing surface 127 of outer cover web 126) such that the lowermost edge 64b of the first material component 64 is closer to the lateral axis 31 than is the bottom edge 66b of the second material component 66, as illustrated in FIG. 2. The web 164 of the first material and the web 166 of the second material can be configured such that after cutting and bonding to the chassis web 109 (e.g., outer cover web 126), the second material component 66 is wider than the first material component 64 in a direction parallel to the lateral axis 31.

The method 1 10 can also include providing a fastening system. As is illustrated on the absorbent article 10 in FIGS. 1 and 2, some embodiments of the absorbent article 10 can include a primary fastening system 47 and a secondary fastening system 49. As will be discussed in more detail below, the primary fastening system 47 can include a primary second fastening component 54 disposed in the front waist region 12. The primary second fastening component 54 can be formed by the second material component 66 of the pocket 60. Additionally, the secondary fastening system 49 can include one or more secondary first fastening components 51 disposed in the front waist region 12. The secondary first fastening components 51 can be disposed on the second material component 66. Thus, in some embodiments, bonding the second material component 66 to the chassis 9 can provide for the bonding of the primary second fastening component 54 and the secondary first fastening components 51 to the chassis 9. The back ears 50 can each provide a primary first fastening component 52 and a secondary second fastening component 53. Providing the back ears 50 and bonding them to the chassis 9 or chassis web 109 as is known in the art can be done before or after the first material component 64 and second material component 66 are bonded to the chassis 9 or chassis web 109 to form the pocket 60.

If the chassis 9 is provided in the form of a chassis web 109, the method 1 10 can also include cutting the chassis web 109 to form individual absorbent articles 10 (such as depicted in FIGS. 1 -3). In one embodiment, cutting the chassis web 109 can be done with a cutoff module (not shown) as is known in the art.

Absorbent Body:

The absorbent body 34 can be suitably constructed to be generally compressible, conformable, pliable, non-irritating to the wearer's skin and capable of absorbing and retaining liquid body exudates. The absorbent body 34 can be manufactured in a wide variety of sizes and shapes (for example, rectangular, trapezoidal, T-shape, l-shape, hourglass shape, etc.) and from a wide variety of materials. The size and the absorbent capacity of the absorbent body 34 should be compatible with the size of the intended wearer (infants to adults) and the liquid loading imparted by the intended use of the absorbent article 10. The absorbent body 34 can have a length and width that can be less than or equal to the length and width of the absorbent article 10.

In an embodiment, the absorbent body 34 can be composed of a web material of hydrophilic fibers, cellulosic fibers (e.g., wood pulp fibers), natural fibers, synthetic fibers, woven or nonwoven sheets, scrim netting or other stabilizing structures, superabsorbent material, binder materials, surfactants, selected hydrophobic and hydrophilic materials, pigments, lotions, odor control agents or the like, as well as combinations thereof. In an embodiment, the absorbent body 34 can be a matrix of cellulosic fluff and superabsorbent material. In an embodiment, the absorbent body 34 may be constructed of a single layer of materials, or in the alternative, may be constructed of two or more layers of materials.

Various types of wettable, hydrophilic fibers can be used in the absorbent body 34. Examples of suitable fibers include natural fibers, 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 from inherently wettable thermoplastic polymers, such as particular polyester or polyamide fibers, or composed of nonwettable thermoplastic polymers, such as polyolefin fibers which have been hydrophilized by suitable means. The fibers may be hydrophilized, for example, by treatment with a surfactant, treatment with silica, treatment with a material which has a suitable hydrophilic moiety and is not readily removed from the fiber, or by sheathing the nonwettable, hydrophobic fiber with a hydrophilic polymer during or after formation of the fiber. Suitable superabsorbent materials can be selected from natural, synthetic, and modified natural polymers and materials. The superabsorbent materials can be inorganic materials, such as silica gels, or organic compounds, such as cross-linked polymers. In an embodiment, the absorbent body 34 can be free of superabsorbent material.

The absorbent body 34 can be superposed over the outer cover 26 and can be bonded to the outer cover 26, such as by being bonded thereto with adhesive. However, it is to be understood that the absorbent body 34 may be in contact with, and not bonded with, the outer cover 26 and remain within the scope of this disclosure. In an embodiment, the outer cover 26 can be composed of a single layer and the absorbent body 34 can be in contact with the singer layer of the outer cover 26. In other embodiments, the outer cover 26 can be composed of more than one layer, and the absorbent body 34 can be in contact with the innermost layer of the outer cover 26. In an embodiment, a layer, such as but not limited to, a fluid transfer layer 38, can be positioned between the absorbent body 34 and the outer cover 26, as illustrated in FIG. 3.

Bodyside liner:

The bodyside liner 28 of the absorbent article 10 can overlay the absorbent body 34 and the outer cover 26 and can isolate the wearer's skin from liquid waste retained by the absorbent body 34. In various embodiments, a fluid transfer layer 38 can be positioned between the bodyside liner 28 and the absorbent body 34. In various embodiments, an acquisition layer 39 can be positioned between the bodyside liner 28 and the absorbent body 34 or a fluid transfer layer 38, if present. In various embodiments, the bodyside liner 28 can be bonded to the acquisition layer 39, or to the fluid transfer layer 38 if no acquisition layer 39 is present, via adhesive and/or by a point fusion bonding. The point fusion bonding may be selected from ultrasonic, thermal, pressure bonding, and combinations thereof. In an embodiment, the bodyside liner 28 can extend beyond the absorbent body 34 and/or a fluid transfer layer 38, if present, and/or an acquisition layer 39, if present, to overlay a portion of the outer cover 26 and can be bonded thereto by any method deemed suitable, such as, for example, by being bonded thereto by adhesive, to substantially enclose the absorbent body 34 between the outer cover 26 and the bodyside liner 28. The bodyside liner 28 may be narrower than the outer cover 26, but it is to be understood that the bodyside liner 28 and the outer cover 26 may be of the same dimensions, or that the bodyside liner 28 may be of greater width than the outer cover 26. It is also contemplated that the bodyside liner 28 may not extend beyond the absorbent body 34 and/or may not be secured to the outer cover 26. It is further contemplated that the bodyside liner 28 may be composed of more than one segment of material. The bodyside liner 28 can be of different shapes, including rectangular, hourglass, or any other shape. The bodyside liner 28 can be suitably compliant, soft feeling, and non-irritating to the wearer's skin and can be the same as or less hydrophilic than the absorbent body 34 to permit body exudates to readily penetrate through to the absorbent body 34 and provide a relatively dry surface to the wearer.

The bodyside liner 28 can be manufactured from a wide selection of materials, such as synthetic fibers (for example, polyester or polypropylene fibers), natural fibers (for example, wood or cotton fibers), a combination of natural and synthetic fibers, porous foams, reticulated foams, apertured plastic films, or the like. Examples of suitable materials include, but are not limited to, rayon, wood, cotton, polyester, polypropylene, polyethylene, nylon, or other heat-bondable fibers, polyolefins, such as, but not limited to, copolymers of polypropylene and polyethylene, linear low-density polyethylene, and aliphatic esters such as polylactic acid, finely perforated film webs, net materials, and the like, as well as combinations thereof.

Various woven and non-woven fabrics can be used for the bodyside liner 28. The bodyside liner 28 can include a woven fabric, a nonwoven fabric, a polymer film, a film-fabric laminate or the like, as well as combinations thereof. Examples of a nonwoven fabric can include spunbond fabric, meltblown fabric, coform fabric, carded web, bonded-carded web, bicomponent spunbond fabric, spunlace, or the like, as well as combinations thereof. The bodyside liner 28 need not be a unitary layer structure, and thus, can include more than one layer of fabrics, films, and/or webs, as well as combinations thereof. For example, the bodyside liner 28 can include a support layer and a projection layer that can be hydroentagled. The projection layer can include hollow projections, such as those disclosed in U.S. Patent Application Publication No. 2014/0121623 invented by Kirby, Scott S.C. et al. In a preferred embodiment, the bodyside liner 28 includes a bodyfacing surface that provides an uneven surface at least in the front waist region 12, such as a bodyfacing surface that includes projections as disclosed in U.S. Patent Application Publication No. 2014/0121623 noted above. Such a bodyside liner 28 provides additional benefits in softness and assists in cleaning the wearer's skin when the caregiver uses the pocket 60 of the absorbent article 10 to wipe the wearer.

For example, the bodyside liner 28 can be composed of a meltblown or spunbond web of polyolefin fibers. Alternatively, the bodyside liner 28 can be a bonded-carded web composed of natural and/or synthetic fibers. The bodyside liner 28 can be composed of a substantially hydrophobic material, and the hydrophobic material can, optionally, be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity. The surfactant can be applied by any conventional means, such as spraying, printing, brush coating or the like. The surfactant can be applied to the entire bodyside liner 28 or it can be selectively applied to particular sections of the bodyside liner 28.

In an embodiment, a bodyside liner 28 can be constructed of a non-woven bicomponent web. The non-woven bicomponent web can be a spunbonded bicomponent web, or a bonded-carded bicomponent web. An example of a bicomponent staple fiber includes a polyethylene/polypropylene bicomponent fiber. In this particular bicomponent fiber, the polypropylene forms the core and the polyethylene forms the sheath of the fiber. Fibers having other orientations, such as multi-lobe, side- by-side, end-to-end may be used without departing from the scope of this disclosure. In an embodiment, a bodyside liner 28 can be a spunbond substrate with a basis weight from about 10 or 12 to about 15 or 20 gsm. In an embodiment, a bodyside liner 28 can be a 12 gsm spunbond-meltblown- spunbond substrate having 10% meltblown content applied between the two spunbond layers.

Although the outer cover 26 and bodyside liner 28 can include elastomeric materials, it is contemplated that the outer cover 26 and the bodyside liner 28 can be composed of materials which are generally non-elastomeric. In an embodiment, the bodyside liner 28 can be stretchable, and more suitably elastic. In an embodiment, the bodyside liner 28 can be suitably stretchable and more suitably elastic in at least the lateral or circumferential direction 32 of the absorbent article 10. In other aspects, the bodyside liner 28 can be stretchable, and more suitably elastic, in both the lateral and the longitudinal directions 32, 30, respectively.

Fluid Transfer Layer:

In some embodiments, the absorbent article 10 can include a fluid transfer layer 38. The fluid transfer layer 38 can be disposed between the absorbent body 34 and the bodyside liner 28. In some embodiments, the fluid transfer layer 38 can be in contact with and at least partially wrap the absorbent body 34. The fluid transfer layer 38 can be pliable, less hydrophilic than the absorbent body 34, and sufficiently porous to thereby permit liquid body exudates to penetrate through the fluid transfer layer 38 to reach the absorbent body 34. In an embodiment, the fluid transfer layer 38 can have sufficient structural integrity to withstand wetting thereof and of the absorbent body 34. The fluid transfer layer 38 can be a single layer of material or a laminate constructed from two or more layers. The fluid transfer layer 38 can include, but is not limited to natural and synthetic fibers such as polyester, polypropylene, acetate, nylon, polymeric materials, and cellulosic materials, and mixtures thereof. In some embodiments, the fluid transfer layer 38 can include spunbond and/or meltblown materials. The fluid transfer layer 38 can have a longitudinal length the same as, greater than, or less than the longitudinal length of the absorbent body 34.

Acquisition Layer:

In some embodiments, the absorbent article 10 can include an acquisition layer 39. The acquisition layer 39 can be disposed between the absorbent body 34 and the bodyside liner 28. The acquisition layer 39 can serve to quickly collect and temporarily hold liquids discharged by the wearer and then release the liquids to the absorbent body 34. Various woven and nonwoven materials can be used to construct the acquisition layer 39. For example, the acquisition layer 39 can be a layer of a spunbonded or meltblown web of polyolefin fibers. The acquisition layer 39 can also be a bonded carded web of natural and synthetic fibers. The acquisition layer 39 can be a substantially hydrophobic material and, optionally, can be treated with a surfactant or otherwise to impart a desired level of wettability and hydrophilicity.

Leg Elastics:

Leg elastic members 46, 48 (shown in FIG. 2) can be secured to the outer cover 26, such as by being bonded thereto by laminate adhesive, generally laterally inward of the longitudinal side edges, 18 and 20, of the absorbent article 10. The leg elastic members 46, 48 can form elasticized leg cuffs that further help to contain body exudates. In an embodiment where the outer cover 26 is comprised of an inner layer and an outer layer, the leg elastic members 46, 48 may be disposed between the inner layer and outer layer. In some embodiments, the leg elastic members 46, 48 can be located between other layers of the absorbent article 10. The leg elastic members 46, 48 can be a single elastic member, or each leg elastic member 46, 48 can include more than one elastic member, such as illustrated herein. A wide variety of elastic materials may be used for the leg elastic members 46, 48. Suitable elastic materials can include sheets, strands or ribbons of natural rubber, synthetic rubber, or thermoplastic elastomeric materials. The elastic materials can be stretched and secured to a substrate, secured to a gathered substrate, or secured to a substrate and then elasticized or shrunk, for example, with the application of heat, such that the elastic retractive forces are imparted to the substrate. Of course, the leg elastic members 46, 48 can be omitted from the absorbent article 10 without departing from the scope of this disclosure.

Fastening System:

In an embodiment, the absorbent article 10 can include a fastening system. The fastening system can include a primary fastening system 47 and a secondary fastening system 49. The fastening system can be configured to secure the absorbent article 10 about the waist of the wearer and maintain the absorbent article 10 in place during use in fastened configuration.

The primary fastening system 47 can include at least one primary first fastening component 52 and at least one primary second fastening component 54. As shown in FIGS. 1 -3, the absorbent article 10 can include a primary first fastening component 52 on each of the back ears 50. The primary first fastening components 52 can be disposed in the rear waist region 14 and the primary second fastening component 54 can be disposed in the front waist region 12. The primary first fastening components 52 are adapted for refastenable engagement with the primary second fastening component 54. The primary first fastening components 52 and the primary second fastening component 54 can comprise any refastenable fasteners suitable for absorbent articles, such as adhesive fasteners, cohesive fasteners, mechanical fasteners, or the like. In one suitable embodiment, the primary fastening components 52, 54 can comprise mechanical fastening components, such as hook and loop fasteners. For example, suitable hook and loop components can be provided by interlocking geometric shaped materials. As used herein, "hook" broadly refers to any suitable mechanical fastener adapted to engage loop components including, e.g., hooks, bulbs, mushrooms, arrowheads, balls on stems, stems, structures having stems that engage foam such as open cell foam or the like, etc. Other suitable mechanical fastening components include male and/or female mating components, buckles, snaps, or the like. In the illustrated embodiment, the primary first fastening components 52 comprise hook fasteners and the primary second fastening component 54 comprises a complementary loop fastener formed by the second material component 66 of the pocket 60. Alternatively, the primary first fastening components 52 may comprise loop fasteners and the primary second fastening component 54 may comprise complementary hook fasteners. It can also be appreciated that while the embodiments disclosed herein illustrate that the second material component 66 can form the primary second fastening component 54, one alternative can be to have the primary second fastening component(s) 54 be bonded to the second material component 66.

The secondary fastening system 49 can include at least one secondary first fastening component 51 and at least one secondary second fastening component 53. As illustrated in FIGS. 1- 3, the absorbent article 10 can include a secondary second fastening component 53 on each of the back ears 50 (the secondary first fastening components 51 not being shown in FIGS. 4 and 5 for clarity purposes). The secondary first fastening components 51 can be disposed in the front waist region 12 and can be disposed on the second material component 66 of the pocket 60. The secondary first fastening components 51 are adapted for refastenable engagement with the secondary second fastening components 53. As noted above with respect to the primary fastening components 52, 54, the secondary fastening components 51 , 53 can comprise mechanical fastening components, such as hook and loop fasteners, but other suitable mechanical fastening components can include male and/or female mating components, buckles, snaps, or the like. In the illustrated embodiment, the secondary first fastening components 51 comprise hook fasteners and the secondary second fastening components 53 comprise loop fasteners. Alternatively, the secondary first fastening components 51 may comprise loop fasteners and the secondary second fastening components 53 may comprise complementary hook fasteners. In one embodiment, the secondary first fastening components 51 may be constructed of polyethylene or other suitable polymer blends.

A benefit to having a pocket 60 that includes a first material component 64 and a second material component 66 is that the lower lateral edge 76 of the pocket 60 can be independent from the location of the secondary first fastening components 51. Specifically, when the secondary first fastening components 51 are disposed on the second material component 66, but the lower lateral edge 76 of the pocket 60 is defined by a component other than the second material component 66, such as by the lowermost edge 64b of the first material component 64, then the secondary first fastening components 51 can be independent from the lower lateral edge 76 of the pocket 60. Such a configuration provides the benefit of being able to provide a pocket 60 of a desired length 82 and desired location in the front waist region 12, yet keep the secondary first fastening components 51 away from the longitudinal edges 18, 20 of the absorbent article 10 that define leg openings when the product is in the fastened configuration. Keeping the secondary first fastening components 51 away from the longitudinal side edges 18, 20 helps to reduce the possibility that the secondary first fastening components 51 may irritate the wearer's skin on the wearer's legs.

It is to be understood, however, that the fastening system can be omitted from the absorbent article 10 without departing from the scope of this disclosure.

Waist Elastic Members:

In an embodiment, the absorbent article 10 can have one or more waist elastic members, such as rear waist elastic member 44, which can be formed of any suitable elastic material. The rear waist elastic member 44 can be in a rear waist region 14 of the absorbent article 10. Suitable elastic materials for waist elastic members can include, but are not limited to, sheets, strands or ribbons of natural rubber, synthetic rubber, or thermoplastic elastomeric polymers. The elastic materials can be stretched and bonded to a substrate, bonded to a gathered substrate, or bonded to a substrate and then elasticized or shrunk, for example, with the application of heat, such that elastic retractive forces are imparted to the substrate. It is to be understood, however, that the waist elastic member can be omitted from the absorbent article 10 without departing from the scope of this disclosure.

Embodiments

Embodiment 1 : An absorbent article including a front waist region including a front waist edge, a rear waist region including a rear waist edge, and a crotch region, the absorbent article further including a longitudinal axis and a lateral axis, the absorbent article comprising: a chassis including an outer surface; and a pocket disposed on the outer surface of the chassis in the front waist region, the pocket including a first side edge, a second side edge opposite from the first side edge, an upper lateral edge, a lower lateral edge, and a bottom surface, the pocket being closed with respect to the chassis at the first side edge, the second side edge, and the upper lateral edge, the pocket being open with respect to the bottom surface at the lower lateral edge, the pocket comprising a first material component and a second material component, the first material component including an uppermost edge, a lowermost edge, and two opposing side edges and the second material component including a top edge, a bottom edge, and two opposing side edges, and the second material component being bonded to the first material component and the chassis to form the upper lateral edge of the pocket.

Embodiment 2: An absorbent article including a front waist region including a front waist edge, a rear waist region including a rear waist edge, and a crotch region, the absorbent article further including a longitudinal axis and a lateral axis, the absorbent article comprising: a chassis including an outer surface; and a pocket disposed on the outer surface of the chassis in the front waist region, the pocket including a first side edge, a second side edge opposite from the first side edge, an upper lateral edge, a lower lateral edge, and a bottom surface, the pocket being closed with respect to the absorbent assembly at the first side edge, the second side edge, and the upper lateral edge, the pocket comprising a first material component and a second material component, the first material component including an uppermost edge, a lowermost edge, and two opposing side edges and the second material component including a top edge, a bottom edge, and two opposing side edges, the second material component being bonded to the first material component and to the outer surface of the chassis such that the lowermost edge of the first material component is closer to the lateral axis than is the bottom edge of the second material component. Embodiment 3: The absorbent article of embodiment 1 or embodiment 2, wherein the chassis further comprises a bodyside liner, an outer cover, and an absorbent body disposed between the bodyside liner and the outer cover, the outer cover including a garment facing surface.

Embodiment 4: The absorbent article of any of the preceding embodiments, wherein the first material component is directly bonded to the outer surface of the chassis near the two opposing side edges of the first material component to form the first side edge and the second side edge of the pocket.

Embodiment 5: The absorbent article of embodiment 2, wherein the second material component is directly bonded to the outer surface of the chassis to form the upper lateral edge of the pocket.

Embodiment 6: The absorbent article of any of the preceding embodiments, wherein the bottom surface of the pocket is formed by the garment facing surface of the outer cover.

Embodiment 7: The absorbent article of any one of the preceding embodiments, further comprising a fastening system, the fastening system including a primary fastening system including at least one primary first fastening component in the rear waist region and at least one primary second fastening component in the front waist region, wherein the second material component forms the at least one primary second fastening component.

Embodiment 8: The absorbent article of embodiment 1 , wherein the first material component and the second material component are bonded to the chassis such that the lowermost edge of the first material component is closer to the lateral axis than is the bottom edge of the second material component.

Embodiment 9: The absorbent article of any of the preceding embodiments, wherein the top edge of the second material component is closer to the front waist edge than is the uppermost edge of the first material component.

Embodiment 10: The absorbent article of embodiment 3, wherein the second material component is directly bonded to the garment facing surface of the outer cover.

Embodiment 1 1 : The absorbent article of any of the preceding embodiments, wherein the second material component is wider than the first material component in a direction parallel to the lateral axis.

Embodiment 12: A method of manufacturing an absorbent article, the absorbent article including a front waist region including a front waist edge, a rear waist region including a rear waist edge, and a crotch region, the absorbent article further including a longitudinal axis, a lateral axis, and a pocket in the front waist region, the method comprising: providing a chassis including an outer surface; providing a continuous web of a first material; cutting the continuous web of the first material to form a first material component; bonding the first material component to the outer surface of the chassis near opposing side edges of the first material component to form a first side edge and a second side edge of the pocket; providing a continuous web of a second material; cutting the continuous web of the second material to form a second material component; bonding a first portion of the second material component to the first material component; and bonding a second portion of the second material component to the outer surface of the chassis, the bonding of the second portion of the second material component to the outer surface of the chassis forming an upper lateral edge of the pocket, the pocket being open with respect to the chassis at a lower lateral edge of the pocket.

Embodiment 13: The method of manufacturing an absorbent article of embodiment 12, further comprising: bonding the first material component to the outer surface of the chassis near opposing side edges of the first material component to form a first side edge and a second side edge of the pocket.

Embodiment 14: The method of manufacturing an absorbent article of embodiment 12 or embodiment 13, wherein the chassis includes an absorbent assembly including a bodyside liner, an outer cover, and an absorbent body disposed between the bodyside liner and the outer cover, the outer cover including a body facing surface and a garment facing surface. Embodiment 15: The method of manufacturing an absorbent article of any of embodiments

12-14, further comprising applying a first adhesive adjacent to longitudinal side edges of the continuous web of the first material prior to cutting the continuous web of the first material to form the first material component, the first adhesive providing the bonding of the first material component to the chassis to form the first side edge and the second side edge of the pocket. Embodiment 16: The method of manufacturing an absorbent article of any one of embodiments 12-15, further comprising applying a second adhesive to a first surface of the continuous web of the second material prior to cutting the continuous web of the second material to form the second material component, the second adhesive providing the bonding of the first portion of the second material component to the first material component and the bonding of the second portion of the second material component to the outer surface of the chassis.

Embodiment 17: The method of manufacturing an absorbent article of embodiment 14, further comprising: bonding the first material component to the outer surface of the chassis near opposing side edges of the first material component to form a first side edge and a second side edge of the pocket; and wherein the first material component and the second portion of the second material component are each directly bonded to the garment facing surface of the outer cover.

Embodiment 18: The method of manufacturing an absorbent article of any one of embodiments 12-17, wherein bonding the first portion of the second material component to the first material component occurs after the first material component is bonded to the outer surface of the chassis.

Embodiment 19: The method of manufacturing an absorbent article of any one of embodiments 12-18, wherein the first material component further includes an uppermost edge and a lowermost edge, wherein the second material component includes a top edge, a bottom edge, and two opposing side edges, and wherein the first material component and the second material component are each bonded to the outer surface of the chassis such that the lowermost edge of the first material component is closer to the lateral axis than is the bottom edge of the second material component.

Embodiment 20: The method of manufacturing an absorbent article of any one of embodiments 12-19, wherein the second material component is wider than the first material component in a direction parallel to the lateral axis.

All documents cited in the Detailed Description are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of the term in a document incorporated by references, the meaning or definition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

WHAT IS CLAIMED IS:

1. An absorbent article including a front waist region including a front waist edge, a rear waist region including a rear waist edge, and a crotch region, the absorbent article further including a longitudinal axis and a lateral axis, the absorbent article comprising:

a chassis including an outer surface; and

a pocket disposed on the outer surface of the chassis in the front waist region, the pocket including a first side edge, a second side edge opposite from the first side edge, an upper lateral edge, a lower lateral edge, and a bottom surface, the pocket being closed with respect to the chassis at the first side edge, the second side edge, and the upper lateral edge, the pocket being open with respect to the bottom surface at the lower lateral edge, the pocket comprising a first material component and a second material component, the first material component including an uppermost edge, a lowermost edge, and two opposing side edges and the second material component including a top edge, a bottom edge, and two opposing side edges, and the second material component being bonded to the first material component and the chassis to form the upper lateral edge of the pocket.

2. An absorbent article including a front waist region including a front waist edge, a rear waist region including a rear waist edge, and a crotch region, the absorbent article further including a longitudinal axis and a lateral axis, the absorbent article comprising:

a chassis including an outer surface; and

a pocket disposed on the outer surface of the chassis in the front waist region, the pocket including a first side edge, a second side edge opposite from the first side edge, an upper lateral edge, a lower lateral edge, and a bottom surface, the pocket being closed with respect to the absorbent assembly at the first side edge, the second side edge, and the upper lateral edge, the pocket comprising a first material component and a second material component, the first material component including an uppermost edge, a lowermost edge, and two opposing side edges and the second material component including a top edge, a bottom edge, and two opposing side edges, the second material component being bonded to the first material component and to the outer surface of the chassis such that the lowermost edge of the first material component is closer to the lateral axis than is the bottom edge of the second material component.

3. The absorbent article of claim 1 or claim 2, wherein the chassis further comprises a bodyside liner, an outer cover, and an absorbent body disposed between the bodyside liner and the outer cover, the outer cover including a garment facing surface.

4. The absorbent article of any one of the preceding claims, wherein the first material component is directly bonded to the outer surface of the chassis near the two opposing side edges of the first material component to form the first side edge and the second side edge of the pocket.

5. The absorbent article of claim 2, wherein the second material component is directly bonded to the outer surface of the chassis to form the upper lateral edge of the pocket.

6. The absorbent article of claim 3, wherein the bottom surface of the pocket is formed by the garment facing surface of the outer cover.

7. The absorbent article of claim 1 or claim 2, further comprising a fastening system, the

fastening system including a primary fastening system including at least one primary first fastening component in the rear waist region and at least one primary second fastening component in the front waist region, wherein the second material component forms the at least one primary second fastening component.

8. The absorbent article of claim 1 , wherein the first material component and the second material component are bonded to the chassis such that the lowermost edge of the first material component is closer to the lateral axis than is the bottom edge of the second material component.

9. The absorbent article of claim 1 or claim 2, wherein the top edge of the second material component is closer to the front waist edge than is the uppermost edge of the first material component.

10. The absorbent article of claim 3, wherein the second material component is directly bonded to the garment facing surface of the outer cover.

11. The absorbent article of claim 1 or claim 2, wherein the second material component is wider than the first material component in a direction parallel to the lateral axis.

12. A method of manufacturing an absorbent article, the absorbent article including a front waist region including a front waist edge, a rear waist region including a rear waist edge, and a crotch region, the absorbent article further including a longitudinal axis, a lateral axis, and a pocket in the front waist region, the method comprising:

providing a chassis including an outer surface;

providing a continuous web of a first material;

cutting the continuous web of the first material to form a first material component; bonding the first material component to the outer surface of the chassis near opposing side edges of the first material component to form a first side edge and a second side edge of the pocket;

providing a continuous web of a second material;

cutting the continuous web of the second material to form a second material component;

bonding a first portion of the second material component to the first material component; and

bonding a second portion of the second material component to the outer surface of the chassis, the bonding of the second portion of the second material component to the outer surface of the chassis forming an upper lateral edge of the pocket, the pocket being open with respect to the chassis at a lower lateral edge of the pocket.

13. The method of manufacturing an absorbent article of claim 12, further comprising:

bonding the first material component to the outer surface of the chassis near opposing side edges of the first material component to form a first side edge and a second side edge of the pocket.

14. The method of manufacturing an absorbent article of claim 12, wherein the chassis includes an absorbent assembly including a bodyside liner, an outer cover, and an absorbent body disposed between the bodyside liner and the outer cover, the outer cover including a body facing surface and a garment facing surface.

15. The method of manufacturing an absorbent article of claim 13, further comprising applying a first adhesive adjacent to longitudinal side edges of the continuous web of the first material prior to cutting the continuous web of the first material to form the first material component, wherein the first adhesive provides the bonding of the first material component to the chassis to form the first side edge and the second side edge of the pocket.

16. The method of manufacturing an absorbent article of any claim 12 or 13, further comprising applying a second adhesive to a first surface of the continuous web of the second material prior to cutting the continuous web of the second material to form the second material component, wherein the second adhesive provides the bonding of the first portion of the second material component to the first material component and the bonding of the second portion of the second material component to the outer surface of the chassis.

17. The method of manufacturing an absorbent article of claim 14, further comprising:

bonding the first material component to the outer surface of the chassis near opposing side edges of the first material component to form a first side edge and a second side edge of the pocket; and wherein the first material component and the second portion of the second material component are each directly bonded to the garment facing surface of the outer cover.

18. The method of manufacturing an absorbent article of claim 13, wherein bonding the first portion of the second material component to the first material component occurs after the first material component is bonded to the outer surface of the chassis.

19. The method of manufacturing an absorbent article of any one of claims 12-15, 17, or 18, wherein the first material component further includes an uppermost edge and a lowermost edge, wherein the second material component includes a top edge, a bottom edge, and two opposing side edges, and wherein the first material component and the second material component are each bonded to the outer surface of the chassis such that the lowermost edge of the first material component is closer to the lateral axis than is the bottom edge of the second material component.

20. The method of manufacturing an absorbent article of any one of claims 12-15, 17, or 18, wherein the second material component is wider than the first material component in a direction parallel to the lateral axis.