CA2235700A1

CA2235700A1 - Disposable absorbent article having a garment-like appearance

Info

Publication number: CA2235700A1
Application number: CA002235700A
Authority: CA
Inventors: Jody Dorothy Suprise
Original assignee: Individual
Current assignee: Kimberly Clark Worldwide Inc
Priority date: 1995-11-22
Filing date: 1996-10-24
Publication date: 1997-05-29
Also published as: AU7521396A; US6010586A; CO4770937A1; WO1997018785A1; US5853405A; ZA969570B; MX9803714A; US6652497B1

Abstract

A disposable absorbent article defines a first side portion, a second side portion, and a longitudinal centerline between the side portions. The absorbent article comprises an outer cover and an absorbent insert which is connected to the outer cover. The outer cover comprises a first side panel which is located in the first side portion of the absorbent article and a second side panel which is located in the second side portion of the absorbent article. An edge of the first side panel is connected to an edge of the second side panel to provide a seam which extends along the longitudinal centerline between the side portions of the absorbent article. The opposite waist regions on each side panel are configured to encircle the legs of the wearer and releasably engage together about the hips of the wearer. The disposable absorbent article has an aesthetically pleasing garment-like appearance and is readily refastenable about the hips of the wearer.

Description

CA 0223~700 1998-OS-13 DISPOSABLE ABSORBENT ARTICLE HAVING A GARMENT-LIKE APPEARANCE

Backaround of the Invention Field of the Invention The present invention relates to dis~osable absorbent articles which are adapted to contain body eYIld~tQs More particularly, the present invention relates disposable absorbent articles 10 which have a garment-like appearance.

Desc~i~lion of the Related Art Conventional disposable absorbent articles, such as disposable diapers, have typically 15 included a bodyside liner, an outer cover, and an absorbent core disposed between the outer cover and the bodyside liner. Typically, the outer covers of such conventional absorbent articles have been constructed from a generally rectangular sheet of material which has had portions of its side margins removed. Thus, the end margins of the sheet of ,1.ale~idl provide the waist opening region of the absorbent article while the partially removed side ~l~dlyins 20 provide the leg opening regions of the abso,L,ent article. The outer covers of such absorbenl articles have also been constructed with various types of ela~ ed portions at the waist and leg opening regions. Such ela:,lici~ed portions have been used to reduce the leakage of body CA 0223~700 1998-0~-13 ~Y~ ~dat~s from the absorL eill article. The el~ ed po, l;orls of the outer cover have also been used to improve the appearance and fit of the absorbent article about tha wearer. For exa", le, conve,~lional diDposable absorbent articles have generally utilized outer covers which have elastic strands positioned at the leg and waist opening regions to gather the outer cover 5 and absorbent article to hold it against the body of the wearer.

However, conventional disp~- ' IP absorbent articles which include outer covers as described above have e~.hiL,ilad several ShGI Iccjr,. ~gs. For e,.d", le, it has been difficult to con rc"", convenlional absorbent articles and, in particular, the abso, bel ll cores of such articles to the 10 body of the wearer. Typically, the absorbent core on such conventional absorl,ent articles has been bonded to or i".",obl';~ed between the outer cover and the bodyside liner.
Consequently, it has been difficult to control the shape of the abso, L enl article to ,nai"' ~, an aesll ,elk -'Iy pleasing appea.~"ce during use. In an affempt to better gather the absorbent core and the absorbent article, the waist and leg opening ~egions of conveo~ional absorbent 15 articles have included elastics which apply high conl,~i"g or gathering forces on the absorbent article. However, such high forces have undesirably resulted in irritation and red marking of the skin of the wearer. The high forces have also resulted in an undesirable level of bunching of the absorbent article especially in the crotch region.

20 To obtain a better fit snd a,~pe~,~nce sbout dirrerenl sized wearers, it also has been required to provide conventional di -posable absorbent articles in many different sizes. For ~Xdll, 'P, it has been required to provide conventional .li;"~osable diapers in as many as 3-6 different sizes to accommodate different sized infants. As a result, the costs of manufacturing and marketing such articles has been undesirably high.
Despite the aller"pls to develop more aeall ,e~ 'ly pleasing and improved diJposable absorbent articles, there ,~mz;.,s the need for di:"uc~ le absorbent articles which contain body exudstes while providing an optimum fit about the wearer and rll- ~ ,;"9 a pleasing appearance. Moreover, there is a need for a disposable absorbent article which has a 30 garment-like appea,ance and which can be easily secured about and removed from the waist of a wearer.

CA 0223~700 1998-0~-13 ~iummarv of the Invention In it:~poose to the difficulties and prokle "s d~scussed above, a new d;spc--'le &bsorLe,.I
article which has a ga""eril-like appearance has been discovered. In one aspect, the present 5 invention conce" ,s an outer cover which is adapted for use in a disposable absorbent article.
The outer cover cor,.priaes two individual side panels. An edge of one side panel is connected to an edge of the opposite side panel to provide a seam which extends along a longi~ ~ ' .al cenle,li-.e of the outer cover. Each of said side panels defines a pair of opposed waist regions which are r~le~c~hly engageable together to define a leg opening in the outer cover. In a 10 particular aspect, the seam exlends subaldn' -"y continuously along the entire iength of the outer cover. The outer cover may also include a pair of concealment cuffs which are located along the side regions of the outer cover.

In another aspect, the present invention concel, .s a disposable absG-l,e- .L article which defines 15 a first side portion, a second side portion, and a longitudinal centerline between the side portions. The absorbent article con ~p~ ises an outer cover and an absorbent insert which is connected to the outer cover. The outer cover defines a length, a pair of laterally opposed side regions, a pair of longitudinally opposed waist regions, and a crotch region which extends bet~,veen and connects the waist regions. The outer cover com~,rises a first side panel which is 20 located in the first side portion of the absorbent article and a second side panel which is located in the second side portion of the absorl.e. ~l article. An edge of the first side panel is connected to an edge of the second side panel to provide a seam which extends along the longitudinal centerline between the side portions of the absorbent article. The opposite waist regions on each side panel are releasably engageable together to define a pair of leg 25 openings in the outer cover.

In still another aspect, the present invention concerns a .li~,uosable absorbent article which defines a first side portion, a second side portion, and a longitudinal centerline between the side po. Iions. The al~so-L,enl article cor"~,,ises an outer cover which includes two individual 30 side panels which are connected together to provide a seam which exlends along the longitudinal centerline of the absorbent article. The absorbent article further con.prises an absorbent insert which is connected to the outer cover. The absorbent insert defines a pair of longitudinally opposed end margins and a pair of laterally opposed side "~,gins and includes _ CA 0223~700 1998-0~-13 a bodyside liner a backsheet which is connecled to the bodyside liner in a s~ pe. f~osed relation and an absorbent core which is located between the bodyside liner and the backsheet. In a particular aspect the end Illdly;.,s of the abso,i enl insert are connected to the outer cover and the absorbent insert remains unconnected from the outer cover between 5 the end ",~,~ )s. The absorbent core may inciude at least two independent longitudinaily ~,~lend;. ,9 abso, benl strips. The absorbent article may also include a pair of lonoi'~ ~ - 'y extending co, .r"ent flaps which are located on the side margins of the aL,so-L.ent insert.

In yet another aspect the present invention conce" ,s a method of makinS~ a iispc le 10 absorbent article which defines a first side portion a second side portion and a longitl~ )al cenlerli"e between said side portions. The method comprises: (a) cutting a continuously moving web of ",ale~ial into a first side panel and a second side panel; (b) bonding an edge of the first side panel to an edge of the second side panel along a seam to provide an outer cover for the disposabie absorbent article wherein said seam extends along the lons~itl ~ ,al 15 ce"le, ,e of the absorbent article; and (c) allach;ng an absorbent insert which includes a pair of longitl ~ ~ally opposed end l.,a,y;,ls and a pair of laterally opposed side ",a,~ .s to the outer cover.

The present invention advantageously provides a iia~cs~l~le absorbent article which has a 20 garment-like appearance and refaslen. ~le side seams which allow the article to be easily secured about and removed from the waist of the wearer. The disposable abso,i e"l article of the different aspe- ls of the present invention also achieves a good fit while " ~ ~ 9 an ~ aesthetically pleasing appea,tlnce when co,l,pared to conventional absori,enl articles which gather and bunch in the crotch region. Moreover, the disposable absorbent article of the 25 present invention may also provide improved cc",lai.,l,lent of body exudates within the absorbent area of the article by allowing the absorbent core to remain unattached from the outer cover in at least the crotch region of the article.

CA 0223~700 1998-0~-13 Brief Des.i.il,lion of the i~rawin~s The present invention will be more fully understood and further advantages will become apparent when r~fer~:nce is made to the following detailed desclil,lion of the invention and the acco..~pa.-ying drawings wherein like numerals r~:prt:sent like elements. The drawings are merely representaUve and are not intended to limit the scope of the a~pended claims.

Fig. 1 ,~:~,rt senla(ively shows a side elevational view of an e~am le of a disposable abso.benl article accordiny to the present invention;
Fig. 2 representatively shows a front elevational view of the cJisp~se l~ al~soribe,ll article of Fig. 1;

Fig. 3 representatively shows a perspective view of the outer cover of the ~icpo~
15 absorbent article of Figs. 1 and 2 wherein the absorbent insert has been removed and the elastic members have contracted and gathered the edges of the outer cover;

Fig. 4 representatively shows a perspective view of the disposable bLsoli enl article of Figs. 1 and 2 wherein the elastic members have conl,acLed and gathered the edges of the cli ,po--hl~
20 absorbent article;

Fig. 5 representatively shows a plan view of the disposable absorbent article of i~igs. 1-4 in a st- ~l~ hed and laid flat con.lilion with the surface of the article which conld- ls the wearer facing the viewer;
Fig. 6 ~p, ~senl~ ely shows a plan view of one side panel of the outer cover of the disposable absorbent article of Figs. 1-5 in a stretched and laid flat condition;

Fig. 7 rep(esenl~ ely shows a plan view of an exa,n le of an absorbent insert of the 30 disposable absorbent article according to the present invention in a stretched and iaid flat condition;

Fig. 8 repr~senldli~/ely shows a section view of the absorbent insert of Fig. 7 CA 0223~700 1998-0~-13 wo 97/18785 pcT/uss6/l7o9s Fig. 9 representatively shows a side elevational view of another e~ca. . . - e of a d;~pc a ' ' e absolbenl article acco,l ~ to the present invention;

S Fig. 10 .~p.t:senldli~/ely shows a front elevational view of the diapos-~'e ~I,sorl,enl article of Fig. 9;

Fig. 11 representatively shows a perspective view of the outer cover of the diapcs ' 'e abso, L,enl article of Figs. 9 and 10 wherein the absorbent insert has been removed and the 10 elastic members have contracted and gathered the edges of the outer cover; and Fig. 12 representatively shows a perspective view of the di~posable absorbent srticle of Figs. 9 and 10 wherein the elastic members have conl,acled and gathered the edges of thedisposable absorbent article.

Detailed Desc.i~tion of the Invention The present invention conce".s disposable dL so,be. .l articles which have a ~~a~ ..,enl-like 20 appearance. The disposable absorbent articles are adapted to be worn adjacent to the body of a wearer to absorb and contain various exudates dii,char~~ed from the body. As used herein the term .liapoâable refers to articles which are intended to be discarded after a limited use and which are not intended to be laundered or otherwise restored for reuse. The disposable absorbent articles of the present invention will be described in terms of a 25 disposable diaper article which is adapted to be wom by infants about the lower torso. It is understood that the disposable absorbent articles of the present invention are equally z~ rt~hle for use as other types of absorbent articles such as adult incol ~li. ,ent products trainin~ pants r~,.,i.,- ,e hygiene products other personal care or health care ~a".,enls and the like.
Fiç~s. 1-5 and 9-12 representatively illustrate all~ ali~/e e~"" es of ~liJpcs-~le abSOrL~enl articles as ~enerally i. .~ - d at 20 accor.li, ,9 to the present invention wherein like numerals represent like elements. As representatively illustrated in Figs 1-5 the absorbent artide 20 CA 02235700 l998-05-l3 W O 97/18785 PCT~US96/17095 defines a first side portion 22 and a second side portion 24. As used herein .~rert:l.ce to a side portion refers to that psrt of the absorbent article which is gene. 'y located on the sides or hips of a wearer when in use. The absorbent article 20 also defines a longit~ al cenle. i .e 26 which e,~tends along a longitudinal length of the absorbent article 20. The ~iispQs~hlQ
5 absorbent article 20 includes an outer cover 30 and an absorbent insert 80 which is connet led to the outer cover 30. The absorbent insert 80 is configured to contain and/or absorb any body ~YIldat~s ~ ;h~yed from the wearer. Whereas, the outer cover 30 is configured to ~ll5il ,lain the absorbent article about the waist of the wearer conceal the abso,benl insert from view and provide the garment-like appearance.
The absorbent article 20 may also include a pair of concealment cuffs 60 which are connected to the outer cover and configured to hide the absorbent insert 80 from view. The absorbent article 20 may also include a pair of conlai""lent flaps 110 which are connected to the absorbent insert 80 and configured to hold and contain any body ex~l~lat~s within the 15 absorbent insert 80 to avoid soiling the outer cover 30 of the absorbent article 20 and any other outer garments wom by the wearer. The Illustrated absod~enl article 20 further includes a r&Sle n l9 means which is intended to ",a;" ~, the absorbent article 20 about the waist of the wearer when in use. It should be recognized that individual con"~onents of the absorbent article 20 may be optional depending upon the intended use of the absorbent article 20.

As representatively illustrated in Figs. 3 and 5, the outer cover 30 of the absorbent article 20 defines a longitudinally extending length 32, a pair of laterally opposed side regions 34 and 36, a pair of longitudinally opposed waist regions 38 and 40 and a crotch region 42 which extends between and connects the waist regions. The edges of the side regions 34 and 36 of the outer cover 30 define leg openings 54 and 56 (Fig. 2) for the outer cover 30 which may be curvilinear. The waist regions 38 and 40 of the outer cover 30 define a waist opening 58 and co",prise the upper portions of the abso,ben~ article 20 when wom. The waist regions 38 and 40 are configured to wholly or partially cover or encircle the waist of the wearer when wom.
The crotch region 42 of the outer cover 30 co,."~rises the portion of the outer cover 30 which when worn, is positioned between the legs of the wearer and covers the lower torso of the wearer.

CA 0223~700 l998-0~-l3 WO 97/18785 Pcr~TS96/17095 The .-:presen~aLi~/ely illustrated outer cover 3û co"-prises a first sid~ panel 44 which is located in the first side portion 32 of the absorbent article 20 and a second side panel 46 which is located in the second side portion 34 of the absorbent article 20. An edge of the first side panel 44 is suitably connected to an ed~e of the second side panel 46 to provide a seam 48.
5 The edges of the side panels 44 and 46 may be continuously connected together along the seam or, oplionally, may be i"ler,..illenlly connected togeU-er along the seam 48. The seam 48 extends along the longitudinal centerline 26 of the absorbent article 20 between the side po, lions 22 and 24 of the absorbent article 20. The length of the seam 48 may or may not extend along the entire length 32 of the outer cover 30. Desirably, the seam 48 exl~nds 10 suL,sld,llially continuously along the entire length 32 of the outer cover 30 to provide a more garment-like apped, d,1ce to the absorL ent article 20. In such a configuration, each side panel 44 and 46 defines a length which is suLslal1t "y equal to the length 32 of the outer cover 30.

The side panels 44 and 46 of the outer cover 30 may have any configuration which provides 15 the desired garment-like appearance to the absorbent article 20. Desirably, the side panels 44 and 46 are sul,sla,1lially identical for ease of manufacturing. Fig. 6 representatively illustrates an example of a pattern which can be used to provide the side panels 44 and 46. The pattem representatively illustrated defines one side panel 44. The portions of the pattern which corresponds to the seam 48, the waist regions 38 and 40, and the crotch region 42 of the outer 20 cover 30 when asser"' IEd are also illustrated. The illustrated side panel 44 also defines the length 52 of the crotch region 42 of the outer cover 30. The crotch length 52 will vary depending upon the size of the wearer. Desirably, the crotch length 52 is at least about 15 percent and more desirably at least about 20 percent of the length 32 of the outer cover 30 to provide a more garment-like appesrance with less bunching in the crotch region when 25 compared to convenlional absorbent articles. When the disposable absorbent articles is intended to be worn by an infant weighing from about 30 to about 35 pounds, the crotch length 52 is ~enerally from about 5 to about 15 centimeters, desirably at least about 8 centimeters, and more clesirdbly at least about 10 centimeters.

30 The seam 48 between the side po. lions 22 and 24 of the absorbent article 20 is typically constructed by posilior,il ,9 the edges of the side panels 44 and 46 in an ove, lappi. ,9 arrangement and suitably connecting them together. The amount of overlap o~ the edges of the side panels 44 and 46 can be varied to provide any desired width 50 (Fig. 6) of the seam CA 0223~700 1998-0~-13 48. For exal,lr'e, the seam 48 may define a width 50 of from about 0.3 cenlil..el~l:, to about 1.9 cenlil,~elt,rs. Desirably, the seam 48 defines a width 50 of at least about 0.64 cer,li"l~t~
and more desi.~bly at least about 1.3 ce"limelers to provide a more garment-like appearance to the disposable absorbent article 20 and an i. ,(" eased sl~el "Jll, to the outer cover 30 along the seam 48. The edges of the side panels 44 and 46 may be connected together to provide the seam 48 in any of several ways which are well known to those skilled in the art. For e~al", '~, the edges of the side panels 44 and 46 may be ullldson lly bonded, thermally bonded or adhesively bonded together to provide the seam 48.

10 App' -- ~Is have discovered that dispc ~z'-le absorbent articles which are constructed to have a seam which extends along a longitudinal centerline of the article, as described in the present invention, provide a more optimum fit about the wearer and a more ga,lllenl-like apped,~nce when co",pa~d to convenlional absorbent articles. In particular, the incorl,ordlion of a seam along the longitudinal cenlt:,line of the article provides an improved fit and appearance of the 15 crotch region and waist regions which are not constricted by the crotch region.

The outer cover 30 of the absorbent article 20 may suitably be composed of a material which is either liquid permeable or liquid impermeable. Since the absorbent insert 8Q of the .lirrer~:nl aspects of the present invention is designed to contain the body exudates discharged from the 20 wearer, it is generally not necessary that the outer cover 30 be liquid impermeable. For example, the outer cover 30 may include various woven or nonwoven m~lerials such as spunbond material, meltblown mdlerial, cotton material, rayon ll,ale(ial or co",t~inalions thereof such as a spunbond-meltbiown-spunbond (SMS) l~n, ,ale ~l~alerial. The outer cover 30 may also be an elastiçi~ed material such as a stretch-thermal laminate (STL), neck-bonded 25 la~"i. ,dle (NBL), or stretch-bonded laminate (SBL) material. Methods of making such materials are well known to those skilled in the art and described in U.S. Patent No. 4,663,220 issued May 5, 1987 to Wisneski et al., U.S. Patent No. 5,226,992 issued July 13,1993 to M~.lllon, and European Patent Ap,c'i- ~;on No. EP 0 217 032 published on April 8,1987 in the names of Taylor et al., the riis( losl ~res of which are hereby incorporated by reference.
The outer cover 30 may also be at least partially liquid impellll-~~'~ to further prevent any leakage of body ~xlldates. For exall,~!e, a typical outer cover 30 can be manufactured from a thin plastic film or other flexible liquid-impermeable l,l~lerial. In a particular aspect, the outer -CA 0223~700 1998-0~-13 WO 97/1878~ PCI~/US96/17095 cover 30 may be formed from a polyethylene fiim having a thickness of from about 0.012 millimeter (0.5 mil) to about 0.051 ", ~. ..eler (2.0 mils). If it is desired to present the outer cover 30 with a more ~loU ' :e feeling, the outer cover 30 may co".~rise a polyethylene film having a nonwoven web lar. ~ ~aled to the outer surface thereof, such as a spunbond web of 5 polyolefin fibers. For eAa-~ le, a polyethylene hlm having a thickness of about 0.015 Il 'ii ..eler (0.6 mil) may have lherlllally la.~ ~aled thereto a spunbond web of polyolefin fibers, which fibers have a thickness of about 1.5 to 2.5 denier per rila...enl, which nonwoven web has a basis weight of about 24 grams per square meter (0.7 ounce per square yard). The outer cover 30 may also be a stretch-thermal laminate (STL) male~ial which includes a meltblown film layer 10 positioned between two spunbond layers and which has a basis weight of about 73 grams per square meter. The meltblown film layer may be composed of me"' I ~. I polypropylene fibers and the spunbond layers may be con ",osed of polypropylene fibers. The outer cover 30 may also include bicomponent fibers such as polyethylene/polypropylene ti-~...ponenl fibers.
Methods of forming such clothlike outer covers are known to those skilled in the art. Further, 15 the outer cover 30 may be formed of a woven or nonwoven fibrous web layer which has been totally or partially constructed or treated to impart a desired level of liquid impe-...~ y to selected regions. Still further, the outer cover 30 may oplionally be co"-posed of a micro-porous "breathable" ...a~rial which permits vapors to escape from the absorbent article 20 while still preventing liquid Pxl ld~t~s from passi. .g through the outer cover 30.
As representatively illustrated in Figs. 1-5, the outer cover 30 of the ~ po5;~ Q absorL enl article 20 may include a pair of concealment cuffs 60 which are configured to hide the absorbent insert 80 and provide an additional barrier to the lateral flow of body exudates. The concealment cuffs 60 are located along the laterally opposed side regions 34 and 36 of the 25 outer cover 30. Each concealment cuff 60 defines a fixed edge 62 and a free edge 64. Each of the concealment cuffs 60 may also include at least one elongated elastic member 66 which is attached to the free edge 64 of the conce~' ner)l cuff 60 and configured to gather the conceal. "e. ~I cuff 60 when it is relaxed. The conc e' "ent cuffs 60 may extend longitudinally along the entire length 32 of the outer cover 30 or may only extend partially along the length of 30 the outer cover 30. When the concealment cuffs 60 are shorter in length than the outer cover 30, the concealment cuffs 60 can be selectively positioned anywhere along the side regions 34 and 36 of the outer cover 30. In a particular aspect of the invention, the cc,nceal...ent cuffs 60 .

CA 0223~700 1998-0~-13 are positioned along the side regions 34 and 36 primarily in the crotch region 42 of the outer cover 30.

The conce ' I.enl cuffs 60 can be made from any mdlelial which provides the desired col)ce-'nlent of the absorbenl insert 80 and, oplionally, an adcJilional barrier to the lateral flow of body ~Y~Id~t~s For e~an ~'e, the concer' "ent cuffs 60 may be constructed of a .ll~lerial which is similar to the 1. lalel ial COI l l,~,risi, lg the outer cover 30. Other conventional Il Idle~ ;als, such as polymer films, may also be employed. In a particular aspect, the con~ -'n,ent cuffs 60 may be constructed of a STL material composed of a meltblown polypropylene layer 10 between two spunbond layers and having a basis weight of about 73 grams per square meter.

Each concealment cuff 60 is attached to the side regions 34 and 36 of the outer cover 30 such that the concealment cuffs 60 effectively hide or conceal the abso. L,ent insert 80 from view as is representatively illustrated in Fig. 1. The fixed edge 62 of each of the concealment cuffs 60 15 is attached to the side regions 34 and 36 of the outer cover 30 while the free edge 64 of each of the concealment cuffs 60, e, . - ,s ~-. ,atlached from the outer cover 30 in at least the crotch region 42 of the outer cover 30. The fixed edge 62 of the concealment cuffs 60 may be attached to the outer cover 30 in any of several ways which are well known to those skilled in the art. For exd."ple, the fixed edge 62 of the cuffs 60 may be ulti~-so~. 311y bonded, thermally 20 bonded or sdhesively bonded to the side regions 34 and 36 of the outer cover 30. The free edge 64 of each of the concealment cuffs 60 is generally aligned parallel to the longitudinal centerline 26 of the absorbent article 20. In a particular aspect, the free edge 64 of each concealment cuff 60, ~" .a;. ,s unattached from the side regions 34 and 36 of the outer cover 30 along subsLanLidlly the entire length of the free edge 64 to provide improved peIrO""~nce.
Each concealment cuff 60 is also configured such that the free edge 64 of the con~ -' "enl cuff 60 tends to po~ ion itself in a spaced relation away from the outer cover 30 toward a generally upright and perpendicular configuration, especially in the crotch region 42 when in use. As representatively illustrated in Fig. 1, the free edge 64 of each concealment cuff 60 is 30 desirably spaced away from the outer cover 30 when in use thereby hiding or concealing the absorbent insert 80 from view. Desirably, the free edge 64 of each concealment cuff 60 n~ai. .tains a conlacli"g relationship with the body of the wearer while the outer cover 30 may be spaced away from the body of the wearer when in use. Typically, an elastic member 66 is CA 0223~700 1998-0~-13 WO 97/1878~; PCT/US96/17095 attached to the free edge 64 of each concealment cuff 60 to .-.a;..~i-- the spaced awsy l~:ldlionship between the free edge 64 and the outer cover 30. For e~an" 'e, the elastic member 66 may be attached to the free edge 64 in an ela:,li~lly corll,~ ' ' Ie condition such that the co"l- ~clion of the elastic member 66 gathers or contracts and shortens the free 5 edge 64 of the concealment cuff 60 to achieve the desired spaced away ,~lalionsl,i~

Materials sl ~it~hle for use as the elastic member 66 of the concealment cuffs 60 are known to those skilled in the art. Exe-"plary of such ..,alerials are sheets, strands or ribbons of a polymeric, elaslun-eric malerial which are adhered to the cuffs 60 in a stretched con~Jilion, or 10 which are attached to the cuffs 60 while the cuffs are Fls~'~cl, such that elastic con~ live forces are imparted to the cuffs. The elastic member 66 may also include such materials as polyurethane, synthetic and natural rubber. In a particular aspect of the invention, the elastic members 66 may be composed of a plurality of individual strands of 620 decitex Lycra~ which are commercially available from E. l. DuPont de Nemours Co., a business having offices in 15 Wilmington, Delaware. The concealment cuffs 60 may include from 1 to about 10 elastic strands along the free edge 64.

The elastic members 66 may be elc)ngdled prior to being attached to the free edge 64 of the concealment cuffs 60. For example, the elastic members 66 may be elongated at least 20 about 75 percent and desirably from about 100 to about 150 percent before being attached such that the elastic members 66 gather the free edge 64 of the concealment cuffs 60. Since the main purpose of the concealment cuffs 60 is to hide the absorbent insert 80 from view, it is not required that the free edge 64 form a tight seal about the body of the wearer. Accol~ " ~gly, it is desirable that the elastic members 66 be elongated no more than about 150 percent and 25 more desirably no more than about 125 percent before being attached to the concealment cuffs 60. Moreover, it is desirable that the elastic member 66 exerts a tension of no more than about 150 grams and desirably no more than about 90 grams on the free edge 64 of the concealment cuff 60 when the free edge 64 of the conce-' ..e.,l cuff 60 is in a longitudinally extended position. Such low levels of elongation and tension effectively !-,a;.~' ~ the free 30 edge 64 in a spaced away relation from the outer cover 30 while not undesirably i,.il~Li"g the legs of the wearer. The elastic members 66 may be joined to the conc- ' "ent cuffs 60 by any means known to those skilled in the art. For example, adhesive, thermal or ullrasol7 _ bonding techniques may be used to join the elastic members 66 to the concealment cuffs 60. A

CA 0223~700 1998-05-13 W O 97/18785 PCTrUS96/1709~

s- ~i' ' ' e adl .es;ve includes Findley H-2096 hot melt adhesive which is CG~ ially available from Findley Adhesives, Inc., a business having offices located in Wauwatosa, Wisconsin.

The conc ~ -' . .enl cuffs 60 hide the absorbent insert 80 and help prevent leal.~ ~e of bodily 5 emdat~s. In addition, the elasLi.,ity and conror ~ .y of the con~- ..enl cuffs 60 ensures that the abso-l en~ insert 80 will remain between the cuffs 60, the outer cover 30 and the body of the wearer. As a result, it is not required that the outer cover 30 itself hold the abso.l,enl insert 80 against the body of the wearer. Thus, the outer cover 30 of the present invention can be spaced away from the body and have a more ga..--enl-like appearance.
~0 As representatively illustrated in Figs. 4 and 5, the absorbent insert 80 of the abso.Le.ll article 20 of the present invention defines a pair of lon~ih ~ ' ~ally disposed end margins 82, a pair of laterally opposed side ~.,ar~, Is 84, and a crotch section 86 located between the end ~lal5, ~s 82. The crotch section 86 of the abso.l.enl insert 80is configured to fit bet\,veen the legs of 15 the wearer and at least par~ially cover the lower torso of the wearer when in use. As a result, the crotch section 86 is ~ener ' ~r the portion of the aLsorl,enl insert 80 which is configured to initially receive the body ~YI l~l~tQs from the wearer when in use. The absorbenl insert 80 further defines a length 88 and a width 90.

20 The absorbent insert 80 is ~ael~er~ '1y conformable and c~p~ ' 'e of ~L,sorL ~g and (~ body exudates. The absorbent insert 80 may have any of a number of shapes and sizes. For e~d"",lc, as ,~:prt:senl~lively illustrated in Figs. 4 and 12, the absorbent insert 80 may be rectangular, I-shaped or T-shaped. The size and absorbent capacity of the absorbent insert 80 should be compatible with the size of the intended wearer and the fluid loading imparted by 25 the intended use of the absorbent article 20. Typically, it is desirable that the absorbent insert 80 have an absorbent capacity of at least about 300 grams of urine. It is generally prere, l~d that the ~bsolbenl insert 80 be narrower in the crotch section 86 than in the end l,.ar~,:ns 82. It has been found that the absorbenl insert 80 of the present invention is particularly useful when the width lli.,~e~ ,:,ion 90 of the crotch section 86 of the absorbent insert 80 is from about 2.5 to about 10.2 ce, lli".ele~ 5 (1.0 to about 4.0 inches), desirably no more than about 7.6 cenli.. e~rs (3.0 inches) and more desirably no more than about 5.1 centimeters (2.0 inches). The narrow crotch width dimension 9() of the crotch section 86 of the absorbenl insert 80 allows the absorbent insert 80 to better fit between the legs of the wearer.

CA 0223~700 1998-0~-13 The absorLent insert 80 of the present invention is suitably connecled to the outer cover 30 to provide the disposable absorbent article 20. The absorbent insert 80 may be connected to the outer cover 30 along the entire leng~h 88 of the al~sorL,enl insert 80 or only along a portion of 5 the length 88. Desirably, only the end Illdl~,' 15 82 of the absolL,enl insert 80 are conne.;led to the outer cover 30 while the remainder of the absorbent insert 80 ren, ,s u"connected from the outer cover 30. For e~am~le, the absorbent insert 80 may be connected to the outer cover 30 along a length of no more than about 5.1 cenli"~elers and desirably no more than about 1.3 cenli..,eters at each of the end ~ S 82 of the abso.l,e.-l insert 80. Desirably, the 10 absorbent insert 80 is connected to the outer cover 30 over a total len~th which is less than about 15 percent and more desirably less than about 10 percent of the length 88 of the absorbent insert 80. In such a configuration, the absorbent insert 80 more readily conro....s to the body and movt:-..enls of the wearer in use without adversely affecting the gamment-like apped,dnce of the outer cover 30. In a particular aspect, the length of the abso.benl insert 80 15 between the connected po,lions of the end Illdly;lls 82 which .e,..c~;..s unconnected to the outer cover 30 is less than the length of the outer cover 30 between the connected portions.
In such a configuration, at least the crotch region 86 of the absorbenl insert 80 ...a;n' .s a spaced away relationship from the outer cover 30 when in use.

20 The absorbent insert 80 may be suitably connected to the outer cover 30 to form the abso.L"2nl article 20 using any means known to those skilled in the art. For example, the absorbent insert 80 may be bonded to the outer cover 30 using adhesive, thermal or ~ ~ ason9c bon " ~9 techniques known to those skilled in the art. Altematively, the absorbent insert 80 may be connected to the outer cover 80 using conventional rasLene,~ such as buttons, hook and loop 25 type fasteners, adhesive tape fasteners, and the like.

Figs. 7 and 8 ,~:preser-ldlively illustrate an ~dlll, le of an absorL e- ll insert 80 acco,di. ,g to the present invention which includes a bodyside liner 92, a backsheet 94 which is connected to the bodyside liner 92 in a superposed relation, and an absorbent core 96 which is located between 30 the bodyside liner 92 and the backsheet 94. In alternative configurations wherein the outer cover 60 is at least partially resistant to the flow of liquids therethrough, the backsheet 94 may oplionally be omitted from the absorbent insert 80.

CA 0223~700 1998-0~-13 WO 97/18785 PCTtUS96/17095 The bodyside liner 92 of the abso,t,e"l insert 80, as r~prt:ser)l~ ely iliustrated in Figs. 7 and 8 suitably plt:senls a bodyfacing surface which is intended to be worn adjacer,l the body of the wearer and is cGIl.pl - 1t soft feeling and non ,ilali, lg to the wearer s skin. Further the bodyside liner 82 may be iess hydrophilic than the absorbent core 96 to present a relatively 5 dry surface to the wearer and may be sufficiently porous to be liquid permeable permitting liquid to readily penetrate through its thickness. A suitable bodyside liner 92 may be manufactured from a wide selection of web "~dlerials such as porous foams retic~ t~ t foams apertured plastic films natural fibers (for exaf~"~le wood or cotton fibers) synthetic fibers (for e,~d"" e polyestcr or polypropylene fibers) or a comL .. ,alion of natural and 10 synthetic fibers. The bodyside liner 92 is suitably er." l~yed to help isolate the wearer's skin from fluids held in the absorbent core 96 of the absorbent insert 80.

Various woven and nonwoven fabrics can be used for the bodyside liner 92. For example the bodyside liner may be composed of a ",o I rln or spunbonded web of polyolefin fibers. The 15 bodyside liner may also be a bonded-carded web composed of natural and/or synthetic fibers.
The bodyside liner may be composed of a suLsldnlially hydrophobic material and the hydrophobic material may oplion ly be treated with a SIJI ra~ nl or otherwise processed to impart a desired level of w~; _L y and hydrophilicity. In a particular embodiment of the present invention the bodyside liner 92 co"-prises a nonwoven spunbond polypropylene 20 fabric composed of about 2.8-3.2 denier fibers formed into a web having a basis weight of about 22 grams per square meter and a density of about 0.06 grams per cubic cenli".eter.
The fabric is surface treated with about 0.28 weight percent of a su,ra- l~r,l co"""er~ -1y ~ available from Rohm and Haas Co. under the trade desig"alion Triton X-102.

25 The backsheet 94 of the absorbent insert 80, as representatively illustrated in Figs. 7 and 8, may suitably be composed of a material which is either liquid permeable or liquid impermeable.
It is generally pr~ren ed that the bachsheet 94 be formed from a " ,alerial which is subsld, ~ ty impermeable to fluids. F-or e,~d""~le a typical backsheet can be manufactured from a thin plastic film or other flexible liquid-i""~e""~ q~le n,dlerial. ~or ex~ ,lc the backsheet 94 may 30 be formed from a polyethylene film having a thickness of from about 0.012 millimeter (0.5 mil) to about 0.051 milli."eter (2.0 mils). The backsheet 94 may also co",prise a film layer having a nonwoven web laminated to the outer surface thereof such as a spunbond web of polyolefin fibers. The backsheet 94 may also be constructed of a material which is similar to the material CA 0223~700 1998-0~-13 co.. "~ isi. .ç~ the outer cover, such as an STL n,ale~ ial. Further, the bacl~l ,eet 94 may be formed of a woven or nonwoven fibrous web layer which has been totally or partially constructed or treated to impart a desired level of liquid i-.-per,n~ ' ' y to selected regions that are adjacent or p.-"~i"lale the absorbent core 96. Still further, the backsheet 94 may option ~'1y 5 be composed of a micro-porous "breathable" material which permits vapors to escape from the absorbent core 96 while still preventing liquid exudates from passing through the backsheet 94.

The bodyside liner 92 and backsheet 94 are generally adhered to one another so as to form a 10 pocket in which the absorbent core 96 is located to provide the absorbent insert 80. The bodyside liner 92 and backsheet 94 may be adhered directly to each other around the outer periphery of the absorbent insert 80 by any means known to those skilled in the art such as adhesive bonds, sonic bonds or thermal bonds. For example, a uniform continuous layer of adhesive, a patterned layer oF adhesive, a sprayed or meltblown pattem of adhesive or an 15 array of lines, swirls or spots of adhesive may be used to affix the bodyside liner 92 to the backsheet 94. It should be noted that both the bodyside liner 92 and the backsheet 94 need not extend completely to the outer periphery of the absorbent insert 80. For exd..., le, the backsheet 94 may extend to the outer periphery of the absorbent insert 80 while the bodyside liner 92 may be attached to the backsheet 94 inboard of the outer periphery of the absorbent 20 insert 80, or more towards the longit~ ~ ' .al centerline 26, of the absorbent article 20. In alle., .tllive configurations, especially wherein the backsheet 94 is omitted, the bodyside liner 92 may be suitably adhered directly to the absorbent core 96.

The absorbent core 96, as representatively illustrated in Figs. 7 and 8, is positioned between 25 the bodyside liner 92 and the backsheet 94 to form the absorbent insert 80 The absorbent core 96 is desi.~l.ly conro"."-le and caF~'9e of a~sorL- ,g and ,~:lai"i"g body f~Y(ldatps The absorbent core 96 may have any of a number of shapes and sizes. For example, thecomposite absorbent core may be rectangular, l-shaped or T-shaped. It is generally prere" ~:d that the absorbent core 96 be narrower in the crotch section 86 of the absorbent insert 80.
30 The size of the absorbent core 96 should be cor,-palible with the size of the intended wearer and the desired absorbent capaclty of the absorbent insert 80.

CA 0223~700 1998-0~-13 WO 97/1878~; PCT/US96/17095 In a particular e".bodi ~,e"l, as representatively illustrated in Figs. 7 and 8, the abso.L~nl core 96 of the absorbent insert 80 is desirably a plurality of absorL.e.lL strips 98 which extend along the longitu " 1&1 length 88 of the absorbent insert 80. The absorbent strips 98 are generally rectangular in shape and define a length, a width, a thickness and a pair of opposile 5 longitudinal side edges. The absorbent strips 98 are configured to pivot about one of the longitudinal side edges while the opposite longitudinal side edge of the absorbent strips 98 , ~", - ~s free to move. The absorbent core 96 may include any number of absorbent strips 98 which provides the desired conldi"f~,ent of body ~Yud~t.es. For example, as illustrated in Fig.
7 and 8, the abso. L,enl core 96 may include four lon~itl ~ 'ly extendin~ abso. L,enl strips 98.
10 In altemative configurations, the absorbent core 96 may include from 1 to about 10 absorbent strips 98. The arrangement oF the absorbent strips 98 provides channels bet~,veen each strip to better distribute and contain fluid P-~udates. Moreover, the a~angemenl of the strips 98 provides a greater surface area in contact with the body exudates to more effectively absorb and contain the exudates.
The absorbent strips 98 are also very conro".,P~'s in the crotch section 86 of the absorbent insert 80. As representatively illustrated in Fig. 8, the absorbent strips 98 are arranged such that they may overlap each other in a shingled arrangement when s~ cted to a lateral force such as exerted by the legs of a wearer in use. Accord;nylr, the absorbent strips 98 provide 20 an abso.Lent core 96 which is readily adap' ~'e to change dimensions depending upon the position and movement of the wearer. For example, if the absorbent core 96 includes four absorLen~ strips 98, each of which has a width of 2.0 ce. .li.oeters, the effective width of the absorbent core 96 may be from about 4.0 to about 8.0 ce..li...eler~ dependi--~ upon the amount of overlap of each strip 98 with the adjacent strip. Thus, when co...pa.fdd to 2~ conventional solid, le~an~.llar-shaped absorbent cores, the use of absorLenl strips 98 such as is illustrated in Figs. 7 and 8 provides an absorbent core 96 for an absorbent article which has an improved fit especially in the crotch region. Such improved fit may enhance the appearance of the absorbent article 20 and pe.ro....ance of the absorbent core 96.

30 The absorbent strips 98 may have any length and width which provides sufficient aLsor,~ e capacity. Desi.~Lly, the absorl,enl strips 98 extend along the entire length 88 of the abso-l,ent insert 80 and have a width of from about 1.3 to about ~.1 cenli-"eters. Various configurations for the absorbent strips 98 are described in U.S. Patent Application Serial No. 081476,742 of CA 0223~700 lss8-0~-l3 WO 97/18785 PCT~S96/17095 S. Gryskiewicz et al. entitled ABSORBENT ARTICLE INCLUDING LIQUID CONTAINMENT
BEAMS AND LEAKAGE BARRIERS and filed June 7 1995 (Attomey Docket No. 12 187); the s~lQs~ Ire of which is hereby incorporated by rerer~:nce in a manner that is col) ~isl~n~
herewith.
The absorbent core 96 o~ the absorbent insert 80 may suitably co,..~,ise various types of wettable hyd,v,uh;l;c fibrous o,alerials. Exampies of suit~le materials include naturally occurring organic fibers composed of i. ~lli-.sically wet'.ah'o material such as ~ s c fibers;
synthetic fibers composed of c ~ Icse or ce " l~a se derivatives such as rayon fibers; i, .orya" -10 fibers cGr"posed of an inherently wettable material such as glass fibers; synthetic fibers madefrom inherently wettable thermopldslic polymers such as particular polyester and polyamide fibers; and synthetic fibers cGr.,posed of a nonwettable thermoplastic polymer, such as polypropylene fibers which have been hyd,uphili~ed by apploplidle means known to those skilled in the art. The absorbent core 96 may also co"lprise selected blends of the various 15 types of fibers mentioned above.

In a particular aspect of the invention the absorbent core 9~ may include a matrix of hyd,uphil;c fibers such as a web of c~ ic fibers mixed with particles of a high-absorbency material such as that co"""only known as superabsorbent ~"dlerial. As used herein the term 20 "high-absorbency material" refers to materials that are cap-~le of absorbing at least 10 times their own weight in liquid. In a particular e".bo.Ji",ent the absorbent core 96 comprises a mixture of supe, dbsorbe"l hydrogel-forming particles and wood pulp fluff. The wood pulp fluff ~ may be ex l ,al1ged with synthetic polymeric meltb~own fibers or with a combination of m~ m fibers and natural flbers. The high-absorbency material may be su~,sla"lially 25 homogeneously mixed with the hydrophilic fibers or may be nonuniformly mixed. The high-absorbency material may also be arranged in a generally discrete layer within the matrix of hyd, uphilic fibers. Alternatively the absorbent core 96 may co",~, ise a laminate of fibrous webs and high-absorbency mdlerial or other s~ le means of ,. ~ 9 a high-absorbency material in a lor~ 7rd area.
The high-absorbency ~-,alerial can be select~d from natural synthetic and modified natural polymers and materials. The high-abso,Le"cy materials can be inoryan:c ",dle,ials, such as silica gels or organic compounds such as ~;,o~ hed polymers. The term ''clussli,.ked'' refers CA 0223~700 1998-0~-13 to any means for effectively ,t:nde,inç~ nommally water-soluble o,ale-ials suL~lan -'ly water i"sal~lhlc but swellable. Such means can include, for e~a""~le, physical enld,-.O - "enl, crystalline domains, covalent bonds, ionic cor" 13. ~5 and associations, hyd,oph-"~
associalions such as hydrogen bon~:ling, and hydrophobic associations or Van der Waals 5 forces.

E~dmF'e s of synthetic, polymeric, high-absorbency materials include the alkali metal and a"""oni.Jm salts of poly(acrylic acid) and poly(methacrylic acid), poly(acryla,l,:~es), poly(vinyl ethers), maleic anhydride copolymers with vinyl ethers and alpha-olefins, poly(vinyl 10 pyl~,lidone), poly(vinyl morpholinone), poly(vinyl alcohol), and mixtures and copolymers thereof. Further polymers sui'~'-lE for use in the absorbent core include natural and modified natural polymers, such as hydrolyzed acrylonitrile-grafted starch, acrylic acid grafted starch, methyl c~ cse, carboxymethyl ce"ulcse, hydroxypropyl cellu'~se, and the natural gums, such as alginates, xanthum gum, locust bean gum, and the like. Mixtures of natural and wholly or 15 partially synthetic absorbent polymers can also be useful in the present invention.

The high-absorbency material may be in any of a wide variety of geometric forms. As a general rule, it is pl~felled that the high-absorbency n,c.le~ial be in the form of discrele particles. However, the high-absorbency male~ ial may also be in the form of fibers, flakes, 20 rods, spheres, needles, or the like. Cons1cme,dlt s of particles of high-absorbency material may also be used. An example of a su~,erdbsorlJent polymer sl l~ lE for use in the present invention is a superabsorbent polymer designated IM5000 which is commercially available from Hoechst-Celanese, a business having offices in Portsmouth, Virginia. Other s~
high-absorbency materials may include superabsorbent polymers which are com",e,~ ~'ly 25 available from Dow Chemical Corp., a business having offices in Midland, Michigan.

As a general rule, the high-absorbency n,alerial is present in the absorbent core 96 of the present invention in an amount of from about 5 to about 95 weight percent and desirably from about 10 to about 60 weight percent based on the total weight of the absorbent core 96. The 30 distribution of the high-absorbency material within the .liffe-~nl po, lion:- of the abso,L ent core 96 can vary depending upon the intended end use of the absorbent core 96.

_ _ CA 0223~700 1998-0~-13 As representatively illustrated in Figs. 1-8 the abso, L.enl insert 80 of the disposable absorbent article 20 may include a pair of co"Lai"."ent flaps 110 which are configured to provide a barrier to the lateral flow of body exudates. The conl~;..r.,ent flaps 110 may be located along the laterally opposed side ."~,~ ,s 84 of the absorbent insert 80. Each conld;"n.enl flap 110 defines an attached edge 112 and an unattached edge 114. Each of the cc" ""ent flaps 110 may 8ISO include at least one GIOn9dled elastic member 1 1~3 which is adhered to the u"alldched edge 114 of the Collldil ~ment flap 110 and configured to gather the IJ"dllaChed edge 114 and forrn a seal against the body of the wearer when in use The co" ,n,ent flaps 110 may extend longitudinally alon~ the entire length 88 of the absorbent insert 1 10 or may 10 only extend partially along the length of the absorbent insert 80. When the con - ""e"l flaps 110 are shorter in length than the absorbent insert 80 the conk,;. ,r"ent flaps 110 can be selectively posiliooed anywhere along the side mafyi"s 84 of the absorbent insert 80. In a particular aspect of the invention the conlai"r"ent flaps 110 extend along the entire length 88 of the absorbent insert 80 to better contain the body exudates.
The con "nent flaps 110 can be made from any l"ale,ial which provides the desired barrier against the flow of body ~n~d~tes For ~d..l~le the conldi~ u--ent flaps 110 may be constructed of a material which is similar to the Illale~ ial cor~pli5i, lg the outer cover 30. Other convel .lional l l laL~:I ials such as polymer films may also be employed. In a particular aspect 20 the conlai,.l.,ent flaps 110 may be constructed of a STL l-lalerial having a basis weight of about 73 grams per square meter and comprising a me" l~ ~Jn layer of l, e _ ~/n polypropylene fibers bet\,veen two spunbond layers of polypropylene fibers.

Each coniaill"lel1t flap 110 is attached to the side margins 84 of the absorl,enl insert 80 such 25 that the conLa;, ~ment flaps 110 provide a barrier to the lateral flow of body ~nld~tes. The attached edge 112 of each of the containment flaps 110 is attached to the side margins 84 of the absorbent insert 80 while the unaUached edge 114 (ellldills unattached from the absorbent insert 80 in at least the crotch section 86 of the absorbent insert 80. The attached edge 112 of the col1La;. Ill-ent flaps 110 may be attached to the absorbent insert 80 in any of several ways 30 which are well known to those skilled in the art. For exdll . Ie the attached edS~e 112 of the flaps 110 may be ulLI asonic ally bonded thermally bonded or adhesively bonded to the outer cover 30. In a particular aspect, the Ul lallacl1ed edge 114 of each of the con- - Il.,enl flaps 110 ~e~,ains ~ alla~ hed from the side l"a,yi,-s 84 of the absorbent insert 80 along CA 0223~700 1998-0~-13 suL:,Ia"lially the entire len~th of the unt.llacl.ed edge 114 to provide improved pe,rulll,al-ce.
Alternatively the containment flaps 110 may be integral with the backsheet 94 of the absorbent insert 80.

Each conla;n,.,ent flap 110 is also configured such that the u.,all~c;hed edge 114 of the containment flap 110 tends to position itself in a spaced relation away from the abso. L enl insert 80 toward a generally upright and perpendicular configuration ~spec; 'y in the crotch section 86 when in use. As r~prtzsenldli~ely illustrated in Figs. 7 and 8, the un~llached edge 114 of each conl~i"",ent flap 110 is desirably spaced away from the absorL,enl insert 80 10 when in use thereby providing a barrier to the lateral flow of body ~x~ ~dat~s. Desirably the unattached edge 114 of each conl; I-"ent flap 110 Il-ai,-l~;.-s a conlacling relationship with the body of the wearer while the absorbent insert 80 may be spaced away from the body of the wearerwhen in use. Typically an elastic member 116 is attached to the unattached ed~e 114 of each con' '""ent flap 110 to ~..;n ~ ~ the spaced away relationship between the 1~ unattached edge 114 and the absorbent insert 80. For e~dl.l~ls the elastic member 116 may be attached to the u, -alla- hed edge 114 in an ~lactic7~lly conl, _ e co"dilion such that the contraction of the elastic member 116 gathers or contracts and shortens the unattached edge 114 of the containment flap 110.

20 M~le~ials s~ ~ - le for use as the elastic member 116 of the conla;. ,.,~ent flaps 110 include those described above as being suitable for use as the elastic member 66 in the concealment cuffs 60. In a particular aspect of the invention the elastic members 116 may be co,-,posed of a plurality of individual strands of 620 decitex Lycra~) which are commercially available from E. I. DuPont de Nemours Co. The conlai,-"~ent flaps 110 may include from about 1 to about 25 10 elastic strands along the unattached edge 114. The elastic members 116 may be elongated prior to being attached to the IJ"alIdCI1ed edge 114 of the con ~ ".,ent flaps 110.
For example the elastic ",en,be-:i 116 may be elongdled at least about 75 percent and desirably from about 100 to about 150 percent before being attached such that the elastic members 116 gather the Ullalla~ hed edge 114 of the con ~-"ent flaps 110. Desirably the 30 elastic members 116 are configured to gather and maintain the IJ, ldlla~h ed edge 114 in a contacting ,elalionship with the wearer s body when in use to effectively provide a seal sgainst the lateral flow of body exudates.

CA 0223~700 1998-0~-13 Alternative constructions snd arrsngements for col .,.,enl flaps 110 are described in U.S.
Patent 4,704,116 issued November 3, 1987, to K. Enloe the ~~isrlosl ~re of which is hereby il ICO~ UI dled by ,t re, ~. .ce in a manner that is consialenl herewith.

5 The absorbent article 20 of the ~ ' 're.~,1l aspects of the present invention may further include a distribution or surge layer which is configured to quickly collect, temporarily hold, and s~lhsequently distribute liquid surges. For e,~d"-ple, as representatively illustrated in Figs. 7 and 8, the absorl,ent article 20 may include a surge layer 106 which can help prevent liquid exudates from pooling and collecting on the absorbent insert 80 thereby improving the overall 10 uptake rate of the absorbent article 20. The surge layer 106 is positioned in the absorbent article 20 to be in liquid communic~lion with the absorbent core 96 of the absorbent insert 80.
In the illustrated embodiment, the surge layer 106 is located on the bodyside liner ~2 of the absorbent insert 80 and is configured to be in contact with the wearer's body. Alternatively, the surge layer may be located bet~een the bodyside liner 92 and the absorbent core 9B of 15 the absorbe"l insert 80. The shown configuration of the surge layer 106 is operably connected to the bodyside liner 92 of the absorbent insert 80 with a conventional pattern of adhesive. The amount of adhesive should be sufficient to provide the desired level of bonding but should be low enough to avoid excessively restricting the movement of liquids between the layers.
Various woven and nonwoven fabrics can be used to construct the surge layer 106. For example, the surge layer 106 may be composed of a meltblown or spunbonded web ofpolyolefin fibers. The surge layer 106 may also be a bonded carded web or an airlaid web composed of natural and synthetic fibers. In desired configurations of the invention, the surge 25 layer 106 can include natural fibers, synthetic fibers, such as synthetic polymer fibers, and cor~,binaLions thereof. The surge layer 106 can, for example, be composed of polyolefin fibers, and in particular configurations the fibers can include ti~,3lllpol1enl fibers. For example, polypropylene/polyethylene bicomponent fibers may be employed in the surge layer 106.

30 The surge layer 106 can be of any desired shape consislel ,l with the absorl,er,..y requ;.~me. ,ls of the absorbent insert 80. Suitable shapes include, for example, circular"t~ yular~
triangular, tr~pr-~ d-l, oblong, dog-boned, hourglass-shaped, or oval. In a particular embodiment, the surge layer 106 is rectangular shaped. The surge layer 106 may extend over CA 0223~700 1998-0~-13 the complete length 88 of the absorbent insert 80 or may extend over only a portion of the length 88 of the absorbent insert 80. Desirably, the surge layer 106 is appruxi",alely cenler~:d about the longitudinal ce"le, i ,e of the absorbent insert 80 and positioned in at least the crotch section 86 of the absorbent insert 80.
Addilional details regarding IlldLt:lidls useful for the surge layer 106 and s~ tech,~ es for incorporating the surge layer 106 in absorbent articles are set forth in U.S. Patent Applicalion Serial No. 206,986 of C. Ellis and D. Bishop, entitled, FIBROUS NONWOVEN WEB SURGE
LAYER FOR PERSONAL CARE ABSORBENT ARTIC~ES AND THE LIKE, and filed March 4, 10 1994 (Attomey docket No. 11,25~); U.S. PatentApF' - ' n Serial No. 206,069 of C. Ellis and R. Everett, entitled, IMPROVED StJRGE MANAGEMENT FIBROUS NONWOVEN WEB FOR
PERSONAL CARE ABSORBENT ARTICLES AND THE LIKE, and filed March 4, 1994 (Attorney docket No. 11,387); U .S. Patent Application Serial No. 310,186 of F. Chen et al., entitled, WET RESILIENT PAPER SHEETS, and filed September 21, 1~194 (Attomey docket 15 No. 11,700); the ~fisrlQsLIres of which are hereby incorporated by ,ererence in a manner that is co. ,sislent herewith.

The absorbent article of the .lirr~rent aspects of the present invention further includes a rasleni"g means for securing the absorbent article about the waist of the wearer. The 20 ~Leni"g means are typically applied to the outermost comers of the side portions 22 and 24 of the absorbent article 20 to provide a means for holding the article 20 on the wearer.
~ypically, the rd:~le~ g means are located on the outer cover 30 of the absorbent article 20 and configured to be rt:rasLel1abl~. The use of fasteners which are refastenable or releasably engageable allows for ease of securing and removing the article from the waist of the wearer.
25 As representatively illustrated in Figs. 1-5, the disposable abso, L enl article 20 of the present invention may include a first fastener 70 which is releasably engageable with a second fastener 72. For example, a first raslener 70 may be located along the side edge of one of the waist regions 38 of each of the side panels 44 and 46 of the outer cover 30 and a second fastener 72 may be located along the side edge of the opposite waist region 40 of each side 30 panel 44 and 46 of the outer cover. In such a configuration, the first fastener 70 and second fastener 72 on each side panel 44 and 46 are releasably engagea~le together along a side seam to ~J~ the article 20 on the wearer. When the fasteners 70 and 72 are rele~c:~hly CA 0223~700 1998-0~-13 WO 97/18785 PCT/US96tl7095 engaged together, the side regions 34 and 36 of the outer cover 30 encircle the leças of the wearer thereby defining the leg openings 54 and 56, respectively.

Desirably, the design of the outer cover 30 is such that the abso,L,e"l article may be reversible 5 about the wearer. For example, each side panel 44 and 46 may be sLIb:,lal.Si~ ~y sy..---.el-ical and sul,sld, -Ually identical to each other. Accordin~ly, the fasteners 70 and 72 may be located more on the front of the wearer or on the back of the wearer depending upon the users prt:fer~nce. By all~cl ,;. .9 the absorl,e,~l article about the wearer such that the fasteners are located more near the back of the wearer, the wearer is less apt to be able to d;sengage the 10 rd~lene,:. 70 and 72 in use. Such a configuration is particularly desirable when the a~sorLenl article 20 is intended to be worn by an infant.

S~ le f~Lel.l lg means are well known to those skilled in the art and can include tape tab fasteners, hook and loop fasteners, mushroom fasteners, snaps, pins, belts and the like, and 15 combinations thereof. Forexd"" le, as .t:pr~senldli\~ely illustrated in Figs. 1-6, the first fastener 70 may be a hook type fastener and the second fastener 72 may be a loop type fastener. Typicaliy, the fasteners 70 and 72 are separate elements which are attached to the absorbent article 20. Alternatively, the fasteners 70 and 72 may be integral with other components of the absorbent article. For example, when the first rasleller 70 is a hook type 20 fastener, the second fastener 72 may be the outer cover 30 or a separate loop eleenl attached to the outer cover 30. Desirably, the first fastener 70 is a hook type fastener which is releasably engageable with the outer cover 30. Such an arrangement provides the ability to vary the size of the waist opening in very small i,-~ l,-ents over a wide range to fit the waist of the wearer.
The rd:,leller~ 70 and 72 may have any shape and size which provides the desired fa~le-- ~g of the absorbent article 20 about the waist of the wearer. For example, Figs. 1~ and 9-12 representatively illustrate all~. "ali~te configurations for the fasteners 70 and 72. Desirably, the fasteners 70 and 72 engage alon~ a length, as measured parallel to the longitudinal ce, -lt:r' Ie 30 26 of the article 20, which is at least about 5.1 ce"limele,:j and desirably at least about 10.2 centimeters to ~.,ai--lai-- the absorbent article about the waist of the wearer and ensure that the side panels 44 and 46 of the outer cover 30 remain in the desired position.

CA 0223~700 1998-0~-13 The ~'isposAhle absorbent article of the cJir~e,~nt aspects of the present invention may further include elastics at the waist opening 58 and leg openings 54 and 56 to further prevent the leakage of body exud~tRs For ~, an-, le, as representativeiy illustrated in Figs. 1-12, the absorbent article 20 of the present invention may include a pair of waist elastic members 120 5 and 122 which are connected to the outer cover 30 and configured to gather and cor.l,d ,l the waist regions 38 and 40 of the outer cover 30. As illustrated in Figs. 9-12, the disposable absorl,ent article 20 may furiher include a pair of leg elastics 124 and 126 which are connected to the laterally opposed side regions 34 and 36 in the crotch region 42 of the oute cover 30. The waist elastics 120 and 122 and leg elastics 124 and 126 are generally adapted 10 to fit about the waist and legs of a wearer, respectively, in use to maintain a positive, contacting relationship with the wearer to effectively reduce or eliminate the leakage of body P~l ~clates from the absorbent article 20. In a particular aspect, the outer cover 30 of the absorbent article 20 does not include leg elastics 124 and 126 such that the outer cover ..,- .Izi"s a more ga,.nenl-like appearance.
Materials s~ - lo for use as the leg elastics 124 and 126 and the walst elastics 120 and 122 are well known to those skilled in the art. Ex~amplary of such ."alerials are sheets or strands or ribbons of a polymeric, eldalur ,e, ic male, ial which are adhered to the outer cover 30 in a sl,t,lched position, or which are attached to the outer cover 30 while the outer cover is plf ated 20 such that elastic constrictive forces are imparted to the outer cover 30. The leg and waist elastics may also include such "IdLerials as polyurethane, synthetic and natural rubber. In a particular aspect of the invention, the elastics may be composed of individual strands of 620 decitex Lycra~) which are con,..,er .ially available from E. l. DuPont de Nemouts Co. When individual strands of elastic are used, the waist and leg elastics may include any s-- - le 2~ number of elastic strands to provide conla;"n,ent of the body exudates. For example, the waist elastics 120 and 122 and leg elastics 124 and 126 may include from about 1 to about 10 elastic strands. The waist and leg elastics may be elongated prior to being attached to the outer cover 30. For example, the waist and leg elastics may be elongated at least about 150 percent and desirably from about 200 to about 500 percent before being attached such that 30 the elastics gather the outer cover 30 when relaxed. The waist elastics 120 and 122 and leg elas~ics 124 and 126 may be joined to the outer cover 30 by any means known to those skilled in the art 38. For ~dl 11, !e, adhesive, thermal or ulb ~son- ~ bondi. ,g tecl ~r.i, les may be used to =
CA 0223~700 1998-0~-13 join the elastics to the outer cover. A su '-''e adhesive includes Findley H-2096 hot melt adhesive which is co,l""e,- 'iy available from Findley Adhesives, Inc.

The different Fl~pectC of the present invention can adva"ldgeously provide a di3posa~1e 5 absorbent article which has a ga""ena-like appea,dnce. As a result, the dis~.o~ ' le absorbent article of the present invention effectively conldi. ,s body exudatQs while ",~ Lail ~ ~9 an optimum fit and an aesthetically pleasing appearall.,e. Moreover, the crotch re~ion of the r~i5po~ -' 1' absorl,enl article of the present invention does not bunch up as convenlional absorbent articles have. As a result, tha absorbent article may have a reduced level of 10 leakage from the crotch region.

While the invention has been described in detail with respect to specific aspects thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alteralions to, variations of and equivalents to these aspects.
15 Accordi-lyl~r, the scope of the present invention should be ~-ssessed as that of the appended claims and any equivalents thereto.

Claims

I Claim:

1. An outer cover which is adapted for use in a disposable absorbent article, said outer cover comprising two individual side panels which are connected together along an edge of each side panel to provide a seam which extends along a longitudinal centerline of said outer cover wherein each of said side panels defines a pair of opposed waist regions which are releasably engageable together to define a leg opening in said outer cover.

2. The outer cover of claim 1 wherein said seam extends substantially an entire length of said outer cover.

3. The outer cover of claim 1 wherein said seam is substantially continuous.

4. The outer cover of claim 1 wherein said side panels overlap along said seam to provide a seam width of at least about 0.64 centimeters.

5. The outer cover of claim 1 wherein said outer cover defines a crotch length which is at least about 15 percent of a length of said outer cover.

6. The outer cover of claim 1 wherein said outer cover defines a crotch length of at least about 8 centimeters.

7. The outer cover of claim 1 wherein said side panels are made from a nonwoven material.

8. The outer cover of claim 7 wherein said nonwoven material is stretchable.

9. The outer cover of claim 1 wherein each of said side panels defines a substantially identical pattern.

10. The outer cover of claim 1 wherein each of said side panels extends along substantially an entire length of said outer cover.

11. The outer cover of claim 1 wherein each of said side panels of said outer cover further comprises a first fastener which is located on one of said waist regions and a second fastener which is located on said opposite waist region and wherein said first fastener and said second fastener on each of said side panels are releasably engageable together.

12. The outer cover of claim 11 wherein said first fastener and said second fastener are complimentary hook and loop type fasteners.

13. The outer cover of claim 1 wherein said outer cover defines a pair of laterally opposed side regions and wherein said outer cover further comprises a pair of concealment cuffs which are located along said side regions.

14. The outer cover of claim 13 wherein each concealment cuff defines a fixed edge which is connected to said side region of said outer cover and a free edge which remains unconnected to said side region of said outer cover in at least a crotch region of said outer cover.

15. The outer cover of claim 14 wherein said free edge of each of said concealment cuffs includes at least one elastic member which is configured to maintain said free edge in a spaced away relationship from said side region of said outer cover in at least said crotch region.

16. The outer cover of claim 15 wherein said elastic member is connected to said free edge of said concealment cuff at an elongation of no more than about 150 percent.

17. The outer cover of claim 15 wherein said elastic member exerts a tension of no more than about 150 grams on said free edge of said concealment cuff when said free edge is fully extended.

18. A disposable absorbent article which defines a first side portion, a second side portion, and a longitudinal centerline between said side portions, said absorbent article comprising:

a) an outer cover which defines a length, a pair of laterally opposed side regions, a pair of longitudinally opposed waist regions, and a crotch region which expends between and connects said waist regions, said outer cover comprising a first side panel which is located in said first side portion of said absorbent article and a second side panel which is located in said second side portion of said absorbent article wherein an edge of said first side panel is connected to an edge of said second side panel to provide a seam which extends along said longitudinal centerline between said side portions of said absorbent article; and b) an absorbent insert which is connected to said outer cover.

19. The absorbent article of claim 18 wherein said opposite waist regions on each side panel are releasably engageable together to define a pair of leg openings in said outer cover.

20. The absorbent article of claim 18 wherein each of said side panels of said outer cover further comprises a first fastener which is located on one of said waist regions and a second fastener which is located on said opposite waist region and wherein said first fastener and said second fastener on each of said side panels are releasably engageable together.

21. The absorbent article of claim 20 wherein said first fastener and said second fastener are complimentary hook and loop type fasteners.

22. The absorbent article of claim 18 wherein said seam extends along substantially said entire length of said outer cover.

23. The absorbent article of claim 18 wherein said seam is substantially continuous.

24. The absorbent article of claim 18 wherein said edges of said side panels overlap along said seam to provide a seam width of at least about 0.64 centimeters.

25. The absorbent article of claim 18 wherein said outer cover defines a crotch length in said crotch region which is at least about 15 percent of said length of said outer cover.

26. The absorbent article of claim 18 wherein said outer cover defines a crotch length in said crotch region which is at least about 8 centimeters.

27. The absorbent article of claim 18 wherein said outer cover is made from a nonwoven material.

28. The absorbent article of claim 18 wherein said first side panel and said second side panel define a substantially identical pattern.

29. The absorbent article of claim 18 and further comprising a pair of concealment cuffs which are located along said side regions of said outer cover, wherein each concealment cuff defines a fixed edge which is connected to said outer cover and a free edge which remains unconnected to said outer cover in at least said crotch region of said outer cover.

30. The absorbent article of claim 29 wherein said free edge of each of said concealment cuffs includes at least one elastic member which is configured to maintain said free edge in a spaced away relationship from said outer cover in at least said crotch region of said outer cover.

31. The absorbent article of claim 30 wherein said elastic member is connected to said free edge of said concealment cuff at an elongation of no more than about 150 percent.

32. The absorbent article of claim 30 wherein said elastic member exerts a tension of no more than about 150 grams on said free edge of said concealment cuff when said free edge is fully extended.

33. A disposable absorbent article which defines a first side portion, a second side portion, and a longitudinal centerline between said side portions, said absorbent article comprising:

a) an outer cover which includes two individual side panels which are connected together to provide a seam which extends along said longitudinal centerline of said absorbent article, and b) an absorbent insert which is connected to said outer cover and which defines a pair of longitudinally opposed end margins and a pair of laterally opposed side margins, and includes a bodyside liner, a backsheet which is connected to said bodyside liner in a superposed relation, and an absorbent core which is located between said bodyside liner and said backsheet.

34. The absorbent article of claim 33 wherein each of said side panels of said outer cover defines a pair of opposed waist regions which are releasably engageable together to define a leg opening in said outer cover.

35. The absorbent article of claim 33 wherein said end margins of said absorbent insert are connected to said outer cover and wherein said absorbent insert remains unconnected from said outer cover between said end margins.

36. The absorbent article of claim 35 wherein each of said end margins of said absorbent insert are connected to said outer cover along a length of no more than about 5.1 centimeters.

37. The absorbent article of claim 33 wherein said absorbent core includes at least two independent, longitudinally extending absorbent strips.

38. The absorbent article of claim 33 wherein said absorbent article further comprises a pair of longitudinally extending containment flaps which are located on said side margins of said absorbent insert.

39. The absorbent article of claim 38 wherein each of said containment flaps defines an attached edge which is at least partially attached to said absorbent insert and an unattached edge which remains unattached to said absorbent insert in at least a crotch section of said absorbent insert.

40. The absorbent article of claim 39 wherein said unattached edge of each of said containment flaps includes at least one elastic member which is configured to maintain said unattached edge in a spaced away relationship from said absorbent insert in at least said crotch section.

41. The absorbent article of claim 38 wherein each of said containment flaps extends along substantially an entire length of said absorbent insert.

42. A disposable absorbent article which defines a first side portion, a second side portion, and a longitudinal centerline between said side portions, said absorbent article comprising:
a) an outer cover which defines a length, a pair of laterally opposed side regions, a pair of longitudinally opposed waist regions, and a crotch region which extends between and connects said waist regions, said outer cover comprising a first side panel which is located in said first side portion of said absorbent article and a second side panel which is located in said second side portion of said absorbent article wherein an edge of said first side panel is connected to an edge of said second side panel to provide a seam which extends along said longitudinal centerline between said side portions of said absorbent article; and b) a pair of concealment cuffs which are located along said side regions of said outer cover and which define a fixed edge which is connected to said outer cover and a free edge which remains unconnected to said outer cover in at least said crotch region of said outer cover;

c) an absorbent insert which is connected to said outer cover and which defines a pair of longitudinally opposed end margins, a pair of laterally opposed side margins, and a crotch section; and d) a pair of longitudinally extending containment flaps which are located along said side margins of said absorbent insert.

43. The absorbent article of claim 42 wherein said end margins of said absorbent insert are connected to said outer cover and wherein said absorbent insert remains unconnected from said outer cover between said end margins.

44. The absorbent article of claim 42 wherein said absorbent article further comprises a waist elastic member located on at least one of said waist regions of said outer cover.

45. The absorbent article of claim 42 wherein said absorbent article further comprises a pair of leg elastics which are located on said side regions of said outer cover in at least said crotch region of said outer cover.

46. A method of making a disposable absorbent article which defines a first side portion a second side portion and a longitudinal centerline between said side portions, said method comprising:

a) cutting a continuously moving web of material into a first side panel and a second side panel;

b) bonding an edge of said first side panel to an edge of said second side panel along a seam to provide an outer cover for said disposable absorbent article wherein said first side panel provides said outer cover in said first side portion of said absorbent article and said second side panel provides said outer cover in said second side portion of said absorbent article and wherein said seam extends along said longitudinal centerline of said absorbent article; and c) attaching an absorbent insert which defines a pair of longitudinally opposed end margins and a pair of laterally opposed side margins to said outer cover.

47. The method of claim 46 and further comprising attaching a concealment cuff to said outer cover along each of a pair of laterally opposed side regions of said outer cover.

48. The method of claim 47 and further comprising attaching fixed edge of each of said concealment cuffs to said side region of said outer cover and maintaining a free edge of said concealment cuffs unattached to said outer cover in at least a crotch region of said outer cover.

49. The method of claim 46 and further comprising attaching said end margins of said absorbent insert to said outer cover and maintaining said absorbent insert between said end margins unattached to said outer cover.

50. The method of claim 46 and further comprising attaching a containment flap to said absorbent insert along each of said side margins of said absorbent insert.

51. The method of claim 46 and further comprising ultrasonically bonding said edge of said first side panel to said edge of said second side panel along said seam.

52. The method of claim 46 and further comprising cutting said continuously moving web of material into substantially identical patterns to provide said first side panel and said second side panel.

53. The method of claim 46 and further comprising attaching an elongated waist elastic member to at least one waist region of said outer cover.

54. The method of claim 46 wherein said continuously moving web of material is a nonwoven material.