HK1123181B - Disposable absorbent article having leg wraps method of making same - Google Patents

Description

Disposable absorbent article with leg wraps and method of making the same

Technical Field

The present invention relates to absorbent articles such as diapers, and more particularly to absorbent articles having elastic leg wraps capable of forming a reservoir for containing liquid and a plurality of fluid barriers capable of retaining liquid to improve the overall containment characteristics of the absorbent article, particularly the containment of loose fecal material.

Background

Disposable absorbent articles are worn to contain and absorb urine and fecal exudates. To this end, absorbent articles are provided with portions or structural features that provide a close, comfortable fit around the legs and waist of the user. This close fit enhances the containment capability and leakage prevention capability of the absorbent article.

The primary elements of a typical disposable absorbent article include a liquid permeable inner layer or topsheet, a liquid impermeable outer layer or backsheet, and an absorbent core sandwiched between the inner and outer layers. Elastic barrier leg cuffs, gather components, and waistbands are commonly used to prevent leakage by enhancing the fit of the absorbent article around the thighs and waist of the user. For example, the elastic members may be disposed generally outboard of the absorbent core, along the longitudinal direction of the article. In addition, several elastic members (e.g., in the form of elongated elastic strands or threads) may be disposed laterally throughout the waist region, including the side waist regions of the disposable absorbent article, to allow the article to extend in use. In this way, the article is able to extend to accommodate deformation in the size of the waist and the size of the legs of the user, while maintaining a proper fit and leg seal during use.

The primary function of absorbent articles, such as disposable diapers and adult incontinent briefs, is to absorb and contain body exudates. Such articles can prevent body exudates from soiling, wetting, or otherwise soiling clothing or other articles (e.g., bedding) that come in contact with the wearer. The disadvantages of such articles are: the leg seals between the absorbent article and the wearer's legs or waist can leak and leak onto the garment. It is most noticeable with loose fecal material that is not easily absorbed by the absorbent article and it tends to flow unconstrained onto the top surface of the absorbent article.

Current disposable diapers have elasticized leg cuffs to improve wearer comfort and the ability to contain body exudates. These elasticized leg cuffs prove somewhat effective in preventing leakage from a liquid-filled absorbent article and onto garments contacting the edges of the article in which the elasticized leg wraps provide a fluid impervious barrier between the absorbent core and the contacting garment, and in addition, ensure a sealing action about the wearer's legs. While these structures are effective, body exudates, particularly loose fecal material, can still leak through the elasticized leg cuffs and contaminate the wearer's clothing because the diaper does not prevent the free flow of such material, but also does not provide a structure to hold such material within the diaper so that it flows along the top surface of the topsheet and tends to route itself through the elasticized leg cuffs.

Accordingly, it is desirable to provide an absorbent article that maintains the proper fit of the absorbent article about the legs of the wearer. Also, it would be desirable to provide an absorbent article that has a low likelihood of leakage in the legs. In addition, it is desirable to provide an absorbent article that is easy to use and/or remove and has improved wearer comfort.

Summary of The Invention

The present invention relates generally to a disposable absorbent article or garment and a method of making the same. More particularly, the present invention relates to a disposable absorbent article such as a baby diaper or disposable elasticized garment including a pair of elasticized leg wraps for preventing leakage of liquid and/or solid exudates and for providing a better fit and appearance. Embodiments of the present invention provide an absorbent article having improved soiling characteristics.

In one aspect of the invention, a disposable absorbent article has a central body and a pair of elasticized leg wraps. The central body comprises an absorbent core and may therefore be referred to herein as a central absorbent assembly. When disposed in a generally flat, open condition, such as prior to being worn by a user or at a later stage in the manufacturing process, the central body is further characterized by: having a front longitudinal edge, a back longitudinal edge opposite the front longitudinal edge, and a longitudinal centerline extending through the front and back side edges. These front and rear edges at least partially define front and rear waist portions, respectively, of the disposable absorbent article. Pairs of elastic leg wraps extend longitudinally adjacent opposite lateral sides of the central body. Each leg wrap is spaced outwardly from a transverse edge of the absorbent article.

In another aspect of the invention, leg wraps incorporated into or with the disposable absorbent article of the present invention are characterized by: having elastic elongation properties or stretchability in the longitudinal direction. The leg wraps are made extensible by the provision of elastic members extending longitudinally along the disposable absorbent article. The leg wrap stretch improves the fit of the disposable absorbent article around the user's thighs. In a particular embodiment, the elastic elements are parallel to and separated from each other, for example by at least a few millimeters. In a preferred embodiment of the present invention, the leg wraps provide an effective sealing function, such as barrier leg cuffs and leg gathers, as well as a fit function, for the disposable absorbent article.

In another embodiment of the present invention, a method of manufacturing a disposable absorbent article is provided. The method comprises the following steps: a central body assembly including an absorbent core is provided and a pair of elasticized leg wraps formed, for example, by a top layer, a bottom layer, and a plurality of elastic elements positioned between the top and bottom layers.

The present invention, which additionally provides space between the absorbent core and the leg wraps to provide a reservoir, provides sufficient elastic resistance to form multiple seals and barrier structures around the leg. In addition, the elasticity of the leg wraps allows the leg wraps themselves to fold between the upper thigh and the body and seal themselves around the wearer's leg, and thus conform to the shape of the wearer. As a result, each leg wrap is effective in preventing leakage of exudates.

It is another object of the present invention to provide an absorbent article having a storage layer and a plurality of improved elasticized leg wraps defining a plurality of fluid barriers to provide dual containment of lateral flow of body exudates.

It is another object of the present invention to provide an absorbent article having improved comfort for the wearer and better initial fit on the wearer.

The above and other objects of the present invention will become apparent upon consideration of the following description taken in conjunction with the accompanying drawings.

The absorbent article and method of making the same of the present invention will be readily understood by the following detailed description of the drawings, wherein various embodiments of the invention are described by way of illustration of the best mode contemplated for carrying out the invention. The invention is capable of other and different embodiments, and its several details are capable of modifications and its several structural and processing details are capable of modifications in various and obvious respects. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.

Brief description of the drawings

FIG. 1 is a plan view of the inside face of a disposable absorbent article in a generally flat, open condition in accordance with the present invention.

FIG. 2 is a plan view of the outer side of the disposable absorbent article of FIG. 1.

Fig. 3 is a cross-sectional view of the article of fig. 1 and 2, as shown along axis 3-3.

Fig. 4 and 5 are alternative embodiments of the absorbent article of the present invention.

Fig. 6 is a cross-sectional view of an absorbent article of the present invention.

Fig. 7 is a plan view of an absorbent article of an embodiment of the present invention.

Fig. 8 is a plan view of another embodiment of the present invention.

Figures 9-24 show cross-sectional views of different embodiments of absorbent articles similar to figures 1 and 2.

Figure 25 shows an application of the absorbent article of the present invention.

Fig. 26 and 27 show cross-sections through the absorbent article and the wearer.

Figure 28 shows an absorbent article on a wearer.

FIG. 29 is a cross-sectional view showing the principle of illustrating the folding of the side flaps in accordance with the present invention.

Figures 30-33 illustrate different embodiments of securing folded side flaps in accordance with the present invention.

Detailed description of the invention

As used herein, the term "disposable absorbent article" refers to articles which are capable of absorbing and containing body exudates and, more particularly, relates to articles which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body, and to articles which are intended to be discarded after a single use and which are not intended to be laundered or otherwise restored or reused. A preferred embodiment of the disposable absorbent article of the present invention is shown in figure 1 and designated by the numeral 8. The term "disposable absorbent article" as used herein refers to garments, typically worn by infants and incontinent persons, which are worn about the lower torso of the wearer. However, it should be understood that: the invention is also applicable to other disposable absorbent articles such as incontinence briefs and the like.

Figure 1 is a plan view of an absorbent article 8 of the present invention in a flat, uncontracted state (i.e., with all elastic induced contraction removed and prior to any folding operation on the article), with a portion of the absorbent article contacting the wearer facing the viewer. The absorbent article 8 includes: a liquid permeable topsheet or cover 10; a liquid impermeable backsheet 12; such as an absorbent core assembly 14 disposed between the coverstock 10 and the backsheet 12; a pair of fasteners 16; a flexible elastic leg wrap 18; elastic members 20 secured within the leg wraps 18 and capable of defining a plurality of liquid barriers 90 (fig. 28) when worn; fastening means such as adhesive dots 94 (fig. 29-33) for fastening a portion of an absorbent article, such as the cover 10, together to form the reservoir layer 26 (not shown in fig. 1) capable of retaining body exudates during use. The liquid coverstock 10, absorbent core 14, and liquid impervious backsheet 12 can be assembled together in a variety of well known configurations as will occur to those of skill in the art.

Figures 1-2 show a preferred embodiment of an absorbent article 8 wherein the liquid covering 10 and the backsheet 12 are coextensive and have length and width dimensions generally greater than the length and width dimensions of the absorbent core assembly 14. The coverstock 10 is superposed on the backsheet 12 to form a periphery of the absorbent article 8 including the end edges 28, 30 and the longitudinal edges 32, 34.

The absorbent article 8 has waist regions 36 and 38 which extend from the end edges 28 and 30, respectively, of the absorbent article toward the transverse centerline 40 of the absorbent article 8 a distance of about 1/3-1/4 of the length of the absorbent article 8. The waist regions 36 and 38 comprise the portions of the absorbent article 8 which, when worn, are positioned between the legs of the wearer and cover the lower torso of the wearer.

Referring to fig. 3, the absorbent core assembly 14 includes an absorbent core 42, a liquid permeable nonwoven coverstock 10 and a liquid impermeable backsheet 12. An auxiliary material layer, such as an auxiliary absorbent, cellulosic material or nonwoven 44, may also be provided within the core assembly, which can provide auxiliary functions, such as urine storage, rapid urine absorption and/or urine distribution. The absorbent core 42 may be composed of a combination of cellulose-based absorbent materials, superabsorbent polymers, synthetic nonwovens, or other absorbent materials. The disposable absorbent article 8 is joined together in such a way that the coverstock 10 and backsheet material 12 completely enclose the absorbent core 42. The coverstock 10 and the backsheet 12 may be joined directly together or the coverstock 10 and the backsheet 12 may be joined together through an intermediate portion. Suitable materials for each of the core 42, coverstock 10 and backsheet 12 are generally known in the art. Some materials and structures suitable for use in the present invention are described in PCT international application WO00/03670 published at 27/1/2000, which is hereby incorporated by reference and forms part of the present specification.

The nonwoven coverstock 10 provides a liquid permeable upper layer of the absorbent core assembly to contain the absorbent core components and allows body exudates to enter the absorbent core 42 during use. The length and width of the coverstock 10 is preferably greater than the length and width of the absorbent core assembly 42. These extended side edges of the nonwoven coverstock 10 may extend to the lateral edges 32, 34 of the absorbent article and serve to provide an upper layer of the composite containing the elastic members 20. The lateral sides of the nonwoven coverstock 10 which extend beyond the elastic leg wraps 18 may or may not be permeable to aqueous liquids.

The cover 10 is comfortable, soft feeling, and non-irritating to the wearer's skin. In addition, the cover 10 is liquid permeable, allowing liquid to readily penetrate through its thickness. Suitable coverings may be made from a variety of materials such as porous sponges, reticulated sponges, apertured plastic films, natural rubber (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene), or a combination of natural and synthetic fibers. Preferably, it is made of a hydrophobic material to isolate the wearer's skin from liquids in the absorbent core 42.

Another embodiment of the invention includes a cover that uses a plurality of regions of differing hydrophilic character achieved by selective treatment of the material with an additive (e.g., a surfactant) that imparts hydrophilic character to the nonwoven. In this embodiment, the cover has a hydrophilic region in the center of the sheet, wherein the central region corresponds to the region of the article in which the absorbent core is disposed. The side regions laterally adjacent to the central region may have a lesser or greater hydrophilicity than the central region. The article thus formed has a hydrophilic water permeable coverstock over the absorbent core to allow urine to enter the core and a hydrophobic water impermeable region of the coverstock over the leg wraps to provide a dry feel around the legs and to prevent liquid leakage through the leg wraps 18.

Leg wraps 18 may include a plurality of elastic strands 20 associated with each side panel 18. In one embodiment, the elastic strands 20 are sandwiched between the nonwoven coverstock 10 and the backsheet laminate 12. The composition of the elastic strands 20, the nonwoven coverstock 10 and the backsheet laminate 12 is secured by using suitable means known to those skilled in the art, such as adhesive bonding using a grooved cover, or spray, spiral or swirl application of a hot melt adhesive, or ultrasonic bonding. In one embodiment, as shown, each side leg flap 18 has 6 elastic strands 20. The elastic cord 20 may be a yarn made of natural or synthetic rubber latex or synthetic elastic material such as highly elastic synthetic fibers. The choice of elastic material should not be limited to elastic strands but may also include bands of elastic material, elastic films, elastic scrims, elastic nonwoven composites, and the like.

Figure 3 is a cross-sectional view of the embodiment of figures 1 and 2 wherein the backsheet material 12 is a laminate of a liquid impermeable polyethylene or polystyrene film 52 with air holes or no air holes and a liquid impermeable polyphenylene nonwoven 54. These materials are known to those skilled in the art as cloth-like or fabric backings. It is also proposed that: the backsheet material 12 may be a single layer of a polystyrene support film or other suitable synthetic material.

The fasteners 16 of the present invention may comprise pressure sensitive adhesive fastening tapes which are secured to the front of a silicone "release" coated polyolefin film, hook and loop tape or any other suitable fastening medium. The absorbent article may also have an elastic waistband that utilizes an elastic sponge, elastic film, elastic band or other suitable elastic, elastic laminate, extensible material secured to or between the cover and backsheet portions.

The disposable absorbent article of the present invention provides a tight fitting seal around the thighs of the user, thereby significantly improving its leakage prevention capability. The tight-fitting seal of the garment of the present invention can be further enhanced by the addition of fasteners 16. The fastener 16 may be provided by known adhesive or hook fastening means. The hook fastening means may be selected so that it can engage with loops formed on the surface of the nonwoven fabric. Thus, the nonwoven material of the stretch panel provides the loop component of a hook and loop fastening system similar to those generally known in the art.

In other embodiments, a loop landing zone may be disposed adjacent to the front waist region of the outer side surface of the inventive article, and a pair of hook fasteners may be disposed in the back inelastic zone of each stretch panel. Thus, the fastening portion is secured directly to the central portion of the stretcher panel rather than to the leading edge thereof. The loop landing zone can be made of a woven, pressed or non-woven material, as is generally known in the art.

Figures 4 and 5 show various other embodiments of the absorbent article 8 of the invention. Fig. 4 shows an alternative embodiment in which the side edges 32, 34 of the absorbent article 8 are bent inwards to define cut-out areas 56. Such a shaped article helps the article fit better around the waist of the wearer and does not increase the amount of material in the side flaps that is gathered around the legs of the user when worn.

Figure 4 discloses elastic members 20 which are parallel to at least a part of the side edges 32, 34 of the absorbent article 8. In contrast, fig. 5 shows another embodiment of the invention, in which the elastic elements 20 follow the inwardly curved side portions of the absorbent article.

In figure 6, a further aspect of the invention is shown wherein the absorbent article 8 is defined by a central absorbent core assembly 14 and a pair of leg wraps 18 separated from the absorbent core assembly 14 by inelastic zones 58 of substantially reduced elasticity. Each inelastic zone 58 is defined between the absorbent core assembly 14 and the nearest elastic strand 20 of the leg wrap 18.

Fig. 7 shows various sizes of the absorbent article 8. A distance h is defined between the side edges of the absorbent core assembly 14 and the elastic strands 20 closest to the absorbent core assembly 14 (or indicated in another way, i.e. the side edges 32, 34 furthest from the absorbent article 8). The distance between the strands 20 of elastic material is denoted as distance e.

FIG. 7 also shows another embodiment of a plurality of fasteners 16 that may be used to implement the present invention. The fastener 16 may be disposed exteriorly of a side flap having one or more elasticized regions 37 and one or more non-elasticized regions 39. Other fastener and wing configurations are disclosed in U.S. Ser. No.11/113,114, entitled "Extensible Side Panels Use with reversible adhesive Articles".

In the preferred embodiment of the present invention, the number of strands 20 per leg wrap 18 is 4 to 10, preferably 4 to 6. The distance h (width of the inelastic zone 58) is preferably 19mm to 64mm, more preferably 25mm to 40 mm. The distance e between the cords 20 is preferably 4mm to 40mm, more preferably greater than 6mm, and most preferably about 8 mm.

A leg cuff member 64 may be provided on the top surface of the cover 10 of the absorbent article 8. Leg cuff elements 64 may be formed from the material of the cover layer 10 or may be formed from a different material that is secured to the top surface in a known manner. Those skilled in the art will appreciate the construction of the leg cuff members 64 in the absorbent article 8. As shown in fig. 8-13, the leg cuff members 64 may be disposed at different distances from the absorbent core 14.

FIGS. 9-24 illustrate cross-sections of another embodiment of the present invention. In some aspects, a three-piece construction may be utilized in place of the continuous full width nonwoven coverstock 10. In the central region 10 of the absorbent article, a liquid permeable hydrophilically treated polypropylene nonwoven material 66 is disposed over the absorbent core to contain the absorbent material and permit urine to enter the absorbent core 14. Another material element 68 forms the top layer of the elastic side flap 18 along each side edge of the article. Such materials may be selected from suitable materials such as water-permeable polypropylene nonwovens, water-impermeable polypropylene nonwovens, polypropylene films and the like. Figure 9 shows the absorbent core cover material 66 overlaid with an outer elastic composite cover material 68. Figure 10 shows an absorbent core covering material 66 with an elastic composite covering material 68 folded underneath.

Fig. 11 shows another embodiment of the present invention. In this embodiment, the absorbent core assembly 42 is enclosed by a nonwoven liquid permeable coverstock 70 and a liquid impermeable backsheet 72. In this embodiment, the cover 70 and the backsheet 72 do not extend to the outer edges of the absorbent article. The single layer of nonwoven fabric 74 is folded around and encloses the elastic strands 20. The elastic composite is then secured to the sides of the absorbent core 14 by any suitable means, such as by hot melt adhesive or ultrasonic bonding.

Fig. 12 shows another embodiment of the invention, in which the coverstock material 10 extends continuously over the entire width of the absorbent article 8, as in the first embodiment of the invention. In this embodiment, the underside of the elastic composite on each leg wrap 18 is closed with a separate piece of suitable material 78.

Fig. 13 shows another alternative to the embodiment shown in fig. 11. The scheme is different in that: the elastic strands 20 within the elastic composite secured between the covering and the backsheet portion of the core assembly 14 are enclosed by two separate layers of suitable material.

Figures 14-24 show other embodiments in which the underside of the elastic composite side flaps are formed from a material such as a liquid impermeable polypropylene nonwoven that extends continuously across the entire width of the absorbent article.

FIGS. 25-28 show a disposable absorbent article of the present invention suitable for use on a wearer. The absorbent article 8 is folded inwardly at point 80 and outwardly at point 82. The absorbent article 8 may of course conform to the shape shown in figures 25-28. The article must be pre-secured in this configuration, either by use of multiple adhesives 94 (fig. 29-33) or by use of any other suitable means for ensuring proper fit of the article to the wearer.

The effect of this folding pattern of the article is twofold. First, the elastic leg wraps 18 preferably lie against the body of the wearer and fit securely around the thighs or buttocks of the user. This enables a substantially liquid-impermeable seal to be formed around the user's legs, crotch and thighs, so that the effect of leakage can be reduced. Second, the absorbent core assembly 14 is held away from the wearer's body, particularly in the crotch region of the article. This enables the formation of void spaces 84 between the user's body and the absorbent core assembly 14.

As shown in fig. 25, the void space 84 may have a generally trapezoidal appearance with a bottom having a length generally equal to the width of the absorbent core 42, sides having a length equal to or greater than dimension X, and a top having a length dependent upon the angle formed between the bottom and sides. A portion of the article 8 may be rotated relative to one another so that the absorbent core 42 and leg wraps 18 are free to move upwardly along the wearer. This pivoting effect enables the leg wraps 18 to move during use while maintaining an effective leg seal.

The void space 84 formed by the structure of the absorbent article 8 is capable of holding the absorbent core 42 away from direct contact with the wearer's skin or body. For example, rewet or wetting of the user's skin by body waste fluids not fully received by the superabsorbent material in the absorbent core 42 can be reduced, thereby enhancing wearer comfort.

Referring particularly to fig. 25 and 28, the reservoir layer 26 is structured to collect, contain and retain body exudates. Exudates floating or flowing along the top surface flow into and down the sidewalls of the storage layer 26 to be collected at the bottom of the storage layer 26 until the absorbent article 8 is removed. Thus, the storage layer 26 is particularly effective for exudates, particularly loose fecal material that is not readily absorbed by the absorbent core 14 and tends to "float" on the coverstock 10.

For example, the storage layer 26 may be disposed at least partially between the elastic members 20 and the longitudinal centerline of the absorbent article 8 by the region of reduced elasticity 58. The reservoir 26 may be made of a material known in the art that is sufficiently conformable and comfortable to assume a trough-like or dimple-like shape. The material may be absorbent, wicking, or impermeable to exudate. For example, the storage layer 26 may include one component (i.e., the coverstock 10, the backsheet 12 or the leg wrap 18) or any combination of these components or other components of the absorbent article 8 that may be configured or folded into a reservoir. In addition, the reservoir layer 26 may have different shapes and profiles that ensure a trough-like or well-like shape for holding exudates. For example, the storage layer 26 may have a semi-circular, square, or parabolic cross-section.

The reservoir 26 is preferably formed by folding the material in the region of reduced elasticity 58 and securing the folded portion to the portion of the coverstock 10 adjacent the absorbent core 14. Fig. 24 and 25 show cross-sectional views of absorbent articles of the present invention. Fig. 24 and 25 are cross-sectional views of the absorbent article taken along a transverse plane of the user in a horizontal plane at right angles to the vertical sagittal plane that divides the body into upper and lower portions.

Fig. 28 shows temporary storage layer 26 and cavity 84, wherein storage layer 26 contains fluid prior to absorption by core 14. Fluid is prevented from passing through the side leg panels 18 by a series of elastic gathers defining a plurality of fluid barriers indicated by the numeral 90. Fluid passing through one fluid barrier 90 will encounter the more outboard fluid barrier 90. As a result, multiple sealing structures can be provided by the leg wraps 18 of the present invention.

It has been found that: the ideal trapezoidal shape of the cavity 84 and/or storage layer 26 is difficult to form and maintain in every application, as it depends on how the absorbent article 8 is positioned on the user and may move while the user is using the diaper. In order to increase the likelihood that such a shape will be present in the product when fitting the diaper to the wearer and to improve the stability of the desired shape during use, the diaper may be folded in advance in the side regions of the product and the fold fixed by the addition of a bonding element. Thus, the bonding element may employ any combination of adhesives, thermal fusion bonding, ultrasonic bonding, or any other suitable method of bonding plastic and nonwoven-based materials. It is also conceivable: the fold-fix bond is achieved using a hook and loop fastening system or other non-permanent fastening means.

In some embodiments of the invention, a z-fold is formed in the leg wrap 18 of the diaper during manufacture. The leg wraps 18 may be folded towards the core and then secured in place using a suitable bonding method. Subsequently, the side flaps are folded away from the core. The fold may be held in place using a desired bonding method. Figure 29 shows a section of a folded diaper with fold-and-fasten bond areas indicated by the reference numeral 92. Bonded regions 94 are freely selectable and embodiments of the present invention may not necessarily include bonded regions 94. Similarly, other embodiments of the present invention may include one or more bonded regions 94.

The bonding of the folded side regions can be achieved by applying the adhesive longitudinally in a continuous manner using any suitable practical method, such as spiral spraying, intermittent crimping or continuous edging. Alternatively, continuous lines of ultrasonic or heat-fusion bonding may be used. Fig. 30 shows a schematic view of this embodiment.

In other embodiments of the invention, the longitudinal fold fixation bond may not be continuous. The advantages are that: allowing multiple regions to be selected on the diaper where the fold can be unfolded to provide maximum void space while effectively locking the fold in place in other selected regions. In the embodiment of figure 32, two fold-securing bonds on each side flap 18 are provided in the region near the front and back edges of the diaper. In another embodiment of fig. 32, the bond points are moved toward the center of the diaper. In another embodiment of figure 33, one bond point per side flap is provided in the central crotch region of the diaper.

The above schematic figures show possible variants of the folding bottom panel of the invention and possible positions for the folding fixing joint. However, other embodiments of the invention not shown by the above figures are also possible. The location of the fold may vary and may be moved laterally to any location on the side flaps or, alternatively, portions of the absorbent core may be incorporated within the fold region. The number of fold-anchoring bonds per side flap may also vary.

Importantly, the method comprises the following steps: the tension provided by the elastic side leg panel 18 cannot be too high or too low. If the tension provided by the side leg panels 18 is too low, the absorbent article 8 may not fit very tightly in the central region around the legs and waist and the ability of the absorbent article to prevent leakage may be compromised. Higher tension may bind the user's thighs and cause an uncomfortable feeling. In typical prior art disposable absorbent articles, the positioning of the elastic members and the type of elastic members provided do not vary along the length of the elasticized flap. Thus, the elasticity or resiliency of the stretch panel is uniform along the length of the stretch panel. When stretched in a uniform manner, the overall stretch provided by the stretch panel is also uniform along its length. The magnitude of this uniform tension is dependent upon the overall elongation of the leg wrap 18. However, when the absorbent article 8 is worn, the elongation of the leg wrap 18 along its length is generally non-uniform and, as a result, the resulting tension varies. As a result, there are undesirable areas of over-tightness or over-tightness around the length of the leg wrap 18.

In one aspect, the areas without elastic elements-e.g., the areas provided for the finger lift and drop zones-are also special areas of elasticity created by the predetermined arrangement of elastic elements. However, these regions of elasticity differ in that: the elastic members do not apply an elastic force to the elastic panel in these areas, as opposed to the specific areas where the elastic force is applied in the vicinity of the elastic members. Some structures suitable for use in the present invention are described in U.S. Ser. No.10/441,469 entitled DISPOSABLE ABSORBENT ARTICLE WITH ELASTICIZEDSIDE PANELS, AND METHOD PF MAKING THE SAME ", which is hereby incorporated by reference AND made a part of the present specification.

In addition, embodiments of the absorbent article 8 can improve comfort by positioning the elasticized side flaps closer to the side edges of the absorbent core 42. Thus, when initially positioned on a wearer, the elasticized side flaps are positioned in the groin along the inner thighs of the wearer to provide a better initial fit. This positioning provides a better initial fit on the wearer, since the elastic side flaps of conventional diapers are generally initially positioned further down the wearer's thighs and then tend to float or creep up into the groin areas of the wearer during use. As the side flaps are pulled upward, gaps tend to form in the legs and waist, making the wearer less comfortable. However, since the present invention initially locates the elastic leg wraps 18 in the groin area, diaper sagging is reduced, thereby enhancing wearer comfort.

The foregoing description has been presented to illustrate the present invention. It should be emphasized that: the description should not be construed as limiting the invention to the various apparatus and methods described herein. The various aspects of the invention described above are applicable to other types of disposable absorbent articles and garments and methods for making such articles and garments. For example, the feature of elastic side panels having fastening portions as described above may be used with other types of disposable player articles (e.g., training pants). In addition, elastic side panels having the characteristic elasticity described above can also be used in other disposable absorbent articles and garments. These variations of the invention are obvious to one skilled in the art of use in connection with consumer products, or may be used in other related arts with the present disclosure. Accordingly, many modifications and variations are possible in light of the above teaching, and it is desired to provide an improved method and apparatus for practicing the method and apparatus. The embodiments described and illustrated herein are further intended to explain the best modes known for practicing the invention and to enable others skilled in the art to utilize the invention and other embodiments and with various modifications required by the particular applications or uses of the present invention.

Claims (19)

1. A disposable absorbent article, comprising:

an absorbent core disposed between the liquid pervious topsheet and the liquid impervious backsheet; and

a pair of flexible leg wraps extending outwardly in a longitudinal direction from and along side edges of the absorbent core,

each of said leg wraps comprising a plurality of spaced apart elastic strands separated from the absorbent core by a non-elastic zone extending outwardly from said absorbent core in the longitudinal direction and located between said absorbent core and said plurality of spaced apart elastic strands;

wherein, in use, the leg wraps and the absorbent core form a storage layer, and a plurality of fluid barriers are at least partially defined by the plurality of isolated elastic strands during use of the absorbent article, each fluid barrier being capable of collecting an amount of liquid waste material issuing through the leg wraps,

the absorbent core is disposed in a substantially flat open state, the distance between the absorbent core and the nearest elastic string is 10mm to 100mm, the number of elastic strings per leg wrap is 4 to 10, and the distance between the elastic strings is 4mm to 30mm, wherein the storage layer is formed between the body of the wearer and the absorbent core by the distance between the absorbent core and the nearest elastic string; and is

Wherein the backsheet and the topsheet each extend to a lateral edge of the absorbent article and at least one of the plurality of isolated elastic strands is located between the backsheet and the topsheet.

2. The absorbent article of claim 1, wherein: the distance between each elastic rope is 6 mm-8 mm.

3. The absorbent article of claim 1, wherein: the distance between the absorbent core and the nearest elastic cord is 25mm to 40 mm.

4. The absorbent article of claim 1, wherein: the inelastic zone can be folded over to define part of the storage layer.

5. The absorbent article of claim 1, wherein: portions of the inelastic zone are bonded together at one or more locations of the absorbent article.

6. The absorbent article of claim 1, wherein: the distance between adjacent pairs of elastic strands is non-uniform so that the spacing of the elastic strands is not equal.

7. The absorbent article of claim 1, wherein: the top layer has different hydrophilic properties.

8. The absorbent article of claim 6, wherein: the elastic cord is provided with a plurality of different diameters.

9. The absorbent article of claim 8, wherein: the distance between the central absorbent core and the nearest elastic cord is 30mm to 44 mm.

10. The absorbent article of claim 8, wherein: the number of the elastic ropes is 6-8.

11. The absorbent article of claim 8, wherein: the distance between each elastic rope is 6 mm-9 mm.

12. The absorbent article of claim 8, wherein: the distance between the absorbent core and the nearest elastic cord is 19mm to 64 mm.

13. The absorbent article of claim 12, wherein: the distance between the absorbent core and the nearest elastic cord is 42mm to 50 mm.

14. A method of manufacturing a disposable absorbent article, the method comprising:

providing a central body having an absorbent core;

providing a pair of flexible leg wraps extending longitudinally adjacent opposite lateral sides of the central body, each of the leg wraps including a non-elastic region extending outwardly from the absorbent core in a longitudinal direction and between the absorbent core and the plurality of spaced elastic strands extending generally in the longitudinal direction of the absorbent article, and a plurality of spaced elastic strands, wherein the absorbent core and leg wraps are in a relaxed state prior to use, the leg wraps extending in a non-folded manner away from the longitudinal centerline of the central body, wherein the distance between the central absorbent core and the elastic strand closest to the central body is from 10mm to 100mm, and the distance between the elastic strand closest to the central body and the elastic strand furthest from the central body is greater than 38mm, in a condition in which the absorbent article is provided in a flat open orientation, wherein the storage layer is formed between the body of the wearer and the absorbent core by the distance between the absorbent core and the nearest elastic cord; and

wherein the backsheet and the topsheet each extend to a lateral edge of the absorbent article and at least one of the plurality of isolated elastic strands is located between the backsheet and the topsheet.

15. The method of claim 14, wherein: a non-elastic zone having a greatly reduced elasticity is provided between the absorbent core and the plurality of elastic strands, and the width of the non-elastic zone is 19mm to 64 mm.

16. The method of claim 14, wherein: the distance between each elastic rope is 6 mm-8 mm.

17. The method of claim 14, wherein: the distance between the absorbent core and the nearest elastic cord is 25mm to 40 mm.

18. The method of claim 15, wherein: the inelastic zone can be folded over to define part of the storage layer.

19. The method of claim 18, wherein: the partially inelastic zone is bonded together at one or more locations in the absorbent article.