CA2240032A1 - Absorbent article with flip down fasteners - Google Patents

Abstract

An article, such as a diaper (10), has a length-wise longitudinal direction (26), a transverse lateral direction (24), and a first waistband portion (12) at the back or rear of the diaper. The first waistband portion has an inward, bodyside surface (90) and an outward surface (92) thereof. A second, front waistband portion (14) is positioned longitudinally opposite of the first waistband portion (12) and has an inward, bodyside surface (90) and an outward surface (92) thereof. An intermediate, crotch portion (16) interconnects the first and second waistband portion, respectively. The article comprises a backsheet layer (30) and a substantially liquid permeable topsheet layer (28) which is connected in a superposed relation with the backsheet layer (30). A absorbent structure (32) is sandwiched between the backsheet and topsheet layers, and a flip fastener (36) is joined to each of a pair of laterally opposed end regions (86) of the first waistband portion (12). Each flip fastener (36) includes a longitudinally extending flip tab section (60) which is joined to a longitudinally outboard edge region (82) of the first waistband portion (12) to project longitudinally beyond and outboard from the first waistband portion (12). A first fastening component is operatively joined to an appointed fastening surface of each flip tab section (60), and each flip fastener has an appointed folding line (59) which extends along the lateral direction (24) of the article. A first landing zone component (50) is joined to a selected surface of the second waistband portion (14) and anappointed area of the first landing zone component is configured to provide a fastening attachment to each of the first fastening components (52) when each flip tab section (60) is operatively pivoted about its folding line (59) to thereby engage its corresponding area of the first landing zone component.

Description

CA 02240032 l998-07-02 ~, ABSORBENT ARTICLE WITH FLIP DOWN FASTENERS

Field of the Invention The present invention relates to garment articles. More particularly, the present invention relates to absorbent articles, especially disposable absorbent articles, which have more secure fastening with improved fit and performance.

Background of the Invention Conventional garment articles, such as disposable diapers and othe~ disposable absorbent articles, have typically employed adhesive or mechanical fasteners which attach appointed waistband sections of the articles around a wearer. In addition, various configurations of waist elastics, leg elastics, elasticized liners, and elasticized outercovers have been employed on garment articles to help produce and maintain the fit of the articles about the body contours of the wearer.

Conventional garment articles, such as those described above, have not provided desired levels of reliable fit, and have been susceptible to excessive sagging and drooping during the period of wearing. The garment structures have not adequately maintained the desired levels of fit and comfort, and where the garments are configured as absorbent articles, the articles have been susceptible to excessive leakage of liquids and other waste materials. As a result, there has been a continued need for improved garments having more consistent fit and greater resistance to sagging and drooping.

CA 02240032 l998-07-02 Brief DescriPtion of the Invention Generally stated, the present invention provides a distinctive article which includes a backsheet layer, a liquid permeable topsheet layer connected in superposed relation s with the backsheet layer, and an absorbent structure sandwiched between the backsheet and topsheet layers. A flip fastener is joined to each of a pair of laterally opposed ends of a first waistband portion of the article. Each flip fastener includes a longitudinally extending flip tab section which is joined to a longitudinally outboard edge region of the first waistband portion to project longitudinally beyond and 10 outboard from the first waistband portion. Each flip tab section has a first fastening component operatively joined to an appointed fastening surface of the flip tab section, and has an appointed folding line which extends along a lateral direction of the article. A first landing zone component is joined to a selected su,~face of a second waistband portion of the article. The first landing zone component is configured to provide a fastening attachment to each first fastening component when each flip tab is operatively pivoted about its folding line to engage the first landing zone component.

By incorporating its various aspects, the article of present invention can provide more reliable and more consistent fit about the wearer with greater resistance to sagging and drooping. The desired fit can be better maintained even when the wearer is highly active. Where the garment is an absorbent article, the improvedresistance to drooping can reduce gapping between the garment and wearer, and can reduce the leakage of liquid or semi-liquid waste materials.

Brief DescriDtion of the Drawings The present invention will be more fully understood and further advantages will become apparent when reference is made to the following detailed description of the invention and the drawings, in which:

Fig. 1 representatively shows a top view of the outward surfaces of a diaper article of the invention which incorporates the flip fastener;

CA 02240032 l998-07-02 Fig. 2 representatively shows a plan view of the inward, bodyside surfaces of the diaper article illustrated in Fig. 1;

Fig. 3 representatively shows a schematic, longitudinal cross-sectional view of the article illustrated in Fig. 1;

Fig. 4 representatively shows a perspective view of an article of the invention which has been arranged for placement on a wearer;

10 Fig. 5 representatively shows another perspective view of the article of Fig. 4 wherein the back waistband section of the article has been positioned about the wearer;

Fig. 6 representatively shows a further perspective view of the article of Fig. 5 wherein the front waistband section of the article has been aligned and mated with the back waistband section;

Fig. 7 representatively shows a further perspective view of the article of Fig. 6 wherein the flip tab sections of the flip fasteners have been folded to operablyengage the appointed, primary landing zone region on the outer surface of the front waistband section;

Fig. 8 representatively shows a top, plan view of the outward surfaces of a diaper article of the invention which incorporates another arrangement of the flip fastener;

Fig. 9 representatively shows a plan view of the inward, bodyside surfaces of the article of Fig. 8;

Fig. 10 representatively shows a schematic, longitudinal cross-sectional view of the article illustrated in Fig. 8;

Fig. 11 representatively shows a perspective view of the article of Fig. 8 which has been arranged for placement on a wearer;

CA 02240032 l998-07-02 Fig. 12 representatively shows a perspective view of the article of Fig. 11 wherein the front waistband section of the article has been positioned about the wearer;
Fig. 13 representatively shows a further perspective view of the article of Fig. 12 wherein the back waistband section of the article has been aligned and mated with the front waistband section; and Fig. 14 representatively shows a further perspective view of the article of Fig. 13 wherein the flip tab sections of the flip fasteners have been folded to operably10 engage the appointed, primary landing zone region on the inner bodyside surface of the front waistband section.

Detailed Description of the invention 15 The various aspects and embodiments of the invention will be described in thecontext of a disposable absorbent article, such as a disposable diaper. It is, however, readily apparent that the present invention could also be employed withother articles, such as caps, gowns, shoe covers, feminine care articles, children's training pants, incontinence garments and the like. Typically, the disposable articles 20 are intended for limited use and are not intended to be laundered or otherwise cleaned for reuse. A disposable diaper, for example, is discarded after it has become soiled by the wearer.

With reference to Figs. 1, 2 and 3, an article, such as the representatively shown 25 absorbent article of diaper 10, has a length-wise longitudinal direction 26, a transverse lateral direction 24, and a first waistband portion 12 at the back or rear of the diaper. The first waistband portion has an inward, bodyside surface 90 and an outward surface 92 thereof. A second, front waistband portion 14 is positioned longitudinally opposite of the first waistband portion 12 and has an inward, bodyside 30 surface 90 and an outward surface 92 thereof. An intermediate, crotch portion 16 interconnects the first and second waistband portion 12 and 14, respectively. The article comprises a backsheet layer 30 which has an outward surface and an opposed, inward or bodyside surface thereof. As representatively shown, the outward surface of the backsheet layer may provide the outward surface 92 of the35 article. A substantially liquid permeable topsheet layer 28 is connected in a CA 02240032 l998-07-02 superposed relation with the backsheet layer 30, and an absorbent structure 32 is sandwiched between the backsheet and topsheet layers. A flip fastener 36 is joined to each of a pair of laterally opposed end regions 86 of the first waistband portion 12, and each flip fastener 36 includes a longitudinally extending flip tab section 60 which iS joined to a longitudinally outboard edge region 82 of the first waistband portion 12 to project longitudinally beyond and outboard from the first waistband portion 12.
The flip tab section 60 has a distal end region 58, an inward surface 56, and anoutward surface 54. A first fastening component is operatively joined to an appointed fastening surface of the flip tab section 60, and the flip fastener has an 10 appointed folding line 59 which extends along the lateral direction 24 of the article. A
first landing zone component, such as a first landing zone patch 50, is joined to a selected surface, such as an inward surface 90 or the outward surface 92, of thesecond waistband portion 14. The landing zone component is configured to providea fastening attachment to each first fastening component 52 when each flip tab section 60 is operatively pivoted about its folding line 59 to thereby engage the first landing zone component.

In a particular aspect of the invention, the appointed fastening surface of at least one of the flip tab sections 60 is the outward surface 54 of the flip tab section. With this configuration, the first landing zone component can be operatively joined with the outward surface 92 of the second waistband portion 14.

Another aspect of the invention can be configured with the appointed fastening surface of at least one of the flip tab sections 60 provided by the inward surface 56 of the flip tab section. With this configuration, the first landing zone component can be operatively joined with the inward surface 90 of the second waistband portion 14.

In a desired aspect of the invention, the first waistband portion 12 of the article can include at least one separately provided, base panel section 80 which is joined to extend laterally outboard at a lateral side edge portion 86 of a first, back waistband section 12 of the article to provide a carrier member. In the representatively shown arrangements, the base panel section 80 is assembled to extend from a laterally terminal edge of the backsheet layer 30. Each base panel section 80 has an appointed inward, bodyside surface 106, an appointed outward side surface 108, and a laterally extending, longitudinally outboard edge region 110. The longitudinally extending flip tab section 60 is operatively joined to the longitudinally outboard edge region 110 of the base panel section 80 to project longitudinally outboard from the base panel section, and thereby project longitudinally outboard from and beyond the longitudinally terminal edge of the first waistband portion 12.
s The various aspects (individually and in combination) of the present invention can advantageously help to better maintain the desired fit around the wearer. For example, the aspects of the invention can help reduce the sagging and drooping of the crotch region of the garment, and can help reduce roll-over and drooping at the 10 waist region. When incorporated into an absorbent article, the various aspects of the invention can improve fit and appearance, and can reduce undesired gapping and leakage.

A desired garment article of the invention can, for example, be the representatively shown disposable diaper 10. The diaper can include a backsheet layer 30, a liquid permeable topsheet layer 28 connected and integrated with the backsheet layer, and an absorbent structure, such as a structure which includes absorbent body 32. The absorbent structure is sandwiched between the backsheet and topsheet layers, andis operably held therebetween. A fastening system, such as a system including flip fasteners 36, is configured to join together the front and back waistband portions 14 and 12 to encircle the wearer's body and hold the diaper secure on the wearer during use.

As representatively shown, the front waistband section 14 of the diaper 10 has alaterally opposed, front pair of side edge regions 88, and the rear waistband section 12 has a laterally opposed, rear pair of side edge regions 86. The intermediate section 16 interconnects the front and rear waistband section and provides a diaper crotch region which is typically positioned between the legs of the wearer. The article has an appointed fastener landing zone 50 which is disposed on the outward surface 92 of the article. In the example shown in Fig. 1, for example, the landing zone 50 is disposed on the outward surface of the backsheet layer 30. The liquidpermeable topsheet layer 28 is superposed in facing relation with the backsheet layer 30, and the absorbent body 32 is operably connected and affixed between the backsheet layer 30 and topsheet layer 28.

Figs. 1 and 2 show typical plan views of the representative disposable diaper 10 in its generally flat-out, uncontracted state (i.e., with substantially all elastic induced gathering and contraction removed). Portions of the structure are partially cut away to more clearly show the interior construction of the diaper article, and the bodyside surface of the diaper which contacts the wearer is facing the viewer. The outer edges of the diaper define a periphery with longitudinally extending side edge margins 20 and laterally extending end edge margins 22. The side edges define leg openings for the diaper, and optionally, are curvilinear and contoured. The end edges are shown as straight, but optionally, may be curvilinear.

With regard to the designated surfaces of the article, the various inward surfaces are configured to face toward the body of the wearer when the article is placed about the wearer. The outward surface of the article is configured to face awa~ from the wearer's body when the article is placed about the wearer. With regard to the flip fasteners, particularly the flip tab section 60, the inward surface 56 and the outward surface 54 are detemmined when the flip tab section is in its substantially flat-out, unfolded condition.

The diaper 10 typically includes a porous, liquid permeable topsheet 28; a substantially liquid imperrneable backsheet 30; an absorbent structure 32 positioned and connected between the topsheet and backsheet; a surge management - portion 46 located adjacent the absorbent structure; and a system of elastomeric gathering member;" such as a system including leg elastics 34 and waist elastics 42.
The surge management portion is positioned in a liquid communication with a retention portion of the absorbent structure, and the topsheet 28, backsheet 30,absorbent structure 32, surge management portion 46 and elastic members 34 and 42 may be assembled together into a variety of well-known diaper configurations. The diaper can additionally include a system of containment flaps 62, and a system of ear region members 32 or side panels which may be elasticized orotherwise elastomeric Examples of articles which include elasticize ;d side panels and selectively configured fastener tabs are described in co-pending U.S. applications.

Various techniques for forming the desired fastening ~ I .

systems are described in U.S. Patent No. 5,399,219 of T. Roessler et al., entitled METHOD FOR MAKING A FASTENING SYSTEM FOR A DYNAMIC Fll~ING
DIAPER and issued March 21, 1995 (attorney docket No. 11,186?, in U.S. Patent Application Serial No. 286,086 of D. Fries, entitled A PROCESS FOR ASSEMBLING
ELASTICIZED EAR PORTIONS and filed August 3,1994 (attomey docket No.
11,169) which issued as U.S. Patent No. 5,540,796; and in U.S. Patent Application Serial No. 08/415,383 of D. Fries, entitled AN ASSEMBLY PROCESS FOR A
lAMINATED TAPE and filed April 3, 1995 (attorney docket No. 11,950) which issuedas U.S. Patent No. 5,595,618.

Diaper 10 generally defines the longitudinally extending length directlon 26 and the laterally extending width direction 24, as representatively shown in Fig.1. The diaper may have any desired shape, such as rectangular, I-shaped, a generally hourglass shape, or a T-shape With the T-shape, the crossbar of the ~T may comprise the front waistband portion of the diaper, or may alternatively comprise the rear waistband portion of the diaper The topsheet 28 and backsheet 30 may be generally coextensive, and may have length and width dimensions which are generally larger than and extend beyond the corresponding dimensions of the absorbent structure 32 to provide for the corresponding side margins 20 and end margins 22. Optionally, the topshe~t and backsheet layers may not be coextensive. The topsheet 28 is operatively associated with and superimposed on backsheet 30, thereby defining the periphery of the diaper. The waistband regions comprise those portions of the diaper, which when worn, wholly or partially cover or encircle the waist or mid-lower torso of the wearer The intermediate, crotch region 16 lies between and interconnects the waistband regions 14 and 12, and comprises that portion of the diaper which, when worn, ispositioned between the legs of the wearer and covers the lower torso of the wearer Thus, the intermediate crotch region 16 is an area where repeated fluid surge typically occur in the diaper or other disposable absorbent article Backsheet 30 can typically be located along an outer-side surface of the absorbent ~ody 32 and may be composed of a liquid permeable material, but desirably comprises a material which is configured to be substantially impermeable to iiquids.
For example, a typical backsheet can be manufactured from a thin plastic film, or other flexible, substantially liquid-impermeable material. As used in the present specification, the term "flexible" refers to materials which are compliant and which will readily conform to the general shape and contours of the wearer's body.
Backsheet 30 prevents the exudates contained in absorbent body 32 from wetting articles, such as bedsheets and overgarments, which contact diaper-10. In particular embodiments of the invention, backsheet 30 can include a film, such as a polyethylene film, having a thickness of from about 0.012 millimeters (0.5 mil) to about 0.051 millimeters (2.0 mils). For example, the backsheet film can have a thickness of about 1.25 mil.

Alternative constructions of the backsheet may comprise a woven or'nonwoven fibrous web layer which has been totally or partially constructed or treated to impart the desired levels of liquid impermeability to selected regions that are adjacent or proximate the absorbent body. For example, the backsheet may include a gas-permeable, nonwoven fabric layer laminated to a polymer film layer which mayor may not be gas-permeable. Other examples of fibrous, cloth-like backsheet materials can comprise a stretch thinned or stretch thermal laminate material composed of a 0.6 mil (0.015 mm) thick polypropylene blown film and a 0.7 ounce per square yard (23.8 gsm) polypropylene spunbond material (2 denier fibers). A
- material of this type forms the outercover of a HUGGIES(~) SUPREME diaper, which is commercially available from Kimberly-Clark Corporation. The backsheet 30 typically provides the outer cover of the article. Optionally, however, the article may 2 5 include a separate outer cover component member which is additional to the backsheet.

Backsheet 30 may alternatively include a micro-porous, "breathable" material which permits gases, such as water vapor, to escape from the absorbent body 32 while substantially preventing liquid exudates from passing through the backsheet. Forexample, the breathable backsheet may be composed of a microporous polymer film or a nonwoven fabric which has been coated or otherwise modified to impart a desired level of liquid impermeability. For example, a suitable microporous film can be a PMP-1 material, which is available from Mitsui Toatsu Chemicais, Inc., a 3s company having offices in Tokyo, Japan; or an XKO-8044 polyolefin film available *denotes trademark g CA 02240032 l998-07-02 from 3M Company of Minneapolis, Minnesota. The backsheet may also be embossed or otherwise provided with a pattern or matte finish to exhibit a more aesthetically pleasing appearance.

In the various configurations of the invention, where a component such as the backsheet 30 or the containment flaps 62 are configured to be permeable to gas while having a resistance and limited permeability to aqueous liquid, the liquidresistant material can have a construction which is capable of supporting a hydrohead of at least about 45 cm of water substantially without leakage 10 therethrough. A suitable technique for determining the resistance of a material to liquid penetration is Federal Test Method Standard FTMS 191 Method 5514, dated 31 December 1968.

The size of the backsheet 30 is typically determined by the size of absorbent body 32 and the particular diaper design selected. Backsheet 30, for example, may have a generally T-shape, a generally I-shape or a modified hourglass shape, and may extend beyond the terminal edges of absorbent body 32 by a selected distance, such as a distance within the range of about 1.3 centimeters to 2.5 centimeters (about 0.5 to 1.0 inch), to provide at least a portion of the side and end margins.

The topsheet 28 presents a body-facing surface which is compliant, soft-feeling, and non-irritating to the wearer's skin. Further, the topsheet 28 can be less hydrophilic than absorbent body 32, and is sufficiently porous to be liquid permeable, permitting liquid to readily penetrate through its thickness to reach the absorbent body. Asuitable topsheet layer 28 may be manufactured from a wide selection of web materials, such as porous foams, reticulated foams, apertured plastic films, natural fibers (for example, wood or cotton fibers), synthetic fibers (for example, polyester or polypropylene fibers), or a combination of natural and synthetic fibers. The topsheet layer 28 is typically employed to help isolate the wearer's skin from liquids held in absorbent body 32.

Various woven and nonwoven fabrics can be used for topsheet 28. For example, thetopsheet may be composed of a meltblown or spunbonded web of the desired fibers,and may also be a bonded-carded-web. The various fabrics can be composed of natural fibers, synthetic fibers or combinations thereof.

CA 02240032 l998-07-02 For the purposes of the present description, the term "nonwoven web" means a webof fibrous material which is formed without the aid of a textile weaving or knitting process. The term "fabrics" is used to refer to all of the woven, knitted and nonwoven fibrous webs.

The topsheet fabrics may be composed of a substantially hydrophobic material, and the hydrophobic material may optionally be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity. In a particular 10 embodiment of the invention, topsheet 28 is a nonwoven, spunbond polypropylene fabric composed of about 2.8 - 3.2 denier fibers formed into a web having a basis weight of about 22 gsm and density of about 0.06 gm/cc. The fabric can be surface treated with an operative amount of surfactant, such as about 0.28~/O~Triton X-102 surfactant. The surfactant can be applied by any conventional means, such as 15 spraying, printing, brush coating or the like.

The topsheet 28 and backsheet 30 are connected or otherwise associated together in an operable manner. As used herein, the term "associated" encompasses configurations in which topsheet 28 is directly joined to backsheet 30 by affixing 20 topsheet 28 directly to backsheet 30, and configurations wherein topsheet 28 is indirectly joined to backsheet 30 by affixing topsheet 28 to intermediate members which in turn are affixed to backsheet 30. Topsheet 28 and backsheet 30 can, forexample, be affixed directly to each other in the diaper periphery by attachmentmeans (not shown) such as adhesive bonds, sonic bonds, thermal bonds, pinning, 25 stitching or any other attachment means known in the art, as well as combinations thereof. For example, a uniform continuous layer of adhesive, a patterned layer of adhesive, a sprayed pattern of adhesive or an array of separate lines, swirls or spots of construction adhesive may be used to affix topsheet 28 to backsheet 30. It should be readily appreciated that the above-described attachment means may also be 30 employed to suitably interconnect, assemble and/or affix together the various other component parts of the articles which are described herein.

The absorbent body 32 provides an absorbent structure which can include a retention portion, such as the shown absorbent pad composed of selected 35 hydrophilic fibers and high-absorbency particles, for holding and storing absorbed liquids and other waste materials. The absorbent body is positioned and sandwiched between the topsheet 28 and backsheet 30 to form the diaper 10. The absorbent body has a construction which is generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining body exudates. It should be understood that, for purposes of this invention, the absorbent body structure may comprise a single, integral piece of material, or alternatively, may comprise a plurality of individual separate pieces of material which are operably assembled together.

10 Various types of wettable, hydrophilic fibrous material can be used to form the component parts of absorbent body 32. Examples of suitable fibers include naturally occurring organic fibers composed of intrinsically wettable material, such as cellulosic fibers; synthetic fibers composed of cellulose or cellulose d~erivatives, such as rayon fibers; inorganic fibers composed of an inherently wettable material, such as glass fibers; synthetic fibers made from inherently wettable thermoplastic polymers, such as particular polyester or polyamide fibers; and synthetic fiberscomposed of a nonwettable thermoplastic polymer, such as polypropylene fibers, which have been hydrophilized by appropriate means. The fibers may be hydrophilized, for example, by treatment with silica, treatment with a material which has a suitable hydrophilic moiety and is not readily removable from the fiber, or by sheathing the nonwettable, hydrophobic fiber with a hydrophilic polymer during or after the formation of the fiber. For the purposes of the present invention, it is contemplated that selected blends of the various types of fibers mentioned abovemay also be employed.

As used herein, the term "hydrophilic" describes fibers or the surfaces of fibers which are wetted by the aqueous liquids in contact with the fibers. The degree of wetting of the materials can, in turn, be described in terms of the contact angles and the surface tensions of the liquids and materials involved. Equipment and techniquessuitable for measuring the wettability of particular fiber materials or blends of fiber materials can be provided by a Cahn SFA-222 Sur~ace Force Analyzer System, or a substantially equivalent system. When measured with such system, fibers having contact angles less than 90~ are designated "wettable", while fibers having contact angles greater than 90~ are designated "nonwettable".

CA 02240032 l998-07-02 The absorbent body structure 32 can comprise a matrix of hydrophilic fibers, such as a web of cellulosic fluff, mixed with particles of high-absorbency material. In particular arrangements, absorbent body 32 may comprise a mixture of superabsorbent hydrogel-forming particles and synthetic polymer meltblown fibers, s or a mixture of superabsorbent particles with a fibrous coform material comprising a blend of natural fibers and/or synthetic polymer fibers. The superabsorbent particles may be substantially homogeneously mixed with the hydrophilic fibers, or may be nonuniformly mixed. For example, the concentrations of superabsorbent partides may be arranged in a non-step-wise gradient through a substantial portion of the10 thickness (z-direction) of the absorbent structure, with lower concentrations toward the bodyside of the absorbent body and relatively higher concentrations toward the outerside of the absorbent structure. Suitable z-gradient configurations are described in U.S.P. 4,699,823 issued October 13, 1987 to Kellenberger et al.

Alternatively, the concentrations of superabsorbent particles may be arranged in a non-step-wise gradient, through a substantial portion of the thickness (z-direction) of the absorbent structure, with higher concentrations toward the bodyside of the absorbent body and relatively lower concentrations toward the outerside of the absorbent structure. The superabsorbent partides may also be arranged in a generally discrete layer within the matrix of hydrophilic fibers. In addition, two or more different types of superabsorbent may be selectively positioned at different locations within or along the fiber matrix. "

The high-absorbency material may comprise absorbent gelling materials, such as superabsorbents. Absorbent gelling materials can be natural, synthetic and modified natural polymers and materials. In addition, the absorbent gelling materials can be inorganic materials, such as silica gels, or organic compounds such as cross-linked polymers. The term "cross-linked" refers to any means for effectively rendering normally water-soluble materials substantially water insoluble but swellable. Such means can include, for example, physical entanglement, crystalline domains, covalent bonds, ionic complexes and associations, hydrophilic associations, such as hydrogen bonding, and hydrophobic associations or Van der Waals forces.

Examples of synthetic absorbent gelling material polymers include the alkali metal and ammonium salts of poly(acrylic acid) and poly (methacrylic acid), poly(acrylamides), poly(vinyl ethers), maleic anhydride copolymers with vinyl ethers and alpha-olefins, poly(vinyl pyrrolidone), poly(vinylmorpholinone), poly(vinyl alcohol), and mixtures and copolymers thereof. Further polymers suitable for use in the absorbent body include natural and modified natural polymers, such as hydrolyzed acrylonitrile-grafted starch, acrylic acid grafted starch, methyl cellulose, chitosan, carboxymethyl cellulose, hydroxypropyl cellulose, and the natural gums, such as alginates, xanthan gum, locust bean gum and the like. Mixtures of natural 10 and wholly or partially synthetic absorbent polymers can also be useful in the present invention. Other suitable absorbent gelling materials are disclosed by Assarsson et al. in U.S. Patent No. 3,901,236 issued August 26, 1975. Processes for preparingsynthetic absorbent gelling polymers are disclosed in U.S. Patent ~o. 4,076,663 issued February 28, 1978 to Masuda et al. and U.S. Patent No. 4,286,082 issued August 25, 1981 to Tsubakimoto et al.

Synthetic absorbent gelling materials typically are xerogels which form hydrogels when wetted. The term "hydrogel", however, has commonly been used to also refer to both the wetted and unwetted forms of the material.

As mentioned previously, the high-absorbency material used in absorbent body 32 is generally in the form of discrete particles. The particles can be of any desiredshape, for example, spiral or semi-spiral, cubic, rod-like, polyhedral, etc. Shapes having a large greatest dimension/smallest dimension ratio, like needles, flakes, and 25 fibers, are also contemplated for use herein. Conglomerates of particles of absorbent gelling material may also be used in absorbent body 32. Desired for use are particles having an average size of from about 20 microns to about 1 millimeter.
"Particle size" as used herein means the weighted average of the smallest dimension of the individual particles.

The hydrophilic fibers and high-absorbency particles can be configured to form an average composite basis weight which is within the range of about 400 - 900 gsm.In certain aspects of the invention, the average composite basis weight is within the range of about 500 - 800 gsm, and alternatively is within the range of about 35 550 - 750 gsm to provide desired performance.

CA 02240032 l998-07-02 To improve the containment of the high-absorbency material, absorbent body structure 32 can include an overwrap, such as wrap sheet 70, which is placed immediately adjacent and around absorbent body 32 and may be bonded to the absorbent structure and to the various other components of the article. The wrapsheet is preferably a layer of absorbent material which covers the major bodyside and outerside surfaces of the absorbent body, and preferably encloses substantially all of the peripheral edges of the absorbent body to form a substantially complete envelope thereabout. Alternatively, the wrap sheet can provide an absorbent 10 wrapping which covers the major bodyside and outerside surfaces of the absorbent body, and encloses substantially only the lateral side edges of the absorbent body.
Accordingly, both the linear and the inwardly curved portions of the lateral side edges of the wrap sheet would be closed about the absorbent body. In suc'h an arrangement, however, the end edges of the wrap sheet may not be completely closed around the end edges of the absorbent body at the waistband regions of the article.

For example, the complete wrap sheet 70, or at least the bodyside layer of the wrap sheet, may comprise a meltblown web composed of meltblown fibers, such as meltblown polypropylene fibers. Another example of absorbent wrap 70 may comprise a low porosity cellulosic web, such as a tissue composed of an approximately 50/50 blend of hardwood/softwood fibers.

The absorbent wrap 70 may comprise a multi-element wrapsheet which includes a separate bodyside wrap layer and a separate outerside wrap layer, each of which extends past all or some of the peripheral edges of absorbent body 32. Such a configuration of the wrap sheet can, for example, facilitate the formation of a substantially complete sealing and closure around the peripheral edges of absorbent body 32. In the back waistband portion of the illustrated diaper, the absorbent wrap may also be configured to extend an increased distance away from the periphery of the absorbent body to add opacity and strength to the back side-sections of the diaper. In the illustrated embodiment, the bodyside and outerside layers of absorbent wrap 70 can extend at least about 1/2 inch beyond the peripheral edges of the absorbent body to provide an outwardly protruding, flange-type bonding area over which the periphery of the bodyside portion of the absorbent wrap may be completely or partially connected to the periphery of the outerside portion of the absorbent wrap.

The bodyside and outerside layers of wrap sheet 70 may be composed of s substantially the same material, or may be composed of different materials. For example, the outerside layer of the wrap sheet may be composed of a relatively lower basis weight material having a relatively high porosity, such as a wet strength cellulosic tissue composed of softwood pulp. The bodyside layer of the wrap sheet may comprise one of the previously described wrap sheet materials which has a 10 relatively low porosity. The low porosity bodyside layer can better prevent the migration of superabsorbent particles onto the wearer's skin, and the high porosity, lower basis weight outerside layer can help reduce costs.

Diaper 10 can also include a surge management layer 46 which helps to decelerateand diffuse surges of liquid that may be introduced into the absorbent body of the article. In the illustrated embodiment, for example, surge layer 46 can be located on an inwardly facing body side surface of topsheet layer 28. Alternatively, surge layer 46 may be located ad3acent to an outer side surface of topsheet 28.
Accordingly, the surge layer would then be interposed between topsheet 28 and 20 absorbent body 32. Examples of suitable surge management layers 46 are described in U.S. Patent Application Serial No. 206,986 of C. Ellis and D. Bishop, entitled FIBROUS NONWOVEN WEB SURGE LAYER FOR PERSONAL CARE
ABSORBENT ARTICLES AND THE LIKE, filed March 4, 1994 (attorney docket No.
11,256) which issued as U.S. Patent No. 5,486,166; and U.S. Patent Application 25 Serial No. 206,069 of C. Ellis and R. Everett, entitled IMPROVED SURGE
MANAGEMENT FIBROUS NONWOVEN WEB FOR PERSONAL CARE --ABSORBENT ARTICLES AND THE LIKE, filed March 4, 1994 (attorney docket No.
11,387) which issued as U.S. Patent No. 5,490,846 .

The leg elastic members 34 are located in the lateral side margins 20 of diaper 10, and are arranged to draw and hold diaper 10 against the legs of the wearer. The elastic members are secured to diaper 10 in a,n elastically contractible condition so that in a norma! under strain configur3tion, the elastic members effectively contract 3~ against diaper 10. The elastic members can be secured in an elastically contractible condition in at least two ways, for example, the elastic members may be stretched and secured while diaper 10 is in an uncontracted condition. Alternatively, diaper 10 may be contracted, for example, by pleating, and the elastic members secured andconnected to diaper 10 while the elastic members are in their relaxed or unstretched condition. Still other mechanisms, such as heat-shrink elastic material, may be used to gather the garment.

In the embodiment illustrated in Fig. 1, the leg elastic members 34 extend essentially along the complete length of the intermediate crotch region 16 of diaper 10.
10 Alternatively, elastic members 34 may extend the entire length of diaper 10, or any other length suitable providing the arrangement of elastically contractible lines desired for the particular diaper design.

The elastic members 34 may have any of a multitude of configurations. For example, the width of the individual elastic members 34 may be varied from about0.25 millimeters (0.01 inch) to about 25 millimeters (1.0 inch) or more. The elastic members may comprise a single strand of elastic material, or may comprise several parallel or non-parallel strands of elastic material, or may be applied in a rectilinear or curvilinear arrangement. Where the strands are non-parallel, two or more of the strands may intersect or otherwise interconnect within the elastic member. The elastic members may be affixed to the diaper in any of several ways which are known in the art. For example, the elastic members may be ultrasonically bonded,heat and pressure sealed using a variety of bonding patterns, or adhesively bonded to diaper 10 with sprayed or swirled patterns of hotmelt adhesive.

In particular embodiments of the invention, the leg elastic members 34 may include a carrier sheet to which are attached a grouped set of elastics composed of a plurality of individual elastic strands. The elastic strands may intersect or be interconnected, or be entirely separated from each other. The carrier sheet may, for example, comprise a 0.002 cm thick polymer film, such as a film of unembossed polypropylene material. The elastic strands can, for example, be composed of Lycra elastomer available from DuPont, a business having offices in Wilmington, Delaware. Each elastic strand is typically within the range of about 470 - 1500 decitex (dtx), and may be about 940 - 1050 dtx. In particular embodiments of the invention, for example, three or four strands can be employed for each elasticized legband.

In addition, the leg elastics 34 may be generally straight or optionally curved. For example, the curved elastics can be inwardly bowed toward the longitudinal centerline of the diaper. In particular arrangements, the curvature of the elastics 5 may not be configured or positioned symmetrically relative to the lateral centerline of the diaper. The curved elastics may have an inwardly bowed and outwardly bowed, reflex-type of curvature, and the length-wise center of the elastics may optionally be offset by a selected distance toward either the front or rear waistband of the diaper to provide desired fit and appearance. In particular embodiments of the invention, 10 the innermost point (apex) of the set of curved elastics can be offset towards the front or rear waistband of the diaper, and the outwardly bowed reflexed-portion can be positioned toward the diaper front waistband.

As representatively shown, the diaper 10 can include a waist elastic 42 positioned in 15 the longitudinal margins of either or both of the front waistband 14 and the rear waistband 12. The waist elastics may be composed of any suitable elastomeric material, such as an elastomer film, an elastic foam, multiple elastic strands, an elastomeric fabric or the like. For example, suitable elastic waist constructions are described in U.S. Patent No. 4,916,005 to Lippert et al.

With reference to the representative conhgurations shown in Figs. 1 and 8, the article can include a system of ~ear" regions or ear members 38. In particular arrangements, each ear region or member 38 extends laterally at the opposèd, 2 5 lateral ends of at least one waistband portion of backsheet 30, such- as therepresentatively shown rear waistband portion 12, to provide terminal side -sections of the article. In addition, each ear region can substantially span from a laterally extending, terminal waistband edge 82 to approximately the location of its associated and corresponding leg opening section of the diaper. The diaper 10, for example,30 has a laterally opposed pair of leg openings provided by the curved margins of the ear regions in combination with the correspondingly adjacent, medial sections of the shown pair of longitudinally extending, side edge regions 20 (Fig. 1).

In the various configuratior.s of the invention, ihe ear regions may be integrally 3 5 formed with a selected diaper component. For example, ear regions 38 can be integrally formed from the layer of material which provides backsheet layer 30, or may be integrally fomled from the material employed to provide topsheet 28. In alternative configurations, the ear regions 38 may be provided by one or more separate members that are connected and assembled to the backsheet 30, to the topsheet 28, in between the backsheet and topsheet, or in various fixedly attached combinations of such assemblies.

In particular configurations of the invention, each of the ear regions 38 may beformed from a separately provided piece of material which is then suitably assembled and attached to the selected front and/or rear waistband portion of the diaper article. For example, each ear region 38 may be attached to the rear waistband portion of the backsheet 30 along a ear region attachment zone, and can be operably attached to either or both of the backsheet and topsheet components of the article. The inboard, attachment zone region of each ear region can be overlapped and laminated with its corresponding, lateral end edge region of the waistband section of the article. The ear regions extend laterally to form a pair of opposed waist-flap sections of the diaper, and are attached with suitable connecting means, such as adhesive bonding, thermal bonding, ultrasonic bonding, clips, staples, sewing or the like. Desirably, the ear regions extend laterally beyond the:
terminal side edges of the backsheet layer and topsheet layer at the corresponding, attached waistband section of the article.

The ear regions 38 may be composed of a substantially non-elastomeric material, such as polymer films, woven fabrics, nonwoven fabrics or the like, as well as combinations thereof. In particular aspects of the invention, ear regions 38 may be composed of a substantially elastomeric material, such as a stretch-bonded-laminate (SBL) material, a neck-bonded-laminate (NBL) material, an elastomeric film, an elastomeric foam material, or the like, which is elastomerically stretchable at least along the lateral direction 24. For example, suitable meltblown elastomeric fibrous webs for forming ear regions 38 are described in U.S P. 4,663,220 issued May 5, 1987 to T. Wisneski et al.
-rcfcrcnc~. Examples of composite fabrics comprising at least one layer of nonwoven textile fabric secured to a fibrous elastic layer are described in European Patent Application EP 0 217 G32 A2 published on April 8,1987 which has the listed 3 5 inventors of J. Taylor et al Examples of NBL materials are described in U.S. Patent No. 5,226,992 issued July 13, 1993to Mormon .

5 As previously mentioned, various suitable constructions can be employed to attach the ear regions 38 to the selected waistband portions of the article. Particularexamples of suitable constructions for securing a pair of elastically stretchable members to the lateral, side portions of an article to extend laterally outward beyond the laterally opposed side regions of the outer cover and liner components of anarticle can be found in U.S. Patent No. 4,938,753 issued July 3, 1990 to P.
VanGompel et al.

Each of the ear regions 38 extends laterally at a one of the opposed lateral ends of at least one waistband section of the diaper 10. In the shown embodiment, for example, a first pair of ear regions extend laterally at the opposed lateral ends of the back waistband section of the backsheet 30, and a second pair of ear regions extend laterally at the opposed lateral ends of the front waistband section of the backsheet.
The illustrated ear regions have a tapered, curved or otherwise contoured shape ir;
20 which the length of the base region is smaller than the length of its relatively outboard end region. Alternatively, the ear regions may have a substantially rectangular shape or a substantially trapezoidal shape.

Diaper 10 can also include a pair of elasticized containment flaps 62 which extend 25 generally length-wise along the longitudinal direction 26 of the diaper. The containment flaps are typically positioned laterally inboard from leg elastics- 34, and substantially symmetrically placed on each side of the lengthwise, longitudinal centerline of the diaper. In the illustrated arrangements, each containment flap 62 has a substantially fixed edge portion 64 and a substantially moveable edge 3 o portion 66, and is operably elasticized to help each containment flap to closely contact and conform to the contours of the wearer's body. Examples of suitable containment flap constructions are described in U.S. Patent No. 4,704,116 issuedNovember 3, 1987, to K. Enloe .
The containment flaps may be 35 composed of a wettable or a non-wettable material, as desired. In addition, the CA 02240032 l998-07-02 containment flap material may be substantially liquid-impermeable, may be permeable to only gas or may be permeable to both gas and liquid. Other suitablecontainment flap configurations are described in U.S. Patent Application Serial No. 206,816 of R. Everett et al., filed March 4, 1994 and entitled ABSORBENT
s ARTICLE HAVING AN IMPROVED SURGE MANAGEMENT (attorney docket No. 11,375), now U.S. Patent 5,562,650 In optional, alternative configurations of the invention, diaper 10 may include internal, 10 elasticized, containrnent waist flaps, such as those described in U.S. Patent No. 4,753,646 issued June 28, 1988, to K. Enloe .

Similar to the construction of the containment flaps, the containment waist flaps may be composed of a wettable or non-wettable material, as desired. The waist flap material may be substantially li~uid-impermeable, permeable to only gas, or permeable to both gas and liquid.

To provide a desired refastenable fastening system, diaper 10 can include one or- more appointed landing zone regions, such as a first, primary landing zone 50 (e g Figs.1 and 9 ), which can provide an operable target area for receiving a releasable and re-attachable securement of the fastener tabs 36 thereon. In particular~
embodiments of the invention, the landing zone patch can be positioned on the front waistband portion 14 of the diaper and is located on the outward surface of the backsheet layer 30 Alternatively, the landing zone patch can be positioned on anappointed inward surface of the diaper, such as the bodyside surface of the topsheet layer 28. The fastening mechanism between the landing zone and the fastener tabs 36 may be adhesive, cohesive, mechanical or combinations thereof. In the context of the present invention, a mechanical fastening system is a system which includes cooperating components which mechanically inter-engage to providea desired securement.

CA 02240032 l998-07-02 A configuration which employs a releasable, interengaging mechanical fastening system can, for example, locate a first element of the mechanical fastener on the landing zone 50 and a second, cooperating element of the mechanical fastener on the fastener tab 36. For example, with a hook-and-loop fastener, the hook material can be operably connected and affixed to the fastener tabs 36 and the loop material can be operably connected and affixed to the landing zone 50. Alternatively, theloop material can be operably connected to the fastener tabs 36 and the hook material can be operably connected to the landing zone.

10 In the various embodiments of the invention, a separately provided tape fastener tab 36 can be located at either or both of lateral end regions 86 and 88 of either or both of the waistbands 14 and 12. The representatively shown embodiment, for example, has one of the fastener tabs 36 located at each of the dis~al side edges of the rear waistband 12. More particularly, each of the fasteners 36 is assembled and attached to extend from a corresponding, immediately adjacent ear region at one of the opposed lateral ends of the back waistband section 12.

With reference to Figs. 1 and 2, a further aspect of invention can include at least one pair of transversely opposed, laterally extending carrier members, such as provided by the shown arrangement of base tab or panel sections 80. In the shown configuration, a base panel section is joined to the diaper at each lateral end of the appointed first waistband portion 12. In the shown configurations, each base panel section 80 is affixed to an associated, corresponding ear region 38, and extendslaterally outboard from its corresponding, immediately adjacent ear region. The shown arrangement has the transversely extending, longitudinally terminal edges 110 of the base panel sections 80 positioned substantially collinear and aligned with the transversely extending, longitudinally terminal edge 82 the back waistband 12. Additionally, the longitudinally terminal edges 110 of the base panel sections 80 can be substantially collinear and aligned with the transversely extending, longitudinally terminal edge of the backsheet layer 30. When the diaper article is typically worn, the total cross-directional width of the overall article is desirably insufficient to allow the back waistband section of the diaper to completely encircle the wearer's waist. More particularly, the opposed base panel sections 80 will substantially avoid overlapping each other when the article is worn. Accordingly, CA 02240032 l998-07-02 the diaper construction can provide improved fastening with an improved economy of material.

The base panel section 80 of each fastener can have any desired shape. The shown arrangement has generally rectangular-shaped base panel sections, but other suitable base panel shapes may be tapered, bell-shaped, trapezoidal and the like, as well as combinations thereof. In the representatively shown configurations, the base panel section 80 can be composed of a polymer film material, or may be composed of woven or nonwoven fabric and the like, as well as combinations thereof. In 10 particular aspects of the invention, the material of base panel section 80 can be composed of a substantially non-elastomeric material, such as polymer films, woven fabrics, nonwoven fabrics or the like, as well as combinations thereof. Alternatively, the base panel material may be composed of a substantially elastonleric material, such as a stretch-bonded-laminate (SBL) material, a neck-bonded-laminate (NBL) material, an elastomeric film, an elastomeric foam material, or thelike, as well as combinations thereof. The elastomeric material can be elastomerically stretchable at least along the longitudinal direction 26. For example, the base panel material may be composed of a spunbond-meltblown-spunbond (SMS) fabric having a core of meltblown fibers sandwiched between two facing layers of spunbond fibers to provide a total composite basis weight within the range of about 50 - 67 g/m2 (about 1.5 - 2 oz/yd2). As another example, the base panelmaterial may be entirely composed of a nonwoven spunbond fabric having a basis weight within the range of about 50 - 67 g/m2 (about 1.5 - 2 oz/yd2).

The flip tab section 60 of each fastener has an areal extent which extends longitudinally outboard and away from a laterally extending, longitudinally outboard edge region of the article. In the illustrated arrangements, for example, the flip tab section extends longitudinally away from a laterally extending, longitudinally outboard edge region 110 of its corresponding base panel section 80. The shown configuration has the outer-most side edge of the flip tab section located substantially collinear and aligned with the outer-most side edge of its corresponding base panel section 80. Accordingly, the flip tab section and corresponding base panel section form a generally L-shaped intersection. Optionally, the flip tab section and corresponding base panel section can be arranged to form a generally T-shaped intersection or other configuration, as desired.

CA 02240032 l998-07-02 With respect to each individual flip fastener 36, the flip tab section 60 may be a separately provided element which is operatively assembled and affixed to its associated base panel section 80. Alternatively, the flip tab section 60 may be integrally formed from the same piece of material employed to construct the basepanel section 80. It should be readily appreciated that the flip tab section 60 can have any desired shape. The shown arrangement has generally rectangular flip tabsections, but other suitable flip tab shapes may be tapered, bell-shaped, trapezoidal and the like, as well as combinations thereof.

The flip tab section 60 of each fastener extends longitudinally beyond the transversely extending, longitudinally terminal edge 82 of the back waistband portion 12, and includes an appointed folding line 59. The folding line extends transversely along the flip tab section, and in desired configurations, can be substantially collinear and aligned with the terminal edge 82 of the back waistband portion 12.

The representatively shown configurations of the flip tab sections 60 can be composed of a polymer film material, or may be composed of a woven or nonwoven fabric, and the like, as well as combinations thereof. It should be readily appreciated that the flip tab sections 60 may be elastomeric or substantially non-elastomeric, and that the flip tab sections may be constructed of materials that are similar or dissimilar to those employed to construct the base panel sections 80. Where the flip tab section is composed of an elastomeric material, the material can be elastomerically stretchable at least along the longitudinal direction 26 of the article.

In its various arrangements, the flip fastener, particularly the flip tab section 60, is desirably configured to be soft and substantially non-irritating to the wearer's skin.
With reference to the configuration representatively shown in Fig. 1, the inward, bodyside surface 56 of the flip fastener 36 is desirably composed of a material which is nonirritating to the wearer's skin. For example, the initially inward, bodyside surface of the flip tab section 60 and the inward surface 106 of the base panel 80 can be composed of a soft, resilient, nonirritating, woven or nonwoven fabric, such as a spunbond fabric.

CA 02240032 l998-07-02 With respect to the configurations representatively shown in Fig. 8, the outwardsurface 54 of the flip fastener 36 is desirably composed of a material which is nonir,il~ling to the wearer's skin. For example, the initially outward surface of the flip tab section 60 may be composed of a soft, resilient, nonirritating, woven or nonwoven fabric, such as a spunbond fabric. Similarly, the outward surface 108 of the base panel section 80 may also be composed of the soft, resilient, woven or nonwoven fabric.

A selected fastening mechanism is operatively joined to each flip tab section 60.
10 With reference to Fig. 1, the selected fastening mechanism is attached to theoutward surface 54 of the flip tab section. The fastening mechanism between the landing zone and the flip tab section 60 may be adhesive, cohesive, mechanical or combinations thereof. A configuration which employs a releasable, in~terengagingmechanical fastening system can, for example, locate a first element of the mechanical fastener on the flip tab section 60. For example, with a hook-and-loop fastener, the hook material can be operably connected to the flip tab section 60 and the loop material can be operably connected to the landing zone 50. Alternatively, the loop material can be operably connected to the flip tab section 60 and the hook material can be operably connected to the landing zone.

In the shown configuration of Figs. 1, 2 and 3, a member of primary hook material can be laminated, or otherwise connected and affixed, to the longitudinally outboard region of the flip tab section with an operable construction attachment to provide the first fastening component 52. In particular, the shown hook member is laminated to a outward-side surface 54 of the flip tab section with the hook elements extending generally outwardly of the article. The outboard, longitudinally distal edge of the hook material may be coterminous with the outboard, laterally distal edge of the flip tab section. Alternatively, the outboard, longitudinally distal edge of the flip tab section may be spaced longitudinally inboard from the terminal, longitudinally distal edge of the flip tab section. In either configuration, the longitudinally distal edge of the flip tab section 60 provides a longitudinally terminal edge of the article.

Further aspects of the invention can include a supplemental fastening system, such as provided by a supplemental fastener component 100 and a cooperating supplemental landing zone 102. With reference to Fig. 2, a second, supplemental CA 02240032 l998-07-02 fastening component 100 can be provided on the inward surface 92 of the second waistband portion 14 of the article at a lateral side or end region 88 of the second waistband portion 14. Desirably, a supplemental fastening component 100 is provided on the inward surface at each of a pair of laterally opposed end or side regions 88 of the second waistband portion.

A second, supplemental landing zone component 102 can be provided on the outward surface 92 of the article along a selected region of the first waistbandportion 12, and is configured to operatively attach to the second fastening component 100. Desirably, the supplemental landing zone component 102 is configured to include spaced-apart portions which engage or otherwise attach to each of the supplemental fastening components 100 disposed on the opposite ends 88 of the second waistband portion 14.

In a particular aspect of the invention, the supplemental landing zone component102 can be provided on an outer surface of either or both of the base panel sections 80. For example, the outward surface 108 of the base panel section 80 can be composed of a fabric which is mechanically engageable with the supplemental fastening component 100. Alternatively, the supplemental landing zone 102 may beprovided by one or more separately provided packages of suitable landing zone material which are attached to the outward surface 108 of the base panel 80.

With reference to Fig. 8, the supplemental fastener component 100 can alternatively be provided on the inward surface 90 of the first waistband portion 12 of the article.
A second, supplemental landing zone component 102 is provided on an outward surface 92 of the second waistband portion 14 of the article, and can be disposed along at least an operative part of the second waistband portion. A section of the second fastening component 100 can be disposed on the inward surface of the article at each lateral end region 86 of the first waistband portion 12, and the second fastening component 102 is configured to operatively attach to the second fastening component 100. The supplemental landing zone component 102 can be positioned on an outward surface 92 of the second waistband portion 14 of the article, and can be disposed along at least an operative part of the second waistband portion.

In particular aspects, the supplemental landing zone component 102 may be provided by a fabric loop material disposed on the inward surface 106 of the base , panel sections 80. The loop component may be separately provided and operativelyattached to the base panel section 80, or may be integrally formed from the materiai of the base panel section. With this arrangement, the cooperating supplemental fastening component 100 can be positioned on an outward surface 92 of the secondwaistband portion 14 of the article, and can be disposed along at least an operative part of the second waistband portion. The supplemental fastening component 100 can be configured such that appointed, spaced-apart portions of the supplementalfastening component can engage or otherwise attach to the regions of the landingzone, loop material for operatively holding the article on a wearer.

In the various configurations of the invention, the first and/or second fastening component may include an adhesive, a cohesive, a complementary element of an interengaging mechanical fastening system, or the like, as well as combinations thereof. The mechanical fastener components can be provided by m~echanical-type fasteners such as hooks, buckles, snaps, buttons and the like, which include cooperating and complementary, mechanically interlocking components. For example, the mechanical fastening system may be a hook-and-loop type of fastening system. Such fastening systems generally comprise a "hook" or hook-like, male component, and a cooperating "loop" or loop-like, female component which engagesand releasably interconnects with the hook component. Desirably, the interconnection is selectively releasable and re-attachable. Conventional systems are, for example, available under the VELCRO'trademark. The hook element may be provided by a single or multiple hook configuration, such as provided by a mushroom-head type of hook element. The loop element may be provided by a woven fabric, a nonwoven fabric, a knitted fabric, a perforated or ape~tured layer, and the like, as well as combinations thereof. The many arrangements and variations of such fastener systems have been collectively referred to as hook-and-loopfasteners.

In desired arrangements of the invention, the first fastening component 52 and/or the second fastening component 100 may include a hook type of mechanical fastening element. Accordingly, the corresponding first landing zone component 52 and/or second landing zone component 102 can include a complementary loop element.

!t should also be readily apparent that, in the various configurations of the invention, the relative positions and/or materials of the fastening component and its * denotes trademark 27 .

corresponding landing zone component can be transposed. For example, in a hook-and-loop fastening system, the first and/or second fastening component may optionally be composed of a loop element and the first and/or second landing zone components may be provided by a hook-type element.
s Examples of suitable hook-and-loop fastening systems are described in U.S.P. 5,019,073 issued May 28, 1991 to T. Roessler et al.

Other examples of hook-and-loop fastening systems are described in U.S. Patent Application Serial No. 366,080 entitled HIGH-PEEL TAB FASTENER, hled December 28,1994 by G. Zehner et al. (attorney docket No. 11,571) which issued as U.S. Patent No. 5,605,735.

- In a typical configuration of a hook-and-loop fastening system, the hook material member is operably connected to the fastening tab 36, and the loop materiaNs employed to construct at least one cooperating landing zone 50. The landing zonecan, for example, be suitably positioned on the exposed, outward-side surface of the backsheet 30. As previously mentioned, an alternative configuration of the hook-and-loop fastening system may have the loop material secured to the fastener tab 36 and may have the hook material employed to form the landing zone 50.

In the various aspects and configurations of the invention, the hook element material can be of the type referred to as micro-hook material. A suitable micro-hook material is distributed under the designation CS200 and is available from 3M
Company, a business having offices in St. Paul, Minnesota. The micro-hook materia! can have hcoks in ~he shape of mushroom "caps", and can be configured with a hook density of about 1600 hooks per square inch; a hook height which is CA 02240032 l998-07-02 within the range of about 0.033 - 0.097 cm (about 0.013 to 0.038 inch); and a cap width which is within the range of about 0.025 - 0.033 cm (about 0.01 to 0.013 inch). The hooks are attached to a base film substrate having a thickness of about 0.0076- 0.01 cm (about 0.003-0.004 inch) and a Gurley stiffness of about 15 mgf.

Another suitable micro-hook material is distributed under the designation VELCROCFM-29 1058, and is available from VELCRO U.S.A., Inc., a business having offfices in Manchester, New Hampshire. The micro-hook material can have hooks in the shape of angled hook elements, and can be configured with a hook density of about 264 hooks per square centimeter (about 1700 hooks per square inch); a hook height which is within the range of about 0.030 - 0.063 cm (about 0.012 - 0.025 inch);
and a hook width which is within the range of about 0.007 to 0.022 cm (about 0.003 to 0.009 inch). The hook elements are coextruded with a base layer substrate having a thickness of about 0.0076 - 0.008 cm (about 0.003 - 0.0035 inch), and the member of hook material has a Gurley stiffness of about 12 mgf (about 12 Gurley units).

For the purposes of the present invention, the various stiffness values are determined with respect to a bending moment produced by a force which is directed perpendicular to the plane substantially defined by the length and width of the component being tested. A suitable technique for determining the stiffness values described herein is a Gurley Stiffness test, a description of which is set forth in TAPPI Standard Test T 543 om-94 (Bending Resistance of Paper (Gurley type tester)). A suitable testing apparatus is a Gurley Digital Stiffness Tester;
Model 4171-D manufactured by Teledyne Gurley, a business having offfices in Troy, New York. This instrument allows the testing of a wide variety of materials through the use of various lengths and widths in combination with the use of a 5, 25, 50, or 200 gram weight placed in one of three positions on the pointer of the apparatus.
For purposes of the present description, the stated Gurley stiffness values are intended to correspond to the values that would be generated by a "standard" sized sample. Accordingly, the scale readings from the Gurley stiffness tester are appropriately converted to the stiffness of a standard size sample, and are traditionally reported in terms of milligrams of force (mgf). Currently, a standard "Gurley unit" is equal to a stiffness value of 1 mgf, and may equivalently be employed to report the Gurley stiffness. The standard size sample has a width of 1"

and a nominal length of 3" (actual length of 3.5"). The actual length of the sample is the nominal length, plus an additional 0.25" of length for holding in the clamp and another 0.25" of length for overlapping the vane. Tables of factors for taking scale readings generated with non-standard sized test samples and converting the readings to the stiffness of the standard size sample are given in the Instruction Manual for the Gurley Stiffness Tester provided by Teledyne Gurley. Accordingly,other designated dimensions for the test sample may also be conveniently employed, so long as the appropriate conversion factor is employed to determine the appropriate value which corresponds to the standard size sample.

In the various aspects and configurations of the invention, the loop material can be provided by a nonwoven, woven or knit fabric. For example, a suitable loop material fabric can be composed of a 2 bar, warp knit fabric of the type availa~ble from Guilford Mills, Inc., Greensborough, North Carolina under the trade designation 15 #34285, as well other of knit fabrics. Suitable loop materials are also available from the 3M Company, which has distributed a nylon woven loop under their SCOTCHMATI~ brand. The 3M Company has also distributed a linerless loop web with adhesive on the backside of the web, and 3M knitted loop tape.

In particular aspects of the invention, the loop material need not be limited to a discrete landing zone patch. Instead the loop material can, for example, be provided ~ by a substantially continuous, outer hbrous layer which is integrated to extend over substantially the total exposed surface area of a cloth-like outer cover employed with the diaper 10. The resultant, cloth-like backsheet 30 can thereby provide the loop 2s material for an operative "fasten anywhere" mechanical fastening system.

In the various configurations of the invention, the engagement force between theparticular fastening component and its appointed landing zone component should be large enough and durable enough to provide an adequate securement of the articleon the wearer during use. In desired configurations, the engagement force can provide a peel force value of not less than about 75 grams-force (gmf).
Alternatively, the peel force is not less than about 100 gmf, and optionally is not less than about 400 gmf. In particular aspects, the peel force is not more than about1,200 gmf. Alternatively. the peel force is not more than about 800 gmf, and optionally is not more than about 600 gmf. The engagement force can additionally * denotes trademark CA 02240032 l998-07-02 provide a shear force value of not less than about 1,000 gmf. Alternatively, theshear force is not less than about 2,000 gmf, and optionally, is not less than about 3,000 gmf . In further aspects, the shear force is not more than about 10,000 gmf.
Alternatively, the shear force is not more than about 9,000 gmf, and optionally is not 5 more than about 8,000 gmf.

The peel force can be determined in accordance with standard procedure ASTM D5170, approved Sept. 15, 1991 and published Nov. 1991. The shearforce value can be determined in accordance with the standard procedure ASTM D-5169, o approved September 15, 1991 and published Nov. 1991.

Each of the fastening components and elements in the various constructions of the invention may be operably attached to its supporting substrate by ernploying any one or more of the attachment mechanisms employed to construct and hold together thevarious other components of the article of the invention. The fastening elements in the various fastening regions, may be integral!y formed, such as by molding, co-extrusion or the like, along with the associated substrate layer. The substrate layer and its associated mechanical fastening elements may be formed from substantially the same polymer material, and there need not be a discrete step of attaching the fastening elements to an initially separate substrate layer. For example, the individual hook elements may be integrally formed simultaneously with a hook base-layer by coextruding the base layer and hook elements from substantially the same polymer material.

It should be readily appreciated that the strength of the attachment or other interconnection between the substrate layer and the attached fastening componentshould be greater than the peak force required to remove the fastener tab 36 from its releasable securement to the appointed landing zone of the article.

Figs. 4 through 7 illustrate the operation of the fastening system provided by adesired configuration of the invention. Fig. 4 shows a representative perspective view of a diaper generally positioned for use on a wearer. With reference to Fig. 5, the diaper can be initially placed and mounted on the wearer by first positioning and wrapping the first, back waistband portion 12 and the two fastener base panel sections 80, around the wearer's back and side torso areas (not shown). Fig. 5 also CA 02240032 l998-07-02 illustrates (with dashed outlines) optional enlargements 100a of the supplemental fasteners 100 and optional enlargements 102a of the supplemental landing zones 102 which may be operatively incorporated into any of the various arrangements of the invention. Such configurations can provide additional supplemental fastening areas which extend to more laterally inboard locations of the article. The additional supplemental fastening area of each supplemental fastener 100 or supplemental landing zone 102 can be provided by a contiguous enlargement of the fastener or landing zone component. Alternatively, such additional fastening area can be provided by one or more, spaced-apart or otherwise 10 noncontiguous segments of the selected fastener component and/or landing zonecomponent which are operatively and cooperatively located within one or more of the regions representatively shown by the dotted outlines.

With reference to Fig. 6, the intermediate region 16 of the diaper can then be brought 15 through the wearer's crotch region, and the second, front waistband portion 14 of the article can be placed into an operatively aligned, mating correspondence with the back waistband portion 12. When appropriately mated, the supplemental fasteners 100, if present, can then be secured to the supplemental landing zones 102, with the assembled front and back waistband portions thereby encircling the wearer's body.
20 The flip tab sections 60 can then be pivoted about their individual folding lines 59 to wrap outwardly and downwardly around the laterally extending, longitudinally terminal edge region 84 of the front waistband portion 14 (Fig. 7). The primary fastener components 52 on the designated outward surfaces 54 of the folded flip tab sections 60 can then be secured to the one or more appointed primary landing zone 25 regions 50 affixed to the outermost surface 92 of the front waistband portion 14. In the shown arrangement, a single primary landing zone strip region can be provided by or otherwise attached to the outer surface of the backsheet layer 30.

Figs.11 through 14 illustrate the operation of the fastening system provided by an 30 alternative configuration of the invention. Fig.11 representatively shows a perspective view of the diaper generally arranged for use. The diaper can be initially placed on the wearer by first positioning and wrapping the first, back waistband 12 and the fastener base panel sections 80, if any, behind the wearer's back (Fig.12).
The intermediate region 16 of the diaper can then be brought through the wearer's 35 crotch region, and the second, front waistband portion 14 of the article can be placed CA 02240032 l998-07-02 in an operative position against the wearer's front and side torso areas (Fig.13).
The placement of the diaper is adjusted to provide an operative alignment and mating correspondence between the back and front waistband portions 12 and 14, respectively. When appropriately mated, the supplemental fasteners 100, if present, can then be secured to the supplemental landing zone or zones 102, with the assembled front and back waistband portions thereby encircling the wearer's body.
With reference to Fig.14, the flip tab sections 60 can then be pivoted about their individual folding lines 59 to wrap inwardly and downwardly around the laterallyextending, longitudinally terminal edge region 84 of the front waistband portion 14.
10 The primary fastener components 52 on the designated inward surfaces 56 of the folded flip tab sections 60 can then be secured to the one or more appointed primary landing zone regions 50 affixed to or otherwise provided on the innermost, bodyside surface 90 of the front waistband portion 14. In the shown arrangement, for example, the primary landing zone region can be a separately provided member which is assembled and attached to the inner surface of the topsheet layer 28.
Alternatively, the landing zone region 50 may be integrally formed with one or more of the components which provide the inner, bodyside surface of the diaper. For example, the landing zone region may be provided by a selected region of the topsheet layer which has been operatively configured to provide sufficient high levels of peel and shear force engagement for the desired fastening operation.

Having described the invention in rather full detail, it will be readily apparent that various changes and modifications can be made without departing from the spirit of the invention. All of such changes and modifications are contemplated as being within the scope of the invention as defined by the subjoined claims.

Claims (22)

1. An absorbent article having a longitudinal direction, a lateral direction, a first waistband portion with an inward surface and an outward surface thereof, a second waistband portion which is positioned longitudinally opposite of said first waistband portion and has an inward surface and outward surface thereof, and an intermediate portion which interconnects said first and second waistband portions, said article comprising:
backsheet layer having an outward surface and an inward surface;
a liquid permeable topsheet layer connected in superposed relation with said backsheet layer;
an absorbent structure sandwiched between said backsheet and topsheet layers;
a flip fastener joined to each of a pair of laterally opposed end sections of said first waistband portion, each flip fastener including a longitudinally extending flip tab section which is joined to a longitudinally outboard edge region of said first waistband portion to project longitudinally beyond and outboard from said first waistband portion, each flip tab section having a distal end region, an inward surface, anoutward surface, a first fastening component operatively joined to an appointed fastening surface of said flip tab section, and an appointed folding line which extends along said lateral direction of the article; and a first landing zone component joined to a selected surface of said second waistband portion, said landing zone component configured to provide a fasteningattachment to each first fastening component when each flip tab section is operatively pivoted about its folding line to thereby engage said first landing zone component.

2. The article as recited in claim 1, wherein said appointed fastening surface of at least one said flip tab section is the outward surface of said at least one flip tab section, and said first landing zone component is provided on the outward surface of said second waistband portion.

3. The article as recited in claim 1, wherein said appointed fastening surface of at least one said flip tab section is the inward surface of said at least one flip tab section, and said first landing zone component is provided on the inward surface of said second waistband portion.

4. The article as recited in claim 1 wherein, said first waistband portion of the article includes at least one separately provided, base panel section which is joined to extend laterally outboard from alateral side portion of a first waistband section of said backsheet layer to provide a carrier member, said base panel section having an appointed bodyside surface, anappointed outward surface and a laterally extending, longitudinally outboard edge region, and said longitudinally extending flip tab section is joined to said longitudinally outboard edge region of said base panel section to project longitudinally outboard from said base panel section.

5. The article as recited in claim 4 wherein, said first fastening component is joined to said outward surface of said flip tab section, and said first landing zone component is provided on said outward surface of said second waistband portion.

6. The article as recited in claim 4 wherein, said first fastening component is joined to said bodyside surface of said flip tab section, and said first landing zone component is provided on said inward surface of said second waistband portion ofsaid article.

7. The article as recited in claim 1, wherein said first fastening component includes a first fastener element of an interengaging mechanical fastening system; and said first landing zone component includes a first complementary element which is mechanically engageable with said first fastener element.

8. The article as recited in claim 7, wherein said mechanical fastening system includes a hook and loop fastening system.

9. The article as recited in claim 8, wherein said first fastener element includes a hook material and said first complementary element includes a loop material.

10. The article as recited in claim 1, wherein said first fastening component includes an adhesive.

11. The article as recited in claim 2, further comprising a second fastening component provided on said inward surface of said second waistband portion of said article at a lateral end region of said second waistband portion; and a second landing zone component which is provided on an outward surface of said first waistband portion of said article and is configured to operatively attach to said second fastening component.

12. The article as recited in claim 3, further comprising a second fastening component which is provided on an inward surface of said first waistband portion of said article with a section of the second fastening component disposed at each lateral end region of said first waistband portion; and a second landing zone component provided on said outward surface of said second waistband portion of said article along at least a part of said second waistband portion, said second landing zone component configured to operatively attach to said second fastening component.

13. The article as recited in claim 11, wherein said second fastening component includes a second fastener element of an interengaging mechanical fastening system; and said second landing zone component includes a complementary element which is mechanically engageable with said second fastener element.

14. The article as recited in claim 13, wherein said mechanical fastening system is a hook and loop fastening system.

15. The article as recited in claim 14, wherein said second fastener element includes a hook material and said second complementary element includes a loop material.

16. The article as recited in claim 11, wherein said second fastening component includes an adhesive.

17. The article as recited in claim 5, further comprising a second fastening component is provided on said inward surface of said second waistband portion of said article at a lateral end region of said second waistband portion; and a second landing zone component which is provided on an outward surface of said first waistband portion of said article and is configured to operatively attach to said second fastening component.

18. The article as recited in claim 17, wherein said second landing component isjoined to an outward surface of said base band section.

19. The article as recited in claim 17, wherein said second fastening component includes a second fastener element of a second interengageable mechanical fastening system; and said second landing zone component includes a second complementary element which is mechanically engageable with said second fastenerelement.

20. The article as recited in claim 19, wherein said mechanical fastening systemincludes a hook and loop fastening system.

21. The article as recited in claim 20, wherein said second fastener element includes a hook material and said second complementary element includes a loop material.

22. The article as recited in claim 17, wherein said second fastening component includes an adhesive.