WO2022094546A1

WO2022094546A1 - Absorbent article with waist containment pouch & method of manufacturing thereof

Info

Publication number: WO2022094546A1
Application number: PCT/US2021/072027
Authority: WO
Inventors: Andrew W. BEILFUSS; Sean P. Follen
Original assignee: Curt G. Joa, Inc.
Priority date: 2020-10-29
Filing date: 2021-10-26
Publication date: 2022-05-05

Abstract

An absorbent article having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections is disclosed. The absorbent article includes a topsheet and a containment pouch positioned over the topsheet in one or more of the front waist section and the rear waist section. The containment pouch and the topsheet form a pocket therebetween having an opening oriented toward the crotch section. The containment pouch includes one or more web layers bonded to the topsheet and one or more elastic members secured to the one or more web layers to provide elastic tension in the containment pouch. The one or more elastic members are oriented generally in a longitudinal direction that is perpendicular to the opening of the containment pouch pocket.

Description

ABSORBENT ARTICLE WITH WAIST CONTAINMENT POUCH & METHOD OF MANUFACTURING THEREOF

BACKGROUND OF THE INVENTION

[0001] Embodiments of the invention relate generally to absorbent sanitary products and, more particularly, to an improved method for manufacturing an absorbent sanitary product that includes an elastic waist pouch. The elastic waist pouch includes elastic strands therein oriented generally perpendicular to an opening of the pouch, with the elastic strands being applied in a machine direction during manufacturing of the absorbent sanitary product.

[0002] Absorbent sanitary products, such as disposable diapers, are typically equipped with elastic composite structures that include one or more elastic threads. These elastic composite structures are positioned at various locations throughout the product, including in the waistbands, leg cuff regions, and throughout all or portions of the front or back panels of the product. One elastic composite structure found in some disposable diapers is an elasticized containment or barrier flap at the back waist section (and possibly the front waist section) of the article, i.e., a containment pouch, to contain body exudates and reduce leaks. Conventionally, the containment pouch at the waist section(s) of an absorbent article includes elastic strands oriented in a lateral direction that function to provide elongation and flexibility in the containment pouch, so as to enable the containment pouch to come into proper contact with the intended wearer and prevent leaks.

[0003] While containment pouches with laterally oriented elastic strands are generally effective in containing body exudates and reducing leaks, it is recognized that the application of the elastic strands in a lateral orientation, i.e., in a cross-machine direction, during fabrication of the disposable diaper can introduce limitations into the manufacturing process. For example, the cross-machine direction application of the elastic strands requires use of a drum with a very large diameter to minimize the product web deflection (onto which the elastic is applied) to conform to the drum. As another example, the cross-machine direction tension resulting from the lateral orientation of the elastic strands realistically limits the application of the containment pouch onto the main product chassis to a time after the product is fully constructed, as the wings or ears of an adult brief absorbent article, for example, cannot cover the application area of a topsheet until after the containment pouch has been applied. Most importantly, the cross-machine direction application of the elastic strands limits the speed capability of the manufacturing process, as such cross-machine or lateral application/ orientation necessitates a subsequent 90° direction of a cut containment pouch (web and elastics) before application onto a main web. This rotation process inherently limits the speed capability of the manufacturing process.

[0004] Accordingly, there is a need for an improved system and method for fabricating a disposable diaper that includes a containment pouch. The improved system and method would provide for an increased speed in the manufacturing process, while producing a product where the containment pouch is effective in containing body exudates and reducing leaks.

BRIEF DESCRIPTION OF THE INVENTION

[0005] In accordance with one aspect of the invention, an absorbent article having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections is disclosed. The absorbent article includes a topsheet and a containment pouch positioned over the topsheet in one or more of the front waist section and the rear waist section. The containment pouch and the topsheet form a pocket therebetween having an opening oriented toward the crotch section. The containment pouch includes one or more web layers bonded to the topsheet and one or more elastic members secured to the one or more web layers to provide elastic tension in the containment pouch. The one or more elastic members are oriented generally in a longitudinal direction that is perpendicular to the opening of the containment pouch pocket.

[0006] In accordance with another aspect of the invention, a method of manufacturing an absorbent article includes providing one or more continuous pouch web layers running in a machine direction, applying one or more elastic members to the one or more continuous pouch web layers such that the one or more elastic members are oriented generally in the machine direction, and cutting the one or more continuous pouch web layers with the one or more elastic members applied thereto into discrete containment pouches. The method also includes bonding the discrete containment pouches to a running topsheet web and cutting the running topsheet web to form a plurality of absorbent articles each having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections. The step of bonding the discrete containment pouches to the running topsheet web includes bonding a containment pouch to at least one of the front waist section and the rear waist section of a respective absorbent article, with the containment pouch and the topsheet forming a pocket therebetween having an opening oriented toward the crotch section.

[0007] In accordance with yet another aspect of the invention, a machine for manufacturing an absorbent article includes a means for applying one or more elastic members to one or more continuous pouch web layers such that the one or more elastic members are oriented generally in a machine direction. The machine also includes a means for cutting the one or more continuous pouch web layers with the one or more elastic members applied thereto into discrete containment pouches, a means for bonding the discrete containment pouches to a running topsheet web, and a means for cutting the running topsheet web to form a plurality of absorbent articles each having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections. The means for bonding the discrete containment pouches to the running topsheet web is configured to bond a containment pouch to at least one of the front waist section and the rear waist section of a respective absorbent article such that the containment pouch and the topsheet form a pocket therebetween having an opening oriented toward the crotch section.

[0008] In accordance with yet another aspect of the invention, a machine for manufacturing an absorbent article includes a web roll unit configured to provide one or more continuous pouch web layers moving in a machine direction, an elastic feed mechanism configured to apply one or more elastic members to the one or more continuous pouch web layers such that the one or more elastic members are oriented generally in the machine direction, a first cutting unit configured to cut the one or more continuous pouch web layers with the one or more elastic members applied thereto into discrete containment pouches, a bonding unit configured to bond the discrete containment pouches to a running topsheet web, and a second cutting unit configured to cut the running topsheet web, with the discrete containment pouches bonded thereon, to form a plurality of absorbent articles each having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections. The bonding unit is configured to bond a respective containment pouch to at least one of the front waist section and the rear waist section of a respective absorbent article along a back edge and side edges of the containment pouch, such that the containment pouch and the topsheet form a pocket therebetween having an opening oriented toward the crotch section.

[0009] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The drawings illustrate embodiments presently contemplated for carrying out the invention.

[0011] In the drawings:

[0012] FIG. 1 is a plan view of a disposable diaper according to one embodiment of the invention.

[0013] FIG. 2 illustrates a system and associated process for forming the disposable diaper of FIG. 1 according to one embodiment of the invention.

[0014] FIG. 3 is a plan view of a web layer having elastics applied in the machine direction, as produced by the system of FIG. 2.

[0015] FIG. 4 is a plan view of a continuous string of disposable diapers produced by the system of FIG. 2 prior to separation into individual disposable diapers.

[0016] FIG. 5 is a plan view of a disposable diaper according to one embodiment of the invention.

[0017] FIG. 6 illustrates a system for forming the disposable diaper of FIG. 5 according to one embodiment of the invention.

[0018] FIG. 7 is a plan view of a web layer having elastics applied in a sinusoidal pattern, which are singulated into discrete rear containment pouches, according to an embodiment of the invention.

[0019] FIGS. 8A, 8B, and 8C are plan views of a continuous string of disposable diapers prior to separation into individual disposable diapers, showing alternate elastic strand orientations resulting from application of the elastics in a sinusoidal pattern, according to an embodiment of the invention.

[0020] FIG. 9 is a plan view of a web layer having elastics applied in a sinusoidal pattern, which are singulated into discrete front and rear containment pouches, according to an embodiment of the invention. [0021] FIGS. 10A and 10B are plan views of a continuous string of disposable diapers prior to separation into individual disposable diapers, showing alternate elastic strand orientations and both front and back containment pouches in the diaper, according to an embodiment of the invention.

DETAILED DESCRIPTION

[0022] Embodiments of the present invention provide for a system and method for fabricating an absorbent article that includes a waist containment pouch. The waist containment pouch includes elastic strands therein oriented generally perpendicular to an opening of the pouch, with the elastic strands being applied in a machine direction during manufacturing of the absorbent article.

[0023] FIG. 1 is a plan view of a disposable diaper 10 according to an exemplary embodiment. The disposable diaper 10 includes a front waistline region 12, a crotch region 14, and a rear waistline region 16. The front waistline region 12 is a portion coming into contact with a front waistline region (belly portion) of a wearer. The rear waistline region 16 is a portion coming into contact with the rear waistline region (back portion) of the wearer. The crotch region 14 is located between the front waistline region 12 and the rear waistline region 16. In the embodiment shown, a direction from the front waistline region 12 toward the rear waistline region 16 is referred to as a longitudinal direction, and a direction orthogonal to the longitudinal direction is referred to as a width direction.

[0024] The disposable diaper 10 includes an absorbent core 18. The absorbent core 18 lies across the crotch region 14 and extends toward at least one of the front waistline region 12 and the rear waistline region 16. The illustrated absorbent core 18 is disposed across the front waistline region 12, the crotch region 14, and the rear waistline region 16.

[0025] A liquid-permeable topsheet 20 is provided and constitutes a skin-facing side of the disposable diaper 10 and thus comes into contact with the wearer. The topsheet 20 is disposed across the front waistline region 12, the crotch region 14, and the rear waistline region 16. The topsheet 20 has fibers and may be formed of a non-woven fabric. A liquid-impermeable backsheet (not shown) is provided on a non-skin-facing side of the disposable diaper 10 opposite the topsheet 20 and is also generally disposed across the front waistline region 12, the crotch region 14, and the rear waistline region 16. The backsheet has fibers and may be formed of a non-woven fabric.

[0026] A pair of cuffs 22 are joined onto the topsheet 20 and disposed at least in part along widthwise outer sides of the disposable diaper 10. The cuffs 22 are aligned substantially symmetrically with respect to an axis of symmetry extending along the widthwise center of the disposable diaper 10. While not shown in FIG. 1, it is recognized that cuffs 22 may be formed from side sheets and elastics, with the side sheets joined to the topsheet 20 and the elastics provided on a portion of each side sheet to form an elasticized cuff portion that provides a three-dimensional gather capable of rising toward the wearer. The cuffs 22 thus form walls rising toward the skin-facing side along outer edges of the absorbent core 18 to prevent exudate from leaking sideward. Cuffs 22 may be omitted in alternate embodiments.

[0027] A pair of back ear panels 24 extend outward of the cuffs 22 in the width direction W in the rear waistline region 16. In the illustrated embodiment, the back ear panels 24 are a composite assembly comprising a stretch laminate material 24A flanked by strips of nonwoven material 24B. Back ear panels 24 may be formed from a single material (e.g., a nonwoven) or a combination of other types of materials in alternate embodiments. A pair of fasteners 26 are provided on the back ear panels 24 in the rear waistline region 16 that are fastenable to the front ears 28 in the front waistline region 12. The fasteners 26 are provided with, for example, an engagement hook, and serve to hold the disposable diaper 10 to the wearer's body by being fastened to front ears 28 in the front waistline region 12, with target portions (not shown) on the front ears 28 catching the engagement hooks of the fasteners 26 and functioning as loops of a hook-and-loop engagement system.

[0028] The disposable diaper 10 also includes a containment pouch (waist pouch) 30 adjacent to a back edge of the disposable diaper 10, in the rear waistline region 16. The containment pouch 30 may be positioned such that it is aligned with the back edge of the diaper 10 or offset inward from the back edge of the diaper 10 in alternative embodiments. The containment pouch 30 creates a pocket between an open or free edge 32 of the containment pouch and the topsheet 20 in the rear waistline region 16 of the diaper 10 for containing body exudates and, in particular, runny fecal material. The containment pouch 30 may be formed from a layer or combination of separate layers 34 which are attached to the topsheet 20 using conventional attachment mechanisms, such as adhesive or ultrasonic or thermal bonds for example. This layer or layers 34 from which the containment pouch 30 is formed may be composed of liquid permeable or liquid impermeable materials.

[0029] In the illustrated embodiment, the at least one layer 34 of the containment pouch 30 includes an attached back edge 36 and attached side edges 38 in the rear waistline region 16 of the diaper 10 formed using adhesive bonds 39, for example. The containment pouch 30 also includes a free edge 32 which extends inwardly towards the crotch region 14 of the diaper 10. The free edge 32 of the containment pouch 30 is configured to remain in a spaced apart relation from the topsheet 20 of the diaper 10 when in use to provide a pocket having an opening for receiving and containing body exudates.

[0030] As shown in FIG. 1, the containment pouch 30 generally defines a central zone 40 that is flanked by a pair of laterally opposed side zones 42, 44 that generally extend to side edges of the diaper 10. In use, the central zone 40 is generally configured to be located on the back of the wearer while the side zones 42, 44 are generally configured to be located on the side hip/buttock regions of the wearer. The side zones 42, 44 of the containment pouch 30 are configured as stretchable portions that exert a force on the outer back hip/buttock regions of the wearer to provide a close-to-the body fit. The elasticity of the side zones 42, 44 also assist in maintaining the free edge 32 of the containment pouch 30 in a spaced apart relation from the topsheet 20 of the diaper 10.

[0031] In order to provide elasticity in the side zones 42, 44, the containment pouch 30 includes one or more elastic members 46 located in the side zones 42, 44. According to the embodiment of FIG. 1, an elastic strand 46 is provided in each of side zones 42, 44 and is oriented in a longitudinal direction 48 that is perpendicular to the free edge 32 and opening of the containment pouch 30. The elastic strands 46 provide elastic tension in the longitudinal direction 48 that is parallel to the attached side edges 38 of the containment pouch 30 and enable side zones 42, 44 to be more elastic or stretchable to provide a more optimum fit and seal about the back region of the wearer. According to alternative embodiments, elastic members 46 may be composed of any suitable elastic material including, for example, sheets, strands or ribbons of thermoplastic elastomers, natural or synthetic rubber, or LYCRA, as nonlimiting examples, but elastic members 46 are hereafter referred to generally as “elastic strands 46.”

[0032] Referring now to FIG. 2, and with continued reference to FIG. 1, an exemplary manufacturing line 50 for producing the disposable diaper 10 of FIG. 1 is illustrated according to an embodiment of the invention. For forming the containment pouch 30 (FIG. 1), a web pouch layer 34 (here after “pouch web 34”) is provided from a material source, such as web roll 51, in a machine direction 52. The pouch web 34 may be provided as a single web or as two separate webs of equal size, according to embodiments. When provided as a single web, as illustrated in FIG. 2, the pouch web 34 is provided to a web slitter 54 that cuts the web into two separate webs that are separated into two divergent web streams 56, 58. Elastic strands 46 are fed from a feed mechanism 59 in the machine direction 52 onto the pouch web 34 on one of the web streams 56, 58, with the elastic strands 46 secured to the pouch web 34 via an adhesive 60 sprayed onto the web of web stream 56 prior to application of the elastic strands 46. Alternatively, it is recognized that the elastic strands 46 could be held in place by utilizing ultrasonic bonds (after the elastic strands 46 are sandwiched between the pouch web 34 of the two web streams 56, 58). In an exemplary embodiment, a pair of elastic strands 46 is provided and applied so as to be arranged at generally opposing sides of the pouch web 34, although it is recognized that a greater number of elastic strands 46 could also be provided, with the greater number of elastic strands 46 again being applied so as to be arranged at generally opposing sides of the pouch web 34. Upon application and adhesion of the elastic strands 46, the pouch web 34 in the two web streams 56, 58 are joined together, such as via the use of one or more rollers and/or bonding devices, whereby the elastic strands 46 are contained between two layers of pouch web 34. A continuous containment pouch web with elastic strands oriented in the machine direction - indicated at 62 and referred to here after as “elasticized continuous pouch web 62” - is thus formed.

[0033] While not shown in FIG. 2, it is recognized that rather than having the elastic strands 46 secured between two distinct layers of pouch web 34 (whether provided via a slit single pouch web or two initial separate pouch webs), that a single layer of pouch web 34 may instead be folded over to secure the elastic strands 46 therebetween. In such an embodiment, the elastic strands 46 could either be applied onto one half of the pouch web 34, with the pouch web subsequently being folded over onto itself to contain the elastic strands 46 therebetween, or applied onto a central region of the pouch web 34, with both sides folded to form a C-fold configuration.

[0034] The elasticized continuous pouch web 62 is then fed to a cutting unit, such as a slip- and-cut applicator 64, that cuts the continuous pouch web into discrete containment pouch pieces 30 and applies the discrete containment pouch pieces 30 onto a running web - which may be in the form of a composite web 65 formed from topsheet 20 and cuffs 22 (as described hereafter) or just the topsheet 20 (with the cuffs 22 added after application of the containment pouch 30 to topsheet 20). The slip-and-cut applicator 64 may be comprised of a cylindrical rotating vacuum anvil 66 and a rotating knife roll 68. The incoming elasticized continuous pouch web 62 is fed at a relatively low speed along the vacuum face of the rotating anvil 66, which is moving at a relatively higher surface speed and upon which the incoming elasticized continuous pouch web 62 is allowed to “slip”. A knife-edge, mounted on the rotating knife roll 68, cuts off a segment of the elasticized continuous pouch web 62 against the anvil face. This knife-edge is preferably moving at a surface velocity similar to that of the surface of the anvil 66. Once cut, the web segment (i. e. , a discrete containment pouch piece 30) is held by vacuum drawn through holes on face of the anvil 66 as it is carried at the anvil's speed downstream to a transfer point 70 where the containment pouch 30 is transferred to the running composite web 65 - with the composite web 65 formed upstream (in machine direction 52) via bonding of cuffs 22 to topsheet 20.

[0035] In transferring the containment pouch 30 to the composite web 65, the containment pouch 30 is secured to the composite web 65 via a bonding unit that, in one embodiment, may be an adhesive applicator 72 that applies an adhesive. The adhesive applied via the adhesive applicator 72 may be applied to composite web 65 upstream from the transfer point 70, with the adhesive being applied in a U-shaped pattern that results in the back edge 36 and side edges 38 of the containment pouch 30 being secured to the composite web 65 via adhesive bonds, while allowing free edge 32 to remain unattached and thereby provide an opening into the pocket of containment pouch 30. In an alternative embodiment, the containment pouch 30 is secured to the composite web 65 with a mechanical, thermal, or ultrasonic bonding unit that may be positioned downstream from the slip-and-cut applicator 64 or integrated therewith.

[0036] Upon securing of the containment pouch 30 to composite web 65, additional processing steps are performed as illustrated in FIG. 2, including the addition of cuffs 22 (if not previously provided on the topsheet 20 as part of the composite web 65), the addition of back ear panels 24 and ears 28, the folding of ear panels 24 and ears 28 via folding device(s) 73 (e.g. plow folding device(s) or folding board(s)), the addition of leg elastics 74, absorbent core 18, and a backsheet and waistband 76, and a final cutting of the formed assembly (via a cutting or knife unit 77, for example) into discrete diapers 10 that may be subsequently folded and packaged (as indicated at 78 and 79, respectively). The performing of these additional processing steps may be done in a known manner to provide the finished diapers 10.

[0037] In the embodiment described above, containment pouch 30 is a single layer structure that creates a pocket when joined to the continuous topsheet. In an alternative embodiment not shown in FIG. 2, the elasticized continuous pouch web 62 may be joined to a continuous web prior to entering the slip-and-cut applicator 64. The web layers are joined together with a bonding or adhesive pattern (e.g., U-shaped) that creates a pocket when the two-layer continuous composite structure is cut into discrete containment pouches 30 by the slip-and-cut applicator 64. These discrete containment pouches 30 are then secured to the composite web 65 by bonding the outward facing surface of the continuous web to the upward-facing surface of the composite web 65.

[0038] FIGS. 3 and 4 more clearly illustrate the elasticized continuous pouch web 62 (FIG. 3) and the construction of diaper 10 (FIG. 4) upon application of a discrete containment pouch 30 to composite web 65 (prior to folding of ears/ extension panels). As can be seen in FIG. 3 especially, elastic strands 46 are oriented in the machine direction 52 of the continuous pouch web 34, so as to allow for increased speeds in laying down the elastic strands 46 on the pouch web 34 during manufacturing, and provide ease in cutting discrete containment pouch pieces 30 from the elasticized continuous pouch web 62 and application of the discrete pouch pieces 30 to the composite web 65. As previously indicated, the composite web 65 may be formed of both the topsheet 20 and cuffs 22 and, in this embodiment, the discrete containment pouch 30 would be positioned over/above the cuffs 22 when applied to the composite web 65. In this arrangement, the cuffs 22 may aid in maintaining the containment pouch 30 in a more open position to better allow the containment pouch 30 to receive body exudates from a wearer. However, in another embodiment where the composite web 65 is formed of only the topsheet 20 (with cuffs 22 being added after application of the containment pouch 30, as shown in phantom in FIG. 2), the discrete containment pouch 30 would be positioned under/beneath the cuffs 22.

[0039] Referring now to FIG. 5, a plan view of a disposable diaper 80 is provided according to another embodiment. The disposable diaper 80 is substantially similar to the disposable diaper 10 of FIG. 1 and thus like components are numbered the same as in FIG. 1 - with the diaper 80 including a front waistline region 12, a crotch region 14, a rear waistline region 16, an absorbent core 18, a liquid-permeable topsheet 20, cuffs 22, and front ears 28.

[0040] The diaper 80 differs from the diaper 10 of FIG. 1 in that a containment pouch is included as part of a larger rear waist assembly 82 that is assembled separately during manufacturing, prior to being applied onto topsheet 20. The rear waist assembly 82 includes a liquid impervious central web 84 and back ear extension panels 86 (with fasteners 88) attached thereto, with the back ear extension panels 86 extending outwardly from the web 84 in the width direction W in the rear waistline region 16. The web 84, alone or in combination with another web patch 99, forms a containment pouch (waist pouch) 90 when the rear waist assembly 82 is secured to topsheet 20. The containment pouch 90 includes an attached back edge 36 and attached side edges 38 in the rear waistline region 16 of the diaper 10 formed using adhesive bonds 91, for example, with an open or free edge 32 left in the containment pouch to provide a pocket in the containment pouch for containing body exudates.

[0041] Similar to the containment pouch of diaper 10 (FIG. 1), containment pouch 90 generally defines a central zone 40 that is flanked by a pair of laterally opposed side zones 42, 44 that generally extend to side edges of the diaper 80. The side zones 42, 44 of the containment pouch 90 include elastic strands 46 oriented in a longitudinal direction 48 that is perpendicular to the free edge 32 and an opening of the containment pouch 90, in order to configure the side zones 42, 44 as stretchable portions that exert a force on the outer back hip/buttock regions of the wearer to provide a close-to-the body fit. The elasticity of the side zones 42, 44 also assist in maintaining the free edge 32 of the containment pouch 90 in a spaced apart relation from the topsheet 20 of the diaper 80.

[0042] Referring now to FIG. 6, an exemplary manufacturing line 92 for producing the disposable diaper 80 of FIG. 5 is illustrated according to an embodiment of the invention. For forming the rear waist assembly 82 (FIG. 5), a central web 84 and stretch web 94 are provided in a machine direction 52. The central web 84 and stretch web 94 are each provided to a slitter 96 that cuts the respective webs into separate web strips. The strips of webs 84, 94 are subsequently bonded back together via a bonder 97 that may adhesively, ultrasonically, or mechanically bond the strips together in a desired arrangement to output a composite ear structure 98 where back ear extension panels 86 (FIG. 5) extend outwardly from the central web 84 (FIG. 5).

[0043] As shown in FIG. 6, elastic strands 46 are fed in the machine direction 52 onto composite ear structure 98, with the elastic strands 46 secured to the composite ear structure 98 via an adhesive 60 sprayed onto the composite ear structure 98 prior to application of the elastic strands 46. In an exemplary embodiment, a pair of elastic strands 46 is provided, although it is recognized that a single elastic strand 46 or a greater number of elastic strands 46 could also be provided in alternate embodiments.

[0044] According to an exemplary embodiment, a patch 99 (FIG. 5) is applied onto the composite ear structure 98 in order to cover the elastic strands 46 and contain the members between the patch 99 and central web 84, with an adhesive 61 securing the patch 99 to central web 84. A continuous web of patch material 100 is provided and fed through a slip-and-cut applicator 102 that cuts the continuous web into discrete patches and applies the discrete patches 99 onto central web 84 of composite ear structure 98. A completed rear waist assembly 82 is assembled upon application of the patch 99 (FIG. 5), although the rear waist assembly 82 is a continuous material structure that requires cutting/separation to form discrete rear waist assemblies 82. The patch 99 and any web structures referred to herein may include nonwoven materials, woven materials, films, foams, and/or composites or laminates of any of these material types.

[0045] While manufacturing line 92 is shown and described in FIG. 6 as applying a patch 99 to web 84 to contain elastic strands 46 therebetween, an alternative embodiment is envisioned where creases are formed in central web 84 to accommodate positioning/retaining of elastic strands 46 therein. In such an embodiment, small folds would be formed in the central web 84 to create these creases, with the elastic strands 46 then laid down in the creases and generally held in place thereby. Inclusion of creases in the central web 84 negates the need for application of a separate patch 99 to web 84. In yet another alternative embodiment, the elastic strands 46 are omitted and the central web 84 is a material that has a memory. In such an embodiment, one or more creases are formed in the central web 84 that cause the central web 84 to separate away from the topsheet 20 when the diaper 80 is worn by a user. A similar material with memory can be used in place of the web and elastic strand composite described with respect to the diaper 10 of FIG. 1.

[0046] Referring again to FIG. 6, subsequent to the application of patch 99 onto central web 84, the sides of the back ear extension panels 86 are folded inward by a folding device 101. The folded continuous structure/chain of rear waist assemblies 82 is provided and fed through a slip-and-cut applicator 64 (including cylindrical rotating vacuum anvil 66 and a rotating knife roll 68) that cuts the continuous structure into discrete rear waist assemblies 82. Once cut, the discrete rear waist assemblies 82 are held by vacuum drawn through holes on the anvil 66 as it is carried at the anvil's speed downstream to a transfer point 70 where the rear waist assemblies 82 are transferred to the running composite web 65 - with the composite web 65 formed upstream (in machine direction 52) via bonding of cuffs 22 to topsheet 20.

[0047] In transferring a rear waist assembly 82 to the composite web 65, the rear waist assembly 82 is secured to the composite web 65 via an adhesive 72, for example. The adhesive 72 may be applied to composite web 65 upstream from the transfer point 70, with the adhesive 72 being applied in a U-shaped pattern (corresponding to back edge 36 and side edges 38 shown in FIG. 5) that results in formation of the containment pouch 90 (FIG. 5) when the rear waist assembly 82 is combined with the composite web 65.

[0048] Upon securing of the rear waist assembly 82 to composite web 65, additional processing steps are performed as illustrated in FIG. 6, including the addition of front ears 28, the folding of front ears 28 via folding device(s) 73 (e.g. plow folding device(s) or folding board(s)), the addition of leg elastics 74, absorbent core 18, and a backsheet and waistband 76, and a final cutting of the formed assembly (via a cutting or knife unit 77, for example) into discrete diapers 80 (FIG. 5) that may be subsequently folded and packaged (as indicated at 78 and 79, respectively). The performing of these additional processing steps may be done in a known manner to provide the finished diapers 80 (FIG. 5).

[0049] While the disposable diapers 10, 80 shown and described in FIGS. 1 and 5 include a containment pouch 30, 90 having linear elastic strands 46 oriented in a longitudinal direction (and applied in a machine direction during manufacturing), an alternative embodiment is envisioned where elastic strands are oriented/applied in a sinusoidal pattern. As shown in FIG. 7 and FIGS. 8A-8C, side zones 42, 44 of a containment pouch 104 include elastic strands 106 that generally extend in a longitudinal/machine direction 108, but that are applied onto pouch web 34 in a sinusoidal pattern. The sinusoidal pattern of elastic strands 106 results in elastic tension being provided in both lateral and longitudinal directions and enables side zones 42, 44 to be more elastic or stretchable and provide an optimum fit and seal about the back region of the wearer. As can be seen in FIGS. 8A-8C, the exact orientation of the elastic strands 106 may vary in each diaper 110 of a string of diapers that are produced by a manufacturing line 50, 92 (FIGS. 2 and 6), because the cutting/formation of each discrete containment pouch 104 (or rear waist assembly) results in the cutting of the sinusoidally applied elastic strands 106 at different points. It is contemplated that elastic strands 106 may be applied to the pouch web 34 in alternative patterns or geometrical configurations, including zigzag and sawtooth patterns as nonlimiting examples.

[0050] As illustrated in FIGS. 9 and 10A and 10B, disposable diapers 112 according to another embodiment may include both front and rear containment pouches 104, rather than just a rear containment pouch 30, 90 as shown in FIGS. 1 and 5. Front and rear containment pouches 104 may be aligned with the front and back edges, respectively, of the diapers 112, or offset inward toward the center of the diapers 112 in alternative embodiments. Each of front and rear containment pouches 104 includes elastic strands 106 generally extending in a longitudinal/machine direction 108, but that are applied onto pouch web 34 in a sinusoidal pattern. The front and rear containment pouches 104 may be formed and placed onto topsheet 20 (or composite web 65) via a slip-and-cut applicator such as shown and described in FIG. 2 - with the slip-and-cut applicator being selectively controlled to provide for transfer of the front and rear containment pouches 104 to the running topsheet 20 (or composite web 65) of FIG. 2 at desired locations. Front and/or rear containment pouches 104 may include straight elastic strands similar to those shown in FIG. 1 according to another embodiment. Diapers 112 may only include front containment pouches 104 according to yet other embodiments.

[0051] Therefore, according to one embodiment of the invention, an absorbent article having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections is disclosed. The absorbent article includes a topsheet and a containment pouch positioned over the topsheet in one or more of the front waist section and the rear waist section. The containment pouch and the topsheet form a pocket therebetween having an opening oriented toward the crotch section. The containment pouch includes one or more web layers bonded to the topsheet and one or more elastic members secured to the one or more web layers to provide elastic tension in the containment pouch. The one or more elastic members are oriented generally in a longitudinal direction that is perpendicular to the opening of the containment pouch pocket.

[0052] In accordance with another embodiment of the invention, a method of manufacturing an absorbent article includes providing one or more continuous pouch web layers running in a machine direction, applying one or more elastic members to the one or more continuous pouch web layers such that the one or more elastic members are oriented generally in the machine direction, and cutting the one or more continuous pouch web layers with the one or more elastic members applied thereto into discrete containment pouches. The method also includes bonding the discrete containment pouches to a running topsheet web and cutting the running topsheet web to form a plurality of absorbent articles each having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections. The step of bonding the discrete containment pouches to the running topsheet web includes bonding a containment pouch to at least one of the front waist section and the rear waist section of a respective absorbent article, with the containment pouch and the topsheet forming a pocket therebetween having an opening oriented toward the crotch section.

[0053] In accordance with yet another embodiment of the invention, a machine for manufacturing an absorbent article includes a means for applying one or more elastic members to one or more continuous pouch web layers such that the one or more elastic members are oriented generally in a machine direction. The machine also includes a means for cutting the one or more continuous pouch web layers with the one or more elastic members applied thereto into discrete containment pouches, a means for bonding the discrete containment pouches to a running topsheet web, and a means for cutting the running topsheet web to form a plurality of absorbent articles each having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections. The means for bonding the discrete containment pouches to the running topsheet web is configured to bond a containment pouch to at least one of the front waist section and the rear waist section of a respective absorbent article such that the containment pouch and the topsheet form a pocket therebetween having an opening oriented toward the crotch section.

[0054] In accordance with yet another embodiment of the invention, a machine for manufacturing an absorbent article includes a web roll unit configured to provide one or more continuous pouch web layers moving in a machine direction, an elastic feed mechanism configured to apply one or more elastic members to the one or more continuous pouch web layers such that the one or more elastic members are oriented generally in the machine direction, a first cutting unit configured to cut the one or more continuous pouch web layers with the one or more elastic members applied thereto into discrete containment pouches, a bonding unit configured to bond the discrete containment pouches to a running topsheet web, and a second cutting unit configured to cut the running topsheet web, with the discrete containment pouches bonded thereon, to form a plurality of absorbent articles each having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections. The bonding unit is configured to bond a respective containment pouch to at least one of the front waist section and the rear waist section of a respective absorbent article along a back edge and side edges of the containment pouch, such that the containment pouch and the topsheet form a pocket therebetween having an opening oriented toward the crotch section.

[0055] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description but is only limited by the scope of the appended claims.

Claims

CLAIMS What is claimed is:

1. An absorbent article having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections, the absorbent article comprising: a topsheet; and a containment pouch positioned over the topsheet in one or more of the front waist section and the rear waist section, the containment pouch and the topsheet forming a pocket therebetween having an opening oriented toward the crotch section; wherein the containment pouch comprises: one or more web layers bonded to the topsheet; and one or more elastic members secured to the one or more web layers to provide elastic tension in the containment pouch, the one or more elastic members oriented generally in a longitudinal direction that is perpendicular to the opening of the pocket.

2. The absorbent article of claim 1 wherein the elastic members comprise linear elastic strands oriented in the longitudinal direction and perpendicular to the opening of the pocket, with the linear elastic strands providing tension in the containment pouch in the longitudinal direction.

3. The absorbent article of claim 1 wherein the elastic members comprise sinusoidal elastic strands, with the sinusoidal elastic strands providing tension in the containment pouch in the longitudinal direction and in a lateral direction.

4. The absorbent article of claim 1 wherein the containment pouch comprises a central zone and a pair of side zones positioned about the central zone, and wherein the one or more elastic members comprise at least one elastic member positioned in each of the pair of side zones.

5. The absorbent article of claim 1 comprising a first containment pouch positioned in the front waist section and a second containment pouch positioned in the rear waist section.

6. The absorbent article of claim 1 further comprising cuffs joined onto the topsheet in the crotch section and extending to one or more of the front waist section and the rear waist section, wherein the containment pouch is positioned over the cuffs.

7. A method of manufacturing an absorbent article, the method comprising: providing one or more continuous pouch web layers running in a machine direction; applying one or more elastic members to the one or more continuous pouch web layers such that the one or more elastic members are oriented generally in the machine direction; cutting the one or more continuous pouch web layers with the one or more elastic members applied thereto into discrete containment pouches; bonding the discrete containment pouches to a running topsheet web; and cutting the running topsheet web to form a plurality of absorbent articles each having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections; wherein bonding the discrete containment pouches to the running topsheet web comprises bonding a containment pouch to at least one of the front waist section and the rear waist section of a respective absorbent article, with the containment pouch and the topsheet forming a pocket therebetween having an opening oriented toward the crotch section.

8. The method of claim 7 comprising bonding the discrete containment pouches to the running topsheet web at locations that correspond to rear waistline regions of respective absorbent articles.

9. The method of claim 7 comprising bonding the discrete containment pouches to the running topsheet web at locations that correspond to front waistline regions of respective absorbent articles.

10. The method of claim 7 comprising applying the one or more elastic members to the one or more continuous pouch web layers in a sinusoidal pattern and generally in the machine direction.

11. The method of claim 7 further comprising: applying the discrete containment pouches to a composite ear structure to form a continuous waist assembly material structure; cutting the continuous waist assembly material structure into discrete waist assemblies; and bonding the discrete waist assemblies to the running topsheet web.

12. The method of claim 7 further comprising feeding the running topsheet web into a transfer point where the discrete containment pouches are bonded to the running topsheet web, the running topsheet web including a topsheet and cuffs attached to the topsheet; wherein the discrete containment pouches are bonded to the running topsheet web so that the discrete containment pouches are positioned above both the topsheet and the cuffs.

13. The method of claim 7 wherein bonding each of the discrete containment pouches to the running topsheet web comprises bonding a back edge and side edges of the containment pouch to the running topsheet web, while leaving a front edge of the containment pouch unbonded to provide the opening to the containment pouch.

14. The method of claim 7 wherein, in bonding the discrete containment pouches to at least one of the front waist section and the rear waist section of the respective absorbent article, the one or more elastic members are oriented perpendicular to the opening of the pocket.

15. The method of claim 7 wherein applying one or more elastic members to the one or more continuous pouch web layers comprises applying one or more elastic members to each of generally opposing sides of a first continuous pouch web layer of the one or more continuous pouch web layers, with the one or more elastic members on each side of the first continuous pouch web layer oriented generally in the machine direction.

16. A machine for manufacturing an absorbent article, the machine comprising: a means for providing and advancing one or more continuous pouch web layers in a machine direction; a means for applying one or more elastic members to the one or more continuous pouch web layers such that the one or more elastic members are oriented generally in the machine direction; a means for cutting the one or more continuous pouch web layers with the one or more elastic members applied thereto into discrete containment pouches; a means for bonding the discrete containment pouches to a running topsheet web; and a means for cutting the running topsheet web to form a plurality of absorbent articles each having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections; wherein the means for bonding the discrete containment pouches to the running topsheet web is configured to bond a containment pouch to at least one of the front waist section and the rear waist section of a respective absorbent article such that the containment pouch and the topsheet form a pocket therebetween having an opening oriented toward the crotch section.

17. The machine of claim 16 wherein the means for applying the one or more elastic members to the one or more continuous pouch web layers is configured to apply the one or more elastic members in a sinusoidal pattern.

18. A machine for manufacturing an absorbent article, the machine comprising: a web roll unit configured to provide one or more continuous pouch web layers moving in a machine direction; an elastic feed mechanism configured to apply one or more elastic members to the one or more continuous pouch web layers such that the one or more elastic members are oriented generally in the machine direction; a first cutting unit configured to cut the one or more continuous pouch web layers with the one or more elastic members applied thereto into discrete containment pouches; a bonding unit configured to bond the discrete containment pouches to a running topsheet web; and a second cutting unit configured to cut the running topsheet web, with the discrete containment pouches bonded thereon, to form a plurality of absorbent articles each

22 having a front waist section, a rear waist section, and a crotch section extending between the front and rear waist sections; wherein the bonding unit is configured to bond a respective containment pouch to at least one of the front waist section and the rear waist section of a respective absorbent article along a back edge and side edges of the containment pouch, such that the containment pouch and the topsheet form a pocket therebetween having an opening oriented toward the crotch section.

19. The machine of claim 18 wherein the elastic feed mechanism is configured to apply the one or more elastic members in a sinusoidal pattern.

20. The machine of claim 18 wherein the one or more elastic members comprise a pair of elastic strands, and wherein the elastic feed mechanism is configured to apply the pair of elastic strands to generally opposing sides of a first continuous pouch web layer of the one or more continuous pouch web layers, with the pair of elastic strands oriented generally in the machine direction.

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