Durable absorbent pant with improved stitching

Abstract

A durable absorbent pant is disclosed. The pant includes an outer pant structure and a triangular liner assembly disposed at least partially in a crotch portion. The triangular liner assembly includes: an absorbent layer; a barrier layer underlying the absorber layer; and an edge barrier overlying a portion of a wearer-facing surface of the triangular liner assembly along a peripheral edge of the triangular liner assembly and effectively continuing on and around the peripheral edge to an outwardly-facing surface of the triangular liner assembly. The edge barrier may be formed from a liquid impermeable edge sealing strip material bonded to the barrier layer, or the edge barrier may be formed from an extension of the barrier layer. The triangular liner assembly may be attached within the crotch portion by various disclosed mechanisms.

Description

Background Art

[0001] Currently, there is a growing market for durable (washable / reusable) absorbent underpants. For the purpose of managing menstrual discharge or unexpected urine discharge caused by incontinence, more and more women are choosing to use durable absorbent underpants in addition to, in addition to, or even as a replacement for conventional disposable feminine hygiene pads, tampons, disposable incontinence pads, and / or disposable absorbent underpants.

[0002] There are currently several designs for durable absorbent underwear on the market. The simplest form is similar to a pair of conventional underwear briefs, where the crotch section or "gusset" includes one or more additional absorbent fabric layers, which are supported from below by a liquid-impermeable barrier layer, included and sewn into the crotch portion of the underwear. In order to address and mitigate the potential for absorbed fluid to wick laterally through the absorbent material outward to the leg opening edges (where the fluid can reach and soil outer clothing), several designs have included one or more layer components around the gusset and, in some designs, a peripheral edge barrier wrapped around the outer pants fabric. In order to further eliminate potential fluid wicking and leakage paths created by bonding stitching, several designs have replaced stitching / sewing with strips or bands formed from heat-activated adhesive materials, which are typically sandwiched between the respective materials to be joined and then subjected to heat and pressure (e.g., via a hot iron or press) to attach and adhere the layers together. This can help manufacturers avoid the use of stitching, which may require piercing and inserting thread through the absorbent gusset assembly and its barrier component, thereby creating potential fluid wicking or leakage pathways.

[0003] However, the use of adhesive strips or bands to join material layers in active areas of a garment may have its own disadvantages. Even in cases where the compounds constituting the adhesive are formulated to impart flexibility and elasticity to the adhesive material, the extended and continuous formation of the adhesive material and / or the penetration of the adhesive material into the interstitial spaces within the fabric knit structure (and adhesion to the constituent fibers / yarns of the joined fabric) also have a bonding effect, thereby increasing the stiffness of the material along the area joined by the adhesive and reducing the elastic stretchability of the material. This is undesirable in areas (e.g., around leg openings) where flexibility and elastic stretchability are particularly desired for the purposes of a secure fit and wearer comfort. In addition, where such bands are included near the edges of the leg openings, they increase the material accumulation present at the leg edges, thereby increasing thickness at the leg edges and creating a potential source of potential discomfort, and contributing to "panty marks" that may be visible through outerwear and perceived by the wearer as undesirable. Therefore, there is room for improvement in structures and methods for assembling absorbent underwear that minimize the possibility of leakage of absorbed fluids while maintaining material flexibility and stretchability. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Figure 1 is a simplified depiction of an example of shorts that appear to be arranged lying flat on a horizontal, flat surface with the front waist portion facing upward.

[0005] Figure 2 yes Figure 1 An example depiction of a pair of shorts in an assembled but open configuration wherein the front waist portion and the rear waist portion have been separated at the hip portions or hip side seams, the shorts appearing to be arranged lying flat on a horizontal, flat surface with the wearer-facing surface facing upward.

[0006] FIG. 3A to FIG. 3C is a partial schematic transverse cross-sectional view of an example of an absorbent gusset assembly proximate the side edges of the leg openings.

[0007] Figure 4A and Figure 4B is a partial schematic longitudinal cross-sectional view of an example of a pant including an absorbent gusset assembly through the crotch portion and the leg opening edges.

[0008] Figure 5 , FIG. 6A to FIG. 6C , FIG. 7A to FIG. 7C , Figure 8 and Fig. 9 is a partial schematic longitudinal cross-sectional view of an additional example of a pant including an absorbent gusset assembly through a crotch portion and leg opening edges.

[0009] FIG. 10A to FIG. 10C is a partial schematic longitudinal cross-sectional view of an example of a pant including an absorbent gusset assembly through an end of the gusset assembly.

[0010] Fig.11 A possible example of a pant having a gusset is a pant having a gusset through the longitudinal center plane (e.g. Figure 1 ), the pants are oriented as they would be positioned on a standing wearer.

[0011] Fig. 12A is a simplified depiction of an example of shorts that appear to be arranged lying flat on a horizontal, flat surface with the front waist portion facing upward.

[0012] Fig. 12B is a simplified depiction of an example of a pair of boxer briefs (or pants with pant legs) that appear to be arranged lying flat on a horizontal, flat surface with the front waist portion facing upward.

[0013] Fig.13A is a plan view of an example of a crotch gusset arranged on a horizontal surface, with the wearer-facing surface facing the viewer.

[0014] Fig. 13Byes Fig.13A A schematic vertical cross-section of a portion of a triangular gusset is shown. DETAILED DESCRIPTION

[0015] definition

[0016] The "crotch gusset 230" is a structural component that includes at least two distinct layers, including an absorbent layer and a liquid-impermeable barrier, and bridges the front waist portion 100 and the back waist portion 120. A crotch gusset has a "liquid-impermeable barrier" if it exhibits no more than 0.1 ml of z-direction leakage of a test fluid into a piece of filter paper in the Liquid Impermeability Test described below. Reference Figure 2 By way of example, for purposes herein, the crotch portion 130 is the portion of the pant located at least between the crotch portion minimum front extent 401 and the crotch portion minimum rear extent 402, longitudinally centered about the crotch portion transverse axis 301 (which is drawn along the minimum width dimension measured between the crotch leg opening edges 140), plus 10% of the total pant length L to the front and rear of the crotch portion transverse axis 301. As indicated by Figure 2 As suggested, for the purpose of better fitting the legs and lower torso of an adult female wearer, it may be desirable to locate the crotch portion transverse axis 301 forward of the transverse axis 300 (which bisects the total length L) rather than being co-located with the transverse axis 300. Thus, for purposes herein, the respective boundaries between the crotch portion 130 and the front and rear waist portions 100, 120 are independent of the location of any seams (such as seams 134, 138) that may exist to connect the material contained in the crotch gusset 230 with the material contained in the front and rear waist portions 100, 120.

[0017] With respect to wearable garments such as underwear, "durable" means that the garment is primarily made of fabrics knitted and / or woven from natural, semi-synthetic or synthetic fibers, threads or yarns and can normally be laundered or hand washed and dried for multiple reuses / rewearing without substantially losing its original shape, structural integrity, absorbent function or other useful mechanical properties that existed prior to laundering or cleaning.

[0018] As used herein, "fabric" refers to a web material knitted or woven from fibers or threads or yarns of fibers. Herein, the term "fabric" does not include films or fibrous nonwoven web materials.

[0019] As used herein, "film" refers to a skin-like or film-like material cast, extruded, or formed in situ from a molten thermoplastic material. Herein, the term "film" does not include fibrous nonwoven web materials or fabrics.

[0020] With respect to pants arranged to lie flat on a horizontal, flat surface in an assembled but open configuration, "longitudinal" means the direction generally perpendicular to a line tangent to each of the left leg opening edge and the right leg opening edge where the left leg opening edge and the right leg opening edge are closest to the front waist edge. With respect to pants arranged to lie flat on a horizontal, flat surface in an assembled configuration with the front waist portion facing upward, "longitudinal" means the direction generally perpendicular to a line tangent to each of the left leg opening edge and the right leg opening edge where the left leg opening edge and the right leg opening edge are closest to the front waist edge. "Length" means a dimension measured in the longitudinal direction. The longitudinal direction is considered to be the "y direction" indicated in the figures.

[0021] With respect to the assembled but opened configuration (e.g., as Figure 2 For pants (such as those exemplified in the example of FIG. 1 ), “lateral” refers to a direction generally parallel to a line tangent to each of the left leg opening edge and the right leg opening edge where the left leg opening edge and the right leg opening edge are closest to the front waist edge. With respect to a pants arranged to lie flat on a horizontal flat surface with the front waist portion facing upward in an assembled configuration (such as a Figure 1 For pants (as illustrated in the figure), "lateral" refers to a direction generally parallel to a line tangent to each of the left leg opening edge and the right leg opening edge where the left leg opening edge and the right leg opening edge are closest to the front waist edge. "Width" refers to the dimension measured along the lateral direction. The lateral direction is considered to be the "x direction" indicated in the figure.

[0022] With respect to the assembled but opened configuration (e.g., as Figure 2 For pants (as illustrated), the “z direction” is a direction orthogonal to the longitudinal direction and the transverse direction, that is, a vertical direction relative to a horizontal flat surface.

[0023] With respect to a device arranged to lie flat on a horizontal flat surface with the wearer-facing surface facing upward in an assembled but open configuration (e.g., Figure 2 The terms "above", "upper", "superadjacent", "below", "lower", "subjacent", and / or "below" describe the arrangement of the components relative to each other along the z-direction. Thus, for example, with reference to Figure 4A, the wearer-facing layer 231 is disposed “above” the outer-facing layer 234, and conversely, the outer-facing layer 234 is disposed “below” the wearer-facing layer 231 and / or the absorbent layer 232. With respect to the two-layer components, “adjacent above” and “adjacent below” also mean that these two-layer components are disposed in direct face-to-face contact with each other.

[0024] A yarn, thread, fiber, filament, web, film or fabric material, or a laminate or composite of any of these, is considered to be "elastically extensible" for the purposes of this document if a tensile force of no more than 50 gf / mm (gf / mm sample width, where the sample width is measured perpendicular to the direction of stretch) is applied to the material in question along the direction of stretch, the material can be extended along that direction to an elongated dimension of at least 130% of its original relaxed dimension (i.e., can be extended by at least 30%) without rupture or breakage that significantly damages the material in question; and when the force is removed from the material in question, the material contracts along the direction of stretch to recover at least 40% of such elongation. For example, if a section of fabric with an original relaxed length of 100 mm and a sample width of 40 mm can be stretched to a length of 130 mm in the direction along its length by a tensile force of 2000 gf (50 gf / mm) without significant damage, and will shrink to a length of no more than 118 mm (130 mm - 118 mm = 12 mm = 40% of 30 mm) when the force is removed, it is "elastically extensible" as defined herein. "Elongation" used herein to quantify and express the amount of strain transferred to an elastically extensible material in the stretching direction means: {[(strain length of strand) - (strand length before strain)] / (strand length before strain)} × 100%. For integral materials (such as cast or extruded film materials), "elastomer" refers to "elastically extensible" as defined herein.

[0025] With respect to two opposing surfaces of a layer component of a pant, "wearer-facing" refers to the surface that faces the wearer's skin when the pant is normally worn; and "outward-facing" refers to the surface that faces away from the wearer's skin. With respect to two different layered components of a pant, the "wearer-facing" component is the component that is disposed closest to the wearer's skin when the pant is normally worn; and the "outward-facing" component is the component that is disposed farthest from the wearer's skin.

[0026] For the purposes of this document, "pants" include any garment adapted to be worn about a person's lower torso, including front and rear waist portions that join around the wearer's hips and below the wearer's crotch to form a garment having a waist opening and a pair of leg openings. As used herein, the term "pants" encompasses, but is not limited to, garments defined herein as "shorts"; garments defined herein as "pants with pant legs", and any other garment having such features, whether suitable for use as underwear or outerwear.

[0027] For the purposes herein, unless otherwise indicated, "predominantly" with respect to the proportion content of a component material in a combination or structure means that the component constitutes the majority of the weight of the combination or structure.

[0028] For purposes herein, "shorts" are distinguished from "pants with pant legs" by the configuration of the inner leg edges, which results from the manner in which the component materials are formed, sized, proportioned, and sewn or otherwise attached together. Fig. 12A An example of shorts is depicted, and Fig. 12B An example of a trouser with trouser legs in an alternative form is depicted. When the garment in an assembled state is arranged to lie flat on a horizontal flat surface, with the front waist portion facing upward, and a transverse crotch tangent line 500 is drawn perpendicular to the longitudinal axis 200 and tangent to the point where the crotch portion lower contour 130a intersects the longitudinal axis 200,

[0029] For shorts, the lowest point 140a along the inner leg opening edge 140 is located along or above the crotch cut line 500 (i.e., toward the front waist edge 102) (see Fig. 12A );and

[0030] For pants with trouser legs, the lowest point 140a along the inner leg opening edge 140 is located below the crotch cut line 500 (i.e., away from the front waist edge 102) (see Figure 5 B).

[0031] like Fig. 12B As reflected in , for purposes of this document, a pant with pant legs may have a leg portion 141 of any length, wherein the lowest point 140a of the inner leg opening edge 140 is disposed below the crotch cut line 500. A boxer pants such as a "boy short" style will typically have a length such as Fig. 12B The shorter leg portion suggested in the solid line portion of the figure, while other pants with trouser legs may have a shorter leg portion as shown in the figure. Fig. 12B The dotted parts suggest different lengths of the leg parts.

[0032] illustrate

[0033] One problem that exists in absorbent systems designed to contain and absorb women's discharged menstrual fluids and unexpected (incontinent) small amounts of urine excretions is caused by cling flow. Cling flow has been a phenomenon associated with menstruation and mild to moderate adult female incontinence due to relatively low excretion velocities, female anatomical features, and the typical surface chemistry of human skin (which can cause the skin surface to attract and be relatively wettable by aqueous solutions such as menstrual fluids and urine). If the features of the selected containment / absorption system do not reliably hold the absorbent material against the wearer's skin to intercept cling flow, leakage can result.

[0034] However, it is believed that to date, there are no commercially available durable adult absorbent shorts (i.e., pants having a crotch portion that includes an absorbent structure and a liquid-impermeable barrier layer outside the absorbent structure) that reliably prevents leakage of adherent streams during various body movements and positions and within a reasonable wear / use duration. Currently commercially available pants products do not effectively maintain the included absorbent structure against the body during various body movements and within a reasonable wear / use duration. It is believed that the clothing industry has not yet recognized that properly oriented elastic stretch is important for maintaining the proximity and / or contact of the absorbent structure with the wearer's body contour and skin surface during various body positions and movements, and that such a structure can be designed, which has a combination of absorbent capacity suitable for preventing leakage caused by menstrual flow or mild to moderate incontinence, while having properly oriented elastic stretch to maintain effective contact of the structure with the wearer's body. The human body, particularly the female lower body and crotch area, has a geometrically irregular, wavy surface. A fabric or web material that does not exhibit an effective amount of elastic stretch along the effective direction will not effectively conform closely to (i.e., maintain contact with) most or all of these surfaces during normal body positions and movements. Increasing the amount of elastic stretch imparted to the crotch gusset increases the variety of body shapes and movements to which the gusset can conform during use. Relatedly, reducing the machine direction stretch modulus (the longitudinal pulling force in the material resulting from machine direction stretch) also tends to increase fit and enhance comfort.

[0035] For underwear, many women prefer shorts over pants with pant legs, such as "boxers," for ordinary everyday wear. This is due to comfort issues; unlike pants with pant legs, boxer-style pants, shorts generally do not ride up and bunch around the legs due to changes in body position and thereby become a source of undesirable material accumulation, tightness around the legs, or other discomfort under outer clothing. In addition, due to the way their leg edges tend to cause the pants to fit the crotch area of ​​the body, shorts with suitable elastic stretch properties may be preferred for maintaining a snug fit around the female genital / urethral area (in order to prevent leakage of menstrual fluid or unintended urine discharge).

[0036] It is understood that a durable absorbent pant can be designed that more reliably and comfortably holds the absorbent structure against / in contact with the wearer's body through the crotch region, better intercepts cling flow at a location, captures discharged liquid in the absorbent material before it can escape, and allows the absorbent component to expand both initially and over a reasonable duration of wear / use of the pad. In order for a fabric or web material to conform to an irregular surface, the fabric or web material must be able to stretch in at least one direction. It has been determined that the direction of stretch that most effectively enables the fabric or web of a pant garment to effectively conform to the contours of a woman's lower torso and crotch region is substantially the longitudinal direction.

[0037] Reference Figure 1 and Figure 2 As an illustrative but non-limiting example, a pant may include a front waist portion 100, a rear waist portion 120, and a crotch portion 130 bridging the front waist portion and the rear waist portion. The front waist portion 100 has a front waist edge 102 and left and right front leg opening edges 104. The rear waist portion 120 has a rear waist edge 122 and left and right rear leg opening edges 124. The crotch portion 130 has left and right crotch leg opening edges 140. The crotch portion 130 may include the entirety or a portion of a crotch gusset 230, which may include several layer components as will be further described below. (For purposes of this document, a "crotch portion 130" is a portion of a pant identified as described herein, and its forward and rearward extents are not associated with a particular component or structure.) As used herein, a "gusset" 230 is a structural component that includes at least two distinct layers, including an absorbent layer and a liquid-impermeable barrier layer, and is disposed in the crotch portion and that bridges the front waist portion 100 and the rear waist portion 120. A gusset has a "liquid-impermeable barrier layer" if it exhibits no more than 0.1 ml of z-direction leakage of a test fluid into a length of filter paper in the Liquid Impermeability Test described below. Reference Figure 2 By way of example, for purposes herein, the crotch portion 130 is the portion of the pant located at least between the crotch portion minimum front extension 401 and the crotch portion minimum rear extension 402. The crotch portion 130 is longitudinally centered about the crotch portion transverse axis 301 (which is drawn along the minimum width dimension measured between the crotch leg opening edges 140) and includes 10% of the total length L of the pant to the front and rear of the crotch portion transverse axis 301. As indicated by Figure 2As suggested, for the purpose of better fitting the legs and lower torso of an adult female wearer, it may be desirable to locate the crotch portion transverse axis 301 forward of the transverse axis 300 (which bisects the total length L) rather than being co-located with the transverse axis 300. Thus, for purposes herein, the respective boundaries 401, 402 between the crotch portion 130 and the front and rear waist portions 100, 120 are independent of the location of any seams (such as seams 134, 138) that may exist to connect the material contained in the crotch gusset 230 with the material contained in the front and rear waist portions 100, 120. The material forming the front and rear waist portions 100, 120 may be unitary and continuous across, or may be joined at the seams, at or near the hip portion 160, to complete a pant structure having a waist opening and a pair of leg openings.

[0038] The material forming one or both of the front portion 132 and the back portion 136 of the crotch portion 130 may be integral and continuous with the material forming the front waist portion 100 and the back waist portion 120, or alternatively, one or both of the front portion 132 and the back portion 136 of the crotch portion 130 and / or the crotch gusset 230 may be substantially formed from one or more sections or layers of material different from the material substantially forming one or both of the front waist portion 100 and the back waist portion 120, and the crotch gusset 230 may be connected to the front waist portion 100 and the back waist portion 120 at one or both of the front seam 134 and the back seam 138. Figure 1 , Figure 2 and FIG. 10A to FIG. 10C In the illustrative but non-limiting example suggested in , the front waist portion 100, the outer facing layer 234 of the crotch portion 130, and the rear waist portion 120 can all be formed partially or entirely from a first single continuous material section (e.g., a fabric from which the main body of the pant can be formed). Figure 4A , Figure 4B , Figure 5 , FIG. 6A to FIG. 6C , FIG. 7A to FIG. 7C , Figure 8 , Fig. 9 and FIG. 10A to FIG. 10C As reflected in the examples shown in the figure, one or more additional material layers 231, 232, 233 may be arranged on the wearer-facing side of the outer layer 234 in the crotch portion 130 as shown, and directly or indirectly connected or attached to the layer 234 at, for example, the front gusset seam 134 and the rear gusset seam 138 and / or along the crotch leg opening edge 140 via, for example, stitching / sewing, adhesive bonding, thermal bonding (fusion or welding) or other suitable attachment / joining mechanisms (hereinafter referred to as attachment mechanisms).

[0039] In other non-limiting examples (not specifically shown), the material sections that form the front waist portion 100, the rear waist portion 120, and the crotch portion 130, respectively, can be completely separate and distinct and joined at, for example, the front seam 134 and the rear seam 138 via any suitable attachment mechanism. This configuration may be preferred in some cases because it may provide the designer with greater flexibility in selecting the respective materials for the waist portion and the crotch portion with respect to appearance, feel, weight, breathability, elongation, stretch properties, and cost. The elongation and stretch properties described below will apply to the combination of one or more layers of material present in the crotch portion 130 and / or the crotch gusset 230.

[0040] Crotch area / crotch gusset

[0041] Triangular gusset parts

[0042] Reference Figure 3A , Figure 3B and Figure 3C , crotch gusset 230 includes components of an absorbent assembly 238, which include at least an absorbent layer 232 and a barrier layer 233. The absorbent layer 232 may be one or more layers of a suitable fabric selected for the desired absorbency and stretch characteristics. The absorbent layer 232 will be supported from below by a barrier layer 233, which may be a suitable polymer film, or alternatively a fabric that effectively prevents liquid from passing therethrough under ordinary wearing conditions of garments of the type described herein. The barrier layer 233 serves to prevent liquid absorbed by the absorbent layer 232 from flowing out to the outer-facing layers of the pants by wicking or capillary action, and from there to outerwear, bedding, etc.

[0043] In some examples (not specifically shown), the absorbent layer 232 may include or be formed of two, three or more different material sublayers arranged adjacent to each other on the upper / lower side. The corresponding sublayers may have different sizes, dimensions and / or surface areas along the x and y directions, and may be formed of or include respectively different materials. In some examples, one or more sublayers may be formed of or include nonwoven web materials. In such examples, for reasons explained herein, it may be preferred that such sublayers may be constructed and manufactured to have elastic extensibility, or alternatively, such sublayers may be arranged in a gusset so as not to be bonded / attached to an upper adjacent layer or a lower adjacent layer (e.g., an elastically extensible layer) (on most of the overlapping surface area therebetween), thereby avoiding hindering the elastic stretching of such upper adjacent layer / lower adjacent layer.

[0044] The barrier layer 233 may be formed of or include a suitable polymer film. The polymer components of the film may be selected to impart thereto one or both of effective liquid impermeability and elastic extensibility. In some examples, the film may be adapted to be liquid impermeable under ordinary use conditions contemplated herein, but to be effectively gas and / or vapor permeable (i.e., "breathable"), so as to allow water vapor to escape the garment more easily, and thereby improve comfort and reduce the chance of overhydration of the wearer's skin (which may cause or contribute to undesirable microbial growth, skin irritation, rash, etc.). In some examples, it may be preferred that the barrier layer 233 may not be attached to the overlying absorbent layer in the middle / center region of the gusset between the peripheral edge seams to reduce the bonding, stiffening, and elasticity-reducing effects of bonding or attaching the upper / lower adjacent layers.

[0045] In some examples, the crotch gusset 230 may include an additional overlying wearer-facing layer 231. The wearer-facing layer 231 may be formed of a suitable fabric that has a comfortable feel against the skin while being configured to direct liquid downward to the absorbent layer 232 after an insult and subsequently isolate the absorbed fluid in the absorbent layer from the wearer's skin, thereby helping to impart a relatively dry feel to the pants to the wearer even after an insult.

[0046] In most designs, it may be preferred to provide the absorbent layer 232 and the wearer-facing layer 231 (if included) with edge seals around the perimeter of these layers (e.g., around a portion or all of the perimeter of the gusset 230), or at least at the peripheral edges of the gusset in the crotch portion 130 of the pant near the leg opening edges 140. Because these layers may be formed of fabrics that are configured to accept and transfer liquids via wicking or capillary action, it may be desirable to inhibit liquid from migrating beyond the peripheral edges of these layers, which migration could result in leakage and contamination of the crotch portion's outer-facing layer 234, outer garments, bedding, etc.

[0047] Reference Figure 3A and Figure 3B, in some examples, edge sealing can be provided by including an edge sealing strip 235. The edge sealing strip can be formed of a film or fabric that is appropriately waterproof or effectively prevents liquid from passing therethrough under the conditions of use contemplated herein. The edge sealing strip 235 is preferably sealingly adhered to the barrier layer 233 so as to be effectively integral with the barrier layer, and wraps around and surrounds the peripheral edges of the absorbent layer 232 and the wearer-facing layer 231 (if included), and is attached to the wearer-facing surface of the uppermost layer near its periphery. So configured, the edge sealing strip can effectively prevent liquid that may be wicked to the peripheral edges of these layers from flowing out of it. The edge sealing strip 235 can be formed of an inherently viscous material having sufficient adhesive properties to enable it to adhere to the barrier layer 233 and the wearer-facing layer 231 with or without the application of heat and pressure, or alternatively, the edge sealing strip 235 can be adhered to these components via a suitable adhesive. In order to maintain any inherent elastic stretchability of the individual layers 231, 232, 233 in the assembly, it may be desirable to form the edge sealing strip 235 from an elastomeric material. In some examples, the edge sealing strip 235 may be formed from a substantially liquid-impermeable polymer film having a partial or predominant silicone (polysiloxane) component, which may be preferred due to its relative softness, flexibility, elastic / elastic extensibility, durability, and resiliency.

[0048] In such Figure 3C In other examples suggested in , the edge seal can be provided by an integral continuous extension of the barrier layer 233, thereby providing a peripheral border portion thereof having a size sufficient to wrap around and surround the peripheral edges of the absorbent layer 232 and the wearer-facing layer 231 (if included), and can be attached to the wearer-facing surface of the uppermost layer near its periphery via an adhesive or other suitable mechanism. So constructed, the peripheral portion of the barrier layer 233 that wraps around can effectively prevent liquid that may be wicked to the peripheral edges of the absorbent layer 232 and the wearer-facing layer 231 (if included) from flowing out thereof.

[0049] thickness

[0050] For the purpose of minimizing bulk, it may be desirable that the combination of layered materials present in the crotch portion 130 and the crotch gusset 230 be selected and configured to have a central z-direction thickness of no more than about 6 mm, more preferably no more than about 5.5 mm, and even more preferably no more than about 5 mm. (Herein, "central z-direction thickness" or "central thickness" is measured at a location of the crotch portion 130 that corresponds to the thickness of the pant when the pant is opened and laid flat on a horizontal, flat surface.) Figure 2) Based on the disclosure herein and the teachings available in the art regarding textiles, one of ordinary skill in the art would be able to select a suitable combination of materials to create a structure in the crotch portion 130 having this thickness along with the other features and properties described herein.

[0051] Absorption capacity

[0052] In order for a durable absorbent pant to provide suitable absorbency for a reasonable wear duration and to prevent leakage of menstrual fluid or unexpected urine discharge, for women experiencing menstruation or mild to moderate incontinence, it may be desirable for the combination of materials forming the structure within the crotch portion 130 of the pant to have an Absorbency Capacity of 0.1 ml / cm2 as measured according to the Absorbency Capacity Measurement Method described below, while balancing considerations for limiting the thickness / bulkiness of the crotch portion while limiting the relatively flat size / surface area required for the absorbent portion. 2 Up to 0.4ml / cm 2 The area absorption capacity and 0.4ml / cm 3 Up to 1.0ml / cm 3 Based on the disclosure herein and the teachings available in the art regarding textiles, one of ordinary skill in the art will be able to select a combination of suitable materials to create a structure in the crotch portion 130 having such an absorbent capacity.

[0053] Elastic stretch properties

[0054] It is known experimentally that imparting appropriate directional elastic stretch properties to the pants within the crotch portion 130 is important for providing pants with a crotch portion that comfortably and securely holds against the wearer's body surface, intercepts and absorbs the adherent flow of menstrual fluid or urine in place, and thereby prevents leakage from the pants during normal body positions and ranges of movement. It is understood that the combination of materials present in the crotch portion 130 should preferably exhibit a maximum longitudinal elongation of 25% to 100% measured according to the maximum elongation measurement method described below. Alternatively or in addition, it may be desirable that the combination of materials present in the crotch portion 130 exhibit a longitudinal tensile modulus of 10 gf / mm to 100 gf / mm measured according to the longitudinal tensile modulus method described below (reflecting the presence of one or more elastic imparting materials). Based on the disclosure herein and the teachings available in the art regarding textiles, a person of ordinary skill in the art will be able to select a combination of suitable materials to create a structure in the crotch portion 130 having such longitudinal elongation and tensile modulus properties.

[0055] Material selection

[0056] In general, the front waist portion 100 and the rear waist portion 120 of suitable examples of pants can be formed from any fabric material or combination of fabrics and other materials known and used as components of underwear, swimwear, or athletic / active wear that exhibits suitable properties, which properties may include (depending on the location of the fabric within the structure) a pleasant feel against the skin (softness and / or low friction / smooth / silky feel), low thickness / bulk, stretchability, elastic extensibility, absorbency, wicking ability, breathability, etc. In one example, the front waist portion 100 and the rear waist portion 120 and the outer-facing layer 234 of the crotch gusset 230 may include or be formed from a knitted stretch fabric, which in some examples is a combination of one or more of nylon, polyester, cotton, and spandex (e.g., Lycra (a product of The Lycra Company of Wilmington, Delaware)).

[0057] Additional layer components of the crotch portion 130 and / or crotch gusset 230 requiring absorbency and longitudinal elastic stretch properties as described herein may include a combination of several materials selected to impart the desired properties to the structure.

[0058] Fabric structure

[0059] Most durable fabrics exhibit anisotropic elongation capabilities.

[0060] The woven fabric formed by weaving is formed by two groups (a warp group and a weft group) of interlaced constituent yarns or threads, and the yarns or threads in each group are substantially parallel to each other along the plane of the fabric and substantially perpendicular to the yarns or threads in the other group. Unless the constituent yarns or threads themselves are formed by extensible materials, the woven material has a relatively low elongation capacity in the warp direction and the weft direction, and has a relatively high elongation capacity in two offset directions of about 45 degrees to the warp direction and the weft direction. Therefore, when it is desired for special reasons that the layer components of the crotch portion 130 and / or the crotch gusset 230 are woven materials, it may be desired that the material is oriented in the crotch portion so that one of the warp direction and the weft direction is about 30 degrees to about 60 degrees, preferably about 38 degrees to about 52 degrees, and more preferably about 45 degrees with the longitudinal direction of the pants, so as to provide the woven layer with the maximum available longitudinal elongation capacity.

[0061] However, when stretched in a bias direction, woven fabrics typically exhibit significant Poisson's effect contraction in the transverse direction of stretch (90 degrees to the stretch direction). When such fabrics are included in the crotch portion 130 and their bias orientation is generally in the longitudinal direction of the pants, the Poisson's contraction effect can cause the crotch portion to narrow in the transverse direction, which is considered undesirable when effective coverage of the wearer's body through the crotch area is desired.

[0062] In contrast, the constituent yarns or threads of a knitted fabric do not follow a straight path along the plane of the fabric and are neither parallel nor perpendicular to one another. Instead, each constituent yarn or thread of a knitted fabric follows a looping path along a continuous row, interlooping with one or more constituent yarns or threads in an adjacent row. Thus, as compared to a woven fabric, a knitted fabric exhibits a relatively greater ability to stretch in all directions, even when the constituent yarns or threads themselves are not extensible. For this reason, unless a woven fabric is desired for a specific reason, it may be preferred to use a knitted fabric to form any one or more or all of the fabric layers present in the crotch portion 130 and crotch gusset 230 of the pants.

[0063] Nevertheless, most types of knitted fabrics have anisotropic stretch capabilities along the plane of the fabric, with a first direction of greatest stretch capability and a second direction of least stretch capability perpendicular to the first direction. Therefore, when knitted fabrics are selected and used to form one or more layers present in the crotch portion 130 and crotch gusset 230 of a pant, it may be desirable that the fabrics forming any, some, or all of the layers be oriented so that their directions of greatest stretch capability are at least approximately parallel to the longitudinal direction of the pant.

[0064] In some cases, it may be desirable that the knit fabric selected for forming the layers be of the rib knit type. Rib knit fabrics exhibit a relatively high ability to stretch in a direction parallel to the knit rows (perpendicular to the "ribs"), and a relatively low Poisson contraction effect in the transverse direction of stretch. Thus, in some cases, it may be desirable that one or more of the layers present in the crotch portion 130 and crotch gusset 230 of a pant be formed of a rib knit fabric, wherein the "ribs" are oriented substantially in the transverse direction of the pant.

[0065] In some cases, it may be desirable to form the absorbent layer 232 from a woven or knitted terry fabric in order to increase the aggregate fiber surface area and capillarity per unit fabric surface area and thereby provide the absorbent layer 232 with increased absorbency while still providing a durable fabric, as opposed to nonwoven batting or matte fibers. In conjunction with or as an alternative, to enhance absorbency, it may be desirable that the constituent fibers of the yarns or threads of the knitted or woven absorbent layer fabric material be in the form of microfibers (i.e., fibers having an average denier of one (1) or less). It may also be desirable that the constituent fibers be split microfibers. Yarns or threads formed from microfibers (particularly split microfibers) provide a relatively large fiber surface area per unit yarn / thread denier. When the fiber surface is hydrophilic, this imparts relatively greater absorbency to the fabric.

[0066] Fabric composition Yarn / thread combination

[0067] As contemplated herein, the wearer-facing layer 231 and the absorbent layer 232 present in the crotch portion and crotch gusset of a pant are expected to be exposed to urine discharges and / or menstrual fluids, and are expected to receive, absorb, and retain these fluids for a reasonable duration of wear, preferably while keeping the wearer-facing surface as dry-feeling as possible. It may be desirable for the wearer-facing layer 231 to have a soft feel against the skin.

[0068] Therefore, it may be desirable that the wearer-facing layer is formed of a material having a soft feel and having suitable wicking properties, so as to effectively guide the discharged liquid to the absorbent layer below, while having a minimized tendency to retain liquid and thereby make the wearer feel wet. Therefore, it may be desirable that the wearer-facing layer 231 does not include a major proportion of fibers that are commonly used as absorbents, such as cotton or other plant fibers, or rayon fibers. (For the purposes of this article, the term "rayon" includes rayon, viscose, lyocell, and any other fiber spun from reconstructed / regenerated cellulose). Preferably, the wearer-facing layer will not include any proportion of such fibers greater than 10% by weight of the fabric of layer 234, and preferably, will not include a significant proportion of such fibers. Suitable materials may include polypropylene, polyester, and polyamide (e.g., nylon). When used for spinning fiber components and / or when suitable hydrophilization treatment has been received, examples of these materials impart suitable hydrophilic surface properties (enhanced wicking action) to the spun fibers, with relatively low individual fiber textures (reducing porosity and capillarity, and thus reducing the absorbency of the fabric). Additional materials may be incorporated into the yarn or thread component for the purpose of enhancing skin feel (e.g., enhancing the smooth or silky feel to the skin) and / or further affecting hydrophilicity and / or reducing absorption tendency. In some examples, polypropylene and / or polyethylene fiber components may be included for these purposes. In some examples, the resin from which the constituent fibers are spun may include additives added to the main polymer component, which are incorporated to enhance skin feel, adjust hydrophilicity, reduce absorbency, etc. In some examples, the polyester or nylon component resin may include an additive containing linolenic acid to the extent described in US 2017 / 0369698, with the purpose of enhancing elongation and skin feel attributes while reducing material usage and cost.

[0069] Although commercially processed cotton or other commercially processed plant fibers or semi-synthetic cellulose-derived materials (such as rayon) may be considered as constituent materials of the absorbent layer due to their inherent absorption properties, some of these materials may have a tendency to retain the components of menstrual fluid or urine undesirably after washing. Therefore, one or more of polyester, polyamide and / or their combination may be preferably used as a component resin or even a main component resin / dominant component resin, and the fiber components of the yarn or thread parts of the fabric for the absorbent layer 232 are formed by these component resins. The constituent lines or yarns of the absorbent layer can be woven in a manner that imparts a relatively bulky and / or dense fibrous network, which has a certain degree of void volume and capillary action, thereby making it suitable for absorbing fluid. In some examples, the knitted fabric can be a knitted terry fabric, or even a knitted / sheared terry fabric. The constituent lines or yarns can be or may include microfibers to increase the fiber surface area per unit xy surface area or volume of the absorbent component.

[0070] For the purpose of imparting elastic extensibility (particularly longitudinal stretch) to the layers present in the crotch region, it may be desirable that the yarn or thread component of one or more of the fabrics present comprises elastically extensible fibers, yarns or threads. In some examples, the elastically extensible fibers, yarns or threads may be formed from or comprise spandex (such as LYCRA, currently available from The Lycra Company, Wilmington, Delaware), which are particularly elastically extensible and durable over multiple washes compared to other elastic materials used to elasticize fabrics.

[0071] In other examples, one or more elastically extensible polymer film layers other than the fabric layers in the crotch portion 130 may be included to impart overall elastic extensibility to the structure in the crotch portion.

[0072] The elastic polymer film layer may be formed of any suitable elastic polymer material. In some examples, the elastically extensible film layer may be formed by extruding or otherwise applying a film resin in molten or semi-molten form to a layer component fabric, whereby the molten resin partially penetrates the fabric and upon cooling forms a film that is partially mechanically entangled in and / or integral with the fabric.

[0073] Antimicrobial Agents

[0074] In order to hinder the growth of microorganisms supported by the components of absorbed urine or menstrual fluid (which may cause odor), it may be desirable to include one or more antimicrobial agents in the material present in the crotch portion 130 or between the materials. Any such antimicrobial agent is preferably included in a form suitable for being kept in place and continuing to be effective after multiple washings of pants. In some examples, the antimicrobial agent may include particles or fibers comprising metals, metal alloys or metal compounds, and the metals, metal alloys or metal compounds include one or more of copper, silver, zinc, aluminum or their combinations. In other examples, the antimicrobial agent may include particles or fibers comprising carbon or a composition or compound comprising carbon. One or more of these materials may be included in the resin spun from it to form the fiber as an additive, or may be included in a composition that is locally applied to the composition yarn, line or fabric after the manufacture of the composition yarn, line or fabric. Such antimicrobial agents are preferably included in the material forming the absorbent layer 232 and / or facing the wearer layer 231.

[0075] Barrier layer

[0076] Where urine or menstrual fluid is absorbed by the fabric layers in the crotch portion 130 and crotch gusset 230, it may be desirable to include a barrier layer, such as barrier layer 233 (see, e.g., FIG. 3A to FIG. 3C) to prevent the absorbed fluid from transferring from the absorbent layer to the outer-facing layer 234 or even to the outer garment. In some examples, the barrier layer 233 may be formed of or include a suitable liquid-impermeable polymer film. In some examples, the film composition may be selected to be elastically extensible so as to provide or supplement suitable elastic stretch properties to the combination of layers present in the crotch portion 130 and / or the crotch gusset 230. In some examples, the barrier layer 233 may be formed of or include a film formed in whole or in part from a polyurethane-based or polyester-based resin. In some examples, the barrier layer 233 may be formed of or include a film formed by extruding or otherwise applying a thermoplastic film resin in molten or semi-molten form directly to the outward-facing surface of an upper covering layer (such as the absorbent layer 232), so that the film resin partially penetrates the fabric while still molten and thereby forms a liquid-impermeable film that is partially mechanically entangled in and / or integral with the fabric of the upper covering layer. This also has the effect of reinforcing these layers, which can reduce the thickness in the crotch portion 130 and reduce or prevent the absorbent layer 232 from wrinkling or bunching when elastically contracted. In a specific example, the polyurethane or polyester film can be formed by extruding or otherwise applying a molten thermoplastic resin directly to the outward-facing surface of a fabric that is used as or forms a component of the absorbent layer 232. However, if the barrier layer 233 is formed separately, it may be desirable to attach it to the upper cover layer (e.g., the absorbent layer 232) via a suitable bonding mechanism (e.g., an adhesive disposed between the barrier layer and the upper cover layer). A configuration that allows the barrier layer and the upper cover layer to separate, thereby creating a void space between them in some cases, may be considered undesirable because this may allow fluid to pool in the void space and thereby be uncontrolled and / or unmanaged by the absorbent structure, thereby creating an increased risk of leakage. On the other hand, if the barrier layer 233 is not unified with the upper cover fabric layer between the peripheral area of ​​the gusset, the gusset may have enhanced flexibility and stretchability because there is no bonding effect created by the integration of these layers. This latter construction may be preferred where, for example, management of only light menstruation or light incontinence is desired, or alternatively where the design of the garment is otherwise characterized by minimizing the potential for void space between the barrier layer and the overlying absorbent layer.

[0077] The material selected for the barrier layer 233 can also be vapor permeable or "breathable" in that it can allow gas or water vapor to pass through by having a combination of a porous structure for vapor permeability, but a sufficiently small pore size for liquid impermeability, and a surface with low wettability (e.g., a hydrophobic surface), while still being effectively liquid impermeable under the ordinary use conditions contemplated herein. Various liquid-impermeable, vapor-permeable films and other materials are known and used in fields including personal hygiene and wound dressing applications. In some cases, a liquid-impermeable but vapor-permeable barrier layer may be preferred for the purpose of venting water vapor to improve wearer comfort and / or to help avoid overhydration of the wearer's skin.

[0078] In some cases, including those described herein (eg, where the barrier layer forms part of an edge seal structure), it may be desirable that the material selected to form barrier layer 233 has a hydrophobic surface or is processed to have a hydrophobic surface.

[0079] Gusset stitched to outer pant construction

[0080] The layers forming the gusset 230 (e.g., the wearer-facing layer 231, the absorbent layer 232, and the barrier layer 233) can be joined together by any suitable mechanism to form an assembly. In some examples, the layers can be joined around their perimeters by a suitable adhesive (not specifically shown) interposed therebetween. In some examples, the layers can be joined around their perimeters by stitching. If stitching is included for this purpose, it may be desirable that the stitching does not penetrate the barrier layer 233 or the edge sealing structure such as the edge sealing strip 235 to avoid creating a liquid leakage path.

[0081] The following objectives are contemplated herein: particularly around and adjacent the leg opening edges 140 in the crotch portion 130 of the pant, it is considered desirable to retain as much of the elasticity and extensibility of the pant structure as possible; to minimize material accumulation that could cause discomfort or impart or exacerbate a "panty mark" visible through outer clothing; to provide a suitable form-fitting fit that holds the absorbent gussets tightly against the wearer's body and avoids gaps at the leg openings as the body moves with displacement; to prevent wicking and leakage of liquids from the side edges of the gussets; and to avoid puncturing the barrier layer and edge sealing structure of the gussets with, for example, stitching, which could provide leak pathways.

[0082] Reference Figure 4A, these objectives are served by the illustrated configuration. The gusset 230, including the absorbent assembly 238, is attached to the outer-facing layer 234 of the crotch portion 130 by a strip or band of adhesive 236, which can be of a type that can be heat pressed between the outer-facing surface of the gusset (in the illustrated example, the outer-facing surface of the barrier layer 233) and the outer-facing layer 234. The adhesive 236 is embedded laterally from the leg opening edge 140 of the pant by an adhesive embedment distance AI. Preferably, the adhesive 236 does not contact the lower portion 235L of the edge sealing strip 235 (when present; it should be noted that the adhesive 236 is not attached to the lower portion 235L of the edge sealing strip 235). Figure 3C 140 ; ​​its transverse outermost edge is disposed at the edge of the transverse inner side of portion 235L. This lateral inset positioning of adhesive 236 can be imparted along the entire portion of gusset 230 proximate leg opening edge 140. This positioning reduces material accumulation in edge sealing strip 235 and also removes adhesive 236 from the vicinity of leg opening edge 140, thereby removing any hardening effect and / or elasticity reducing effect adhesive 236 may have on the structure in which it is applied. In some examples, along the entire gusset edge proximate leg opening edge 140, adhesive inset distance AI can have a minimum value of 2 mm, more preferably 4 mm, even more preferably 7 mm, and still more preferably 10 mm. Where a range within the tolerances supported by a particular manufacturing method is desired, the inset distance AI along each leg edge can be, for example, from 2 mm to 20 mm, more preferably from 4 mm to 17 mm, and even more preferably from 7 mm to 14 mm. If desired based on material selection, a fabric finishing strip 237 may be adhered to the outer-facing layer 234 via a finishing adhesive 237a to provide a more finished-looking edge to the pant structure at the leg opening edge 140. Figure 4B In another example, adhesive 236 may extend across the gusset to a greater extent, but still be inset from the leg opening edge by the distance AI as shown. No stitching is required.

[0083] Figure 5Another example of being configured to serve the above identified goals is illustrated. A discrete "micro-dot" pattern of adhesive 236d can be set at any desired position between the gusset 230 and the outer layer 234, including between the lower portion 235L of the edge sealing strip 235 and the outer layer 234. Adhesive in the form of a discrete micro-dot pattern can be applied to the base material layer by, for example, SEWFREE ON DEMAND equipment available from Bemis Associates, Shirley, Massachusetts, USA. Other alternatives are commercially available, including adhesive micro-dot patterns applied to transfer / release strips or sheets (paper or film), which are configured so that they can be transferred to fabrics via an iron or press. One such alternative is sold as PINBOND transfer adhesive, which is a product of New Textile Technology Co., Ltd. in Balingen, Germany. The discrete micro-dot pattern of adhesive can be an effective fastening mechanism for the purpose of this article, because fastening strength is provided by a large number of discrete, closely spaced fastening points at each micro-dot, and at the same time, the adhesive micro-dots do not have a significant bonding or hardening effect on the stretchable layer substrate to which they are adhered, because the substrate can stretch and flex between the micro-dots. Compared with the continuous strip or band of adhesive, the pattern will also have a substantially lower adhesive basis weight usually. Therefore, the adhesive micro-dots can effectively adhere the corresponding upper adjacent / lower adjacent materials together, but also help to alleviate the material accumulation basically, and avoid the bonding, hardening and reduction elasticity of the substrates they are used to adhere to. No need to sew.

[0084] As an addition, supplement or alternative to adhesive microdots, manufacturers may prefer to join materials where adhesives might otherwise be used via heat compression bonding or ultrasonic bonding (e.g., in the form of a pattern of discrete bonds). Such bonds and their patterns can be arranged and function in a manner similar to the adhesive microdot pattern.

[0085] FIG. 6A to FIG. 6CAdditional examples configured to serve the above identified goals are illustrated. The edge sealing strip 235 is folded around itself in a "V" configuration around the peripheral edge of the absorbent assembly 238 and includes sufficient material boundaries to produce an extension 237e when it is squeezed and adhered to itself outside the edge of the absorbent assembly 238 and near the fold. As shown, the extension 237e can be attached to the outer layer 234 by a micro-dot adhesive 236d. As discussed above, the micro-dot adhesive 236d avoids material accumulation, hardening and elastic loss of the pants structure at its use position (in the example shown, near the leg opening edge 140). These benefits can be utilized because they provide greater opportunity flexibility to include an elastically stretchable fabric finishing strip 237 without substantially compromising stretchability, elasticity and flexibility, thereby at least partially covering the edge outer edge of the sealing strip 235 and providing a finished look around the gusset edge. The trim strip 237 may also be adhered to the upper portion 235u of the edge seal tape by trim adhesive 237ad in the form of micro dots, as described above.

[0086] FIG. 7A to FIG. 7C Additional examples configured to serve the objectives identified above are illustrated. The elastic edge sealing material 235 and the extensible fabric trimming material 237 can be combined into a laminated strip that can then be folded onto itself along its length to form a combined "V"-shaped strip 244, wherein the legs of the "V" are adhered to the wearer-facing and outward-facing surfaces of the absorbent assembly 238, respectively. Sufficient margins can be provided outside the peripheral edge of the assembly 238 to provide an extension flange 244e. The extension flange 244e can then be attached by any suitable mechanism, such as by stitching 243 ( Fig. 7A ) or micro-dot adhesive ( Figure 7B ) is attached to the outer layer 234.

[0087] like Fig. 7A As suggested, where stitching is used to attach the gusset assembly 230 to the outer-facing layer 234, the stitching preferably has a stitching pattern that provides extensibility along the stitching path. Various examples of patterns that may be suitable are known in the art of garment manufacturing, including, for example, zigzag stitches, lightning stitches, triple straight stitches, double needle stitches, overlock stitches, blind hem stretch stitches, honeycomb stitches, feather stretch stitches, and the like. Fig. 7A It will be appreciated that although the stitches penetrate the edge sealing material 235, the boundary of the additional material of the laminate 244 causes its edge sealing material 235 component to adhere to or seal against itself at position 244v on the inside of the stitch 243 within the "V" structure, thereby eliminating a leakage path to the stitch 243.

[0088] exist Figure 7BIn another example illustrated, the gusset 230 may be attached to the outer-facing layer 234 by micro-dot adhesive 236d, as described above.

[0089] Simplified for visual clarity Figure 7C Another possible example is illustrated in which the seam 135 formed by the stitching 243 joining the gusset assembly 230 and the outer-facing layer 234 together is hidden. This configuration can be formed by first stitching the gusset 230 to the outer-facing layer 234 along the leg edge 14 by extending the flange formed by the laminate 244 while each is in an inverted or "turned inside out" configuration relative to each other, while leaving the front and rear ends of the gusset unattached to the outer-facing layer. Next, the attached gusset and outer-facing layer can be inverted or "turned outside out" to produce Figure 7C , which internalizes and hides the seam 243 and presents the leg edge 140 with a taped and finished appearance. Although this configuration may appear to have increased material buildup near the leg edge 140, selecting a relatively low thickness, lower basis weight material for the fabric finishing material layer of the laminate 244 may have a mitigating benefit. In addition, as can be seen, the material of the absorbent assembly 238 forming the gusset is not below or above the seam 135 joining the gusset 230 to the outer-facing layer 234 near the leg edge 140, and therefore does not contribute to material buildup at the leg opening edge. (This avoidance of buildup at the leg opening edge by the absorbent assembly 238 is generally true for all of the examples shown and described herein—in all examples, the peripheral edge of the absorbent assembly 238 (i.e., the peripheral edges of the layers 231, 232, and 233) is disposed laterally inboard of the leg opening edge 140).

[0090] Figure 8 Yet another approach is reflected. In the reflected configuration, an additional border of the outer-facing layer 234 is provided to wrap and fold around the folded peripheral edge of the edge sealing strip 235, thereby providing the leg opening edge 140 with a finished appearance. Deposition of micro-dot adhesive 236d can be used to adhere the gusset 230 to the outer-facing layer 234 at one or more of the locations shown and / or other locations near the wrapped edge of the outer-facing layer 234 (but at least at the upper location shown).

[0091] Combination FIG. 10A to FIG. 10C and Fig.11 Watch Fig. 9Another approach is reflected, referred to herein as a "hammock" configuration. In this configuration, the gusset assembly 230 may not be attached to the outer-facing layer 234 of the pant in the crotch portion 130, and / or may not be attached to the outer-facing layer 234 along or near the leg edges 140, or may even be attached only along seams 134 and 138 at the front and rear ends ( Figure 2 134). The gusset 230 and the outer-facing layer 234 may not be attached to the outer-facing layer 234 between seams 134 and 138. This separation of the gusset 230 and the outer-facing layer 234 allows the outer-facing layer 234 and any elastomeric / elastic components thereof or components attached thereto to move and flex between the front seam 134 and the back seam 138 independently of the components of the gusset 230, and provides a better ability for the outer pant structure including the outer-facing layer 234 and any associated leg band components to push the gusset assembly against the wearer's body, particularly in configurations where the gusset assembly may not be as stretchable / elastically extendable as the outer pant structure including the outer-facing layer 234. In addition, if the wearer desires to wear an underpants with a supplemental sanitary napkin of the type having side "wings", the hammock configuration enables the wearer to wrap the wings over the side / leg edges of the gusset and then under it, between the gusset and the outer-facing layer 234, thereby hiding the wings behind the outer-facing layer. Depending on whether the gusset assembly is more or less elastically extensible in the longitudinal direction as the underlying outer pant structure / outer-facing layer 234, it may be desirable for the relaxed / contracted length of the gusset assembly between the seams 134, 138 to be equal to, greater than, or less than the corresponding relaxed / contracted length of the underlying outer-facing layer 234 between the locations of the seams 134, 138. This may be desirable to help ensure that the outer pant structure, including the outer-facing layer 234, is always under longitudinal tension, thereby helping to urge the gusset assembly against the wearer's body through shifting body movements. Fig.11 , the corresponding length would be the length of the outer-facing layer 234 and gusset assembly 230 between the longitudinal innermost extents of the seams 134 and 138 at the longitudinal axis 200 of the pant.

[0092] like Fig. 9As reflected, the hammock configuration may include an added gusset lining layer 239 disposed below the barrier layer. The gusset lining layer 239 may be formed of the same fabric as the outer-facing layer 234, or of a different fabric material. The gusset lining layer 239 may be included to cover, hide, and protect the barrier layer 233, which in some examples may be fragile and / or may have an undesirable sticky or plastic-like feel and appearance that the manufacturer may wish to hide from the wearer's view and touch. In some examples, the gusset lining layer 239 may be formed of an effectively waterproof fabric (highly resistant to fluids passing therethrough under the use conditions contemplated herein - similar to the barrier layer 233 as described above). In such examples, the gusset lining layer 239 may supplement or even replace and substitute for the barrier layer 233. The gusset lining layer 239 may be attached to the absorbent assembly 238 and / or the edge sealing strip 235 at the locations shown by the hammock adhesive 239a. Near the leg edge 140, it may be desirable for the reasons discussed above that the hammock adhesive 239a be a micro-dot adhesive, while along the front and rear gusset seams 134, 138, the hammock adhesive 239a may be a micro-dot adhesive or a tape or strip adhesive.

[0093] FIG. 10A to FIG. 10C Longitudinal cross-sections of possible examples of configurations for attaching the gusset assembly 230 to the front seam 134 and / or the back seam 138 facing the outer layer 234 in the front portion 100 and the back portion 120 of the pant are schematically illustrated.

[0094] like Fig. 10A As reflected, a fabric trimming strip 237 may be provided having one side for covering the front or rear end of the gusset 230, and a second side for covering the pant structure facing the outer layer 234. The trimming strip 237 may be attached at these locations via any suitable mechanism, such as adhesive, micro-dot adhesive, stitching, etc. It will be appreciated that considerations for material pile-up, bonding, stiffening, and loss of elasticity may not be as great for the front and back seams 134, 138 as for the pant areas proximate the leg openings, including the leg opening edges 140 in the crotch portion 130.

[0095] Fig. 10B and Fig. 10C A more simplified construction is reflected in which the material of the gusset lining layer 239 is attached directly to the outer-facing layer 234 at a location longitudinally outboard of the edge seal strip 123 but longitudinally inboard of the folded edge of the hammock layer. Fig. 10B10c, the outwardly facing portion of the gusset liner layer 239 may be adhered to the outwardly facing layer 234 along the seam 134 (or for the back seam, 138) via a path of micro-dot gusset end adhesive 242. However, it should be noted that the considerations of material pile-up, bonding, hardening, and loss of elasticity may not be as great for the front seam 134 and the back seam 138, and a tape or strip adhesive may be substituted for the micro-dot adhesive 242.

[0096] about 4A to 6C , Figure 7B , Figure 8 , Fig. 9 , Fig. 10A and Fig. 10C , it will be noted that the designs reflected do not include sewn seams, but instead rely on adhesives, micro-dot adhesives, or ultrasonic bonding to join the layers. In some examples of such designs, areas at or near the corners of the gussets may be susceptible to multi-directional stresses that can accelerate the separation of the layers of material that are adhered or bonded at the corners. Therefore, returning to reference Figure 2 , it may be desirable to include temporary stitches 245 near two or all four gusset corners that penetrate and join at least the outer-facing layer 234 and the gusset structure directly or indirectly (e.g., via / through a layer overlying the wearer-facing layer 231). Such temporary stitches are discrete and located near the gusset corners, and such temporary stitches will not substantially impair the elastic stretch of the materials to which they are joined. Where such temporary stitches are included, it may be preferred that the temporary stitches do not contact and / or penetrate or extend through one or more of the absorbent layer 232 and the wearer-facing layer 231 in order to avoid providing a potential leakage path from a layer into / through which fluid may wick. For the purpose of minimizing their potential effect on stretch or potential for causing wrinkling of the outer-facing layer 234, such temporary stitches (where included) preferably have a maximum xy plane dimension of no greater than 15 mm, more preferably no greater than 12 mm, and even more preferably no greater than 10 mm, and still more preferably no greater than 8 mm.

[0097] Other construction details

[0098] In some examples, one or more layers within crotch portion 130 and / or gusset 230 may be bonded together by any suitable bonding mechanism. Fig.13A and Fig. 13B, the wearer-facing layer 231 can be bonded to the lower adjacent absorbent layer 232, the purpose is to keep the layers in close proximity and thus help maintain the low thickness required for the structure, and enhance the fluid communication between the layers, that is, the ability of the reinforcing structure to transfer the excreted urine or menstrual fluid from the wearer-facing layer to the absorbent layer below through the contact between the layers. In such examples, the bonding mechanism should be selected to not block any considerable portion of the interface between the two layers along their interface surface area. Therefore, in some examples, it may be desirable that the bonding mechanism has a discontinuous pattern form of discrete bonding portions (that is, a pattern with unbonded areas between the bonding portions), such as a regular pattern of point bonding portions 240. In some examples, the bonding portions between the layers can be formed by discrete deposition of adhesives between the layers, thereby bonding the layers together at the deposited positions. In other examples, the bonding portions between the layers can be formed by thermocompression bonding. The latter bonding mechanism may be more durable over multiple washes, and as schematically shown in FIG. 14B , a corresponding z-direction depression pattern is created in the wearer-facing layer 231 that can be used to collect discharged urine / fluid and initiate and / or assist its movement (via wicking) downward to the absorbent layer 232. For the purpose of enabling thermocompression bonding, the wearer-facing layer and the lower adjacent absorbent layer can each include a polymer component of a corresponding fusible composition (such as a similar polyester-based composition) that helps form a strong bond between the layers when heat and pressure are locally applied at the bonding site. (In this article, for two corresponding polymers present in two corresponding layers, "fusible composition" means that the two polymers are miscible and can be melted and mixed at a temperature of 250° C. or less to form a single thermodynamic phase.)

[0099] The various layers, such as layers 231, 232, 233, and 234, that may be included in the crotch portion 130 and / or crotch gusset 230 may also be joined to one another at the front and back seams 134, 138, and at the crotch side seams 135 near the leg edges 140 by any suitable mechanism. The joining mechanism may be a stitching system for attaching the layers together; however, for liquid containment purposes, it may be desirable that the joining mechanism include a generally hydrophobic, water-insoluble adhesive or adhesive film (either by itself or in addition to stitching), or alternatively that such stitching be entirely over the barrier layer (not penetrating the barrier layer) or within the containment area of ​​the edge sealing strip 235.

[0100] Measurement method

[0101] General sample preparation

[0102] Unless otherwise specified below, each of the measurements below is made on 10 separate similar samples (taken from 10 separate similar examples of pants), and the average of the 10 separate similar samples is considered the measurement result for that particular set of samples.

[0103] Reference Figure 2 , samples including the entire crotch gusset 230 were collected from examples of the subject pants. Transverse lines 234, 238 tangent to the front-most edge of the front seam 134 and the rear-most edge of the back seam 138, respectively, were identified and the pants were cut along these lines (without cutting the seams themselves) to provide samples including the entire crotch gusset 230.

[0104] If the pants are legged pants, the gusset is cut completely off along a cutting path outside of the seam connecting the gusset to the rest of the pants, rather than cutting the seam itself. For a legged pants, the measurement of "crotch width" for purposes herein will be the width of the removed gusset measured in the transverse direction along the transverse line marking the shortest distance between the leg openings, prior to removing the gusset from the legged pants.

[0105] The samples should be cut from the sample pants with a sharp knife or suitably sharp cutting device to effectively cut the sample accurately and cleanly. A ruler or other suitable drawing / plotting tool may be used to help hold the example down on the work surface and to help guide the cutting device.

[0106] The tests are performed under room temperature conditions (temperature between 15°C and 35°C and relative humidity between 35% and 75%). The samples are conditioned for at least two hours before testing under the same conditions.

[0107] All linear dimensions are measured manually with a ruler in the common xy plane using a ruler traceable to NIST or other standards organizations.

[0108] Longitudinal tensile modulus

[0109] For the longitudinal tensile modulus and maximum longitudinal elongation test methods, the samples described above in "General Sample Preparation" were further modified by cutting 40 mm transverse wide sections symmetrical about the longitudinal axis 200. The leg edge seams were not included in these tests. Figure 2 If the lateral width between the narrowest spacing of the leg edge seams defined by the cut line 270a in the figure is less than 40 mm, the pants are considered unsuitable for the purposes described herein (too narrow through the crotch region for adequate coverage) and are considered outside the scope of the claims.

[0110] The longitudinal tensile modulus of the sample is determined by stretching along the longitudinal axis 200 of the pants using a load cell using a constant extension rate tensile testing machine with a computer interface, such as Instron; MTS; Zwick; etc. (the load measured with the load cell is within 10% to 90% of the limit of the cell), and ensuring an accuracy of 0.1 N for a 5N load. The instrument is equipped with a single-wire contact gripper with a gripper width of 8 cm. Prior to testing, the equipment is calibrated according to the instrument manufacturer's recommendations.

[0111] According to the sample preparation instructions above, the sample width is 40 mm. The stress in the sample is calculated by dividing the force in the load cell by the sample width and is expressed in gf (gram-force) / mm. (The thickness of the sample is not a factor in this calculation.) The sample length is equal to the length of the sample along the longitudinal axis 200 between the transverse lines 234, 238 along which the sample is cut from the exemplary pants, as shown by way of example in Figure 2 as shown in .

[0112] The grips of the tensile testing machine consist of pneumatic grips designed to hold the sample. No slippage is allowed between the sample and the grips. The distance between the grips (along the elongation axis of the machine) should be the sample length minus 6 cm. This distance will be referred to as the "starting gauge length" hereinafter.

[0113] The sample is mounted in the grips with its longitudinal axis 200 parallel to the direction of applied elongation and located at the center of each grip. Two (2) cm of sample length at each end is inserted into each grip. The starting gauge length determined as described above will ensure that there will be 2 cm of longitudinal slack in the sample at the beginning of the test.

[0114] After the sample is mounted, the machine's load channel is set to zero (this eliminates the weight of the sample from the calculations). The grips are slowly moved apart at a rate of 5.08 cm / min (2.0 in / min) until a load of 5 gf (gram-force) is reached. The distance between the grips at this position is recorded as L0.

[0115] (L0 = starting gauge length + additional machine extension to reach 5 gf)

[0116] After reaching a load of 5 gf, extend the sample at a rate of 50.8 cm / min (20 in / min) with a 50 Hz data acquisition rate until a stress of 30 gf / mm is reached or the sample breaks.

[0117] Sample strain is calculated as ΔL / L0. ΔL is any additional extension between the grips after L0 is reached and is recorded along with the load at a rate of 50 Hz. Sample strain is expressed as a number (not a percentage), so for the purposes of these calculations, 100% strain is 1.0.

[0118] Record the sample strain when the sample stress is 10 gf / mm and 20 gf / mm.

[0119] The longitudinal tensile modulus is the linear slope between 10 gf / mm and 20 gf / mm and is calculated as:

[0120] Longitudinal tensile modulus = [20 gf / mm - 10 gf / mm] / [sample strain at 20 gf / mm - sample strain at 10 gf / mm]

[0121] Repeat for 10 samples.

[0122] Maximum longitudinal elongation

[0123] The maximum longitudinal elongation is measured during the longitudinal tensile modulus test. The maximum longitudinal elongation is the sample strain at a sample stress of 20 gf / mm. The maximum longitudinal elongation is expressed as a percent strain, e.g., a 1.0 strain value from the longitudinal tensile modulus method is expressed as 100% strain for elongation.

[0124] Repeat and record the results for 10 samples. Calculate and record the average of the results. The average will be the maximum longitudinal elongation value for the subject pant design.

[0125] Absorption capacity

[0126] The Absorption Capacity test measures the amount of liquid retained within the test sample after a specified number of immersions and vertical drains. The amount of test liquid retained by the test sample is used to calculate and report the Area Absorption Capacity (ml of liquid per square centimeter of sample area) and the Volume Absorption Capacity (ml of liquid per cubic centimeter of sample volume). All tests are conducted in a room controlled at 23°C ± 3°C and 50% ± 2% relative humidity.

[0127] The test procedure follows Part B (Liquid Absorption Capacity) of Pharmacopeia Method WSP 010.1.R3 (12) with the modifications specified below. The test liquid is deionized water at room temperature (23°C ± 3°C); density 1.00 g / ml). For the weighed portion of the test, no cover slip is used because the test liquid is nonvolatile. The overall dimensions of the wire mesh specimen support are large enough (e.g., 12 inches by 12 inches) to accommodate larger test specimen sizes. The test specimen is an entire triangular gusset (as described herein) and is therefore larger than recommended in the Pharmacopeia method.

[0128] Prior to measuring absorbent capacity, the examples of the pants of interest (before removing the samples from the pants of interest) were washed to simulate in-use conditions and follow the recommended "before use" instructions that come with these types of pants (e.g., wash before use). The examples were placed in a mesh underwear bag and then placed in a high-efficiency front-loading washing machine (from any convenient source) along with a single small / light load dose of TIDE brand laundry detergent ("original" designation; "HE" or other high-efficiency washing machine designation; without additives (such as FEBREZE, ODOR DEFENSE, OXI additives), bleach or bleach additives, or fabric softening additives) (a product of The Procter & Gamble Company, Cincinnati, Ohio). The washing machine was set to a delicate cycle using cold water. After the wash cycle, the examples were removed from the mesh bag and laid flat on a drying rack to air dry for about 12 hours. After air drying, the examples were placed in a clothes dryer (from any convenient source) set to a delicate cycle and dried at very low heat for about 5 minutes, or until dry to the touch.

[0129] The test samples were prepared as follows. The pre-washed and dried samples were equilibrated in a room controlled at 23°C ± 3°C and 50% ± 2% relative humidity for approximately 2 hours. The test sample including the entire gusset was removed from the sample as described in the General Sample Preparation section herein. Using scissors, cut the outermost fabric layer of the gusset facing outward along the entire gusset shape on the inside of the seam, being careful not to cut any edge seams that exist.

[0130] Then, follow the soak and drain procedure outlined in the pharmacopoeial method with the modifications mentioned previously. Subtract the dry mass from the wet mass and record as the mass of liquid absorbed, to the nearest 0.01 gram. Since the density of deionized water is 1.00 g / ml, the mass of liquid absorbed is also recorded as the volume of liquid absorbed, to the nearest 0.01 ml. Divide the volume of liquid absorbed (ml) by the total area of ​​the test specimen (cm2) and record as the area absorption capacity, to the nearest 0.01 ml / cm2. Now divide the volume of liquid absorbed (ml) by the volume of the test specimen (area x center thickness) and record as the volume absorption capacity, to the nearest 0.01 ml / cm3.

[0131] In a similar manner, repeat the test specimens for a total of three replicates. Calculate the arithmetic mean of the area absorption capacity and volume absorption capacity and report to the nearest 0.01 ml / cm2 and 0.01 ml / cm3, respectively.

[0132] thickness

[0133] The thickness of the sample including the crotch gusset is measured as the distance between the reference platform on which the sample rests and a pressure foot that applies a specified amount of pressure to the sample for a specified amount of time. All measurements are made in a laboratory maintained at 23°C ± 2°C and 50% ± 2% relative humidity.

[0134] Thickness is measured with a manually operated micrometer equipped with a pressure foot capable of applying a steady pressure of 0.5 kPa ± 0.01 kPa to the test sample. The manually operated micrometer is a deadweight instrument with readings accurate to 0.001 mm. A suitable instrument is a Mitutoyo series 543 ID-C Digimatic, or equivalent, available from VWR International. The pressure foot is a flat circular movable surface with a diameter of 50 mm. The sample is supported by a horizontal flat reference platform that is larger than and parallel to the surface of the pressure foot. The system is calibrated and operated in accordance with the manufacturer's instructions.

[0135] As described above, a sample including a gusset is obtained by removing the gusset from the pants. When cutting the sample from the absorbent article, be careful not to impart any wrinkles or other deformation of the layer during the removal process. Before testing, condition the sample at 23°C ± 2°C and 50% ± 2% relative humidity for 2 hours. To measure the thickness, first zero the micrometer relative to a horizontal flat reference platform. Place the sample on the platform with the desired measurement position centered under the pressure foot. Gently lower the pressure foot at a rate of descent of 1.0 mm ± 0.1 mm per second until full pressure is applied to the sample. Wait for 5 seconds and then record the thickness of the sample to the nearest 0.01 mm. Repeat in a similar manner for a total of 10 replicates. Calculate the arithmetic mean of the thickness and report it to the nearest 0.01 mm.

[0136] Liquid impermeability

[0137] When there is a question as to whether a particular pair of pants has a gusset with a liquid-impermeable barrier, this Liquid Impermeability Test Method can be used to measure the amount of test liquid that will pass through the sample and enable a determination to be made as to whether a "liquid-impermeable barrier" is present in the gusset according to the definition set forth in the description above.

[0138] The Liquid Impermeability Test measures the amount of liquid transferred to the outwardly facing side of a test specimen obtained from a pant after a specified volume of test liquid is added to the test specimen to simulate a liquid insult during actual use / wear of the pant.

[0139] All tests were conducted in a room controlled at 23°C ± 3°C and 50% ± 2% relative humidity.

[0140] Prior to performing the measurements of this method, wash the examples of the pants of interest (before removing the samples from the pants of interest) to simulate in-use conditions and follow the recommended "before use" instructions that come with these types of pants (e.g., wash before use). Place the examples in a mesh underwear bag and place in a high-efficiency front-loading washing machine (from any convenient source) along with a single small / light load dose of TIDE brand laundry detergent ("Original" designation; "HE" or other high-efficiency washing machine designation; without additives (such as FEBREZE, ODOR DEFENSE, OXI additives), bleach or bleach additives, or fabric softening additives) (product of The Procter & Gamble Company, Cincinnati, Ohio) or equivalent. Set the washing machine to a delicate cycle using cold water. After the wash cycle, remove the examples from the mesh bag and lay flat on a drying rack to air dry for about 12 hours. After air drying, place the examples in a clothes dryer (from any convenient source) set to a delicate cycle and dry at very low heat for about 5 minutes, or until dry to the touch.

[0141] The test specimens are prepared as follows. The pre-washed and dried specimens are equilibrated in a room controlled at 23°C ± 3°C and 50% ± 2% relative humidity for approximately 2 hours. The test specimens containing the entire gusset are removed from the specimen as described in the General Sample Preparation section herein. Using scissors, cut the outermost fabric layer of the gusset facing outward along the entire gusset shape, on the inside of the seam, being careful not to cut into any edge seams that exist. Mark the dose location at the intersection of the midpoint of the longitudinal axis of the specimen and the transverse axis located at the narrowest portion of the specimen.

[0142] For each test sample, a single layer of filter paper was cut to 10 cm x 2.54 cm. A suitable filter paper is Ahlstrom grade 989 (available from Ahlstrom-Munksjo North America LLC, Alpharetta, GA) or equivalent. The test liquid was deionized water at room temperature (23°C ± 3°C);

[0143] Record the mass of a layer of pre-cut filter paper and record it as dry mass fp, accurate to 0.0001 grams. Place the pre-weighed filter paper on a flat, horizontal work surface. Place the test specimen in the center of the filter paper, with the garment-facing side of the specimen facing the filter paper. Using a volumetric pipette, apply a 1.0 ml dose of test liquid to a pre-marked dosing position, as follows. Keep the tip of the pipette about 3 mm above the surface of the test specimen, and apply the dose slowly (about 30 seconds) to avoid splashing. Once the entire dose has been applied, start a 1-minute timer. After 1 minute has passed, remove the test specimen and record the mass of the filter paper as wet mass fp, accurate to 0.0001 grams. Subtract the dry mass fp from the wet mass fp and record it as z-direction leakage, accurate to 0.0001 grams.

[0144] Repeat the test specimens in a similar manner for a total of three replicates. Calculate the arithmetic mean of the z-direction leakage and report to the nearest 0.0001 g.

[0145] Common XY plane dimensions

[0146] For purposes herein, when the length or width of a characteristic portion of a pant is specified, that length or width is measured with the pant arranged to lie flat on a horizontal, flat surface (in an open configuration or an assembled configuration, as appropriate) with the material of the pant flattened but in a relaxed state and not pulled or stretched in any planar direction.

[0147] In view of the foregoing description, the following examples are contemplated, although their identification is not intended to limit any asserted claims to any combination of any features identified and / or described herein.

[0148] 1. A durable absorbent pants, comprising:

[0149] Outer trousers structure, the outer trousers structure comprising:

[0150] A front waist portion (100), the front waist portion having a front waist edge (102);

[0151] a rear waist portion (120), the rear waist portion having a rear waist edge (122);

[0152] a crotch portion (130) having a front portion (132) connected to the front waist portion and a rear portion (136) connected to the rear waist portion; and

[0153] left and right hip side portions (160), where the front waist portion and the rear waist portion meet to form a waist opening having a waist opening edge including the front waist edge and the rear waist edge, and forming left and right leg openings having left and right leg opening edges (104, 140, 124); and

[0154] A gusset (230) disposed at least partially in the crotch portion, the gusset having a wearer-facing surface, an outwardly facing surface, and a peripheral edge, and comprising:

[0155] Absorbing layer (232);

[0156] a liquid-impermeable barrier layer (233) disposed beneath the absorbent layer, the barrier layer comprising an outwardly facing surface of the gusset assembly; and an edge barrier overlying a portion of the wearer-facing surface in the crotch portion proximate the peripheral edge and effectively continuing from the wearer-facing surface over and around the peripheral edge to the outwardly facing surface in the crotch region, wherein the edge barrier comprises an extension of the barrier layer (233);

[0157] wherein the outwardly facing surface of the absorbent gusset assembly is attached within the crotch portion (130) by one or more adhesive deposits (236) disposed laterally inboard of the respective proximal left and right leg opening edges (140) at an adhesive insertion distance (AI) of at least 2 mm, more preferably 4 mm, even more preferably 7 mm and still more preferably 10 mm.

[0158] 2. A durable absorbent pants, comprising:

[0159] Outer trousers structure, the outer trousers structure comprising:

[0160] A front waist portion (100), the front waist portion having a front waist edge (102);

[0161] a rear waist portion (120), the rear waist portion having a rear waist edge (122);

[0162] a crotch portion (130) having a front portion (132) connected to the front waist portion and a rear portion (136) connected to the rear waist portion; and left and right hip side portions (160) at which the front waist portion is connected to the rear waist portion to form a waist opening having a waist opening edge including the front waist edge and the rear waist edge, and forming left and right leg openings having left and right leg opening edges (104, 140, 124); and

[0163] A gusset (230) disposed at least partially in the crotch portion, the gusset having a wearer-facing surface, an outwardly facing surface, and a peripheral edge, and comprising:

[0164] Absorbing layer (232);

[0165] a liquid impermeable barrier layer (233) disposed beneath the absorbent layer, the barrier layer comprising an outwardly facing surface of the gusset assembly; and an edge barrier overlying a portion of the wearer-facing surface in the crotch portion proximate the peripheral edge and effectively continuing from the wearer-facing surface to the outwardly facing surface in the crotch region over and around the peripheral edge, wherein the edge barrier comprises one or more sections of liquid impermeable edge sealing strip material (235) joined to the barrier layer proximate the peripheral edge;

[0166] wherein the outwardly facing surface of the absorbent gusset assembly is attached within the crotch portion (130) by one or more adhesive deposits (236) disposed laterally inboard of the edge seal strip material in the crotch portion.

[0167] 3. A durable absorbent pant according to any of the preceding examples, wherein there is no adhesive deposit attaching the absorbent gusset assembly within the crotch portion within less than 1.0 cm of the proximal left or right leg opening edge, the proximal left or right leg opening edge being continuous along a majority of the portion of the proximal leg opening edge within the crotch portion.

[0168] 4. A durable absorbent pants, comprising:

[0169] Outer trousers structure, the outer trousers structure comprising:

[0170] A front waist portion (100), the front waist portion having a front waist edge (102);

[0171] a rear waist portion (120), the rear waist portion having a rear waist edge (122);

[0172] a crotch portion (130) having a front portion (132) connected to the front waist portion and a rear portion (136) connected to the rear waist portion; and left and right hip side portions (160) at which the front waist portion is connected to the rear waist portion to form a waist opening having a waist opening edge including the front waist edge and the rear waist edge, and forming left and right leg openings having left and right leg opening edges (104, 140, 124); and

[0173] A gusset (230) disposed at least partially in the crotch portion, the gusset having a wearer-facing surface, an outwardly facing surface, and a peripheral edge, and comprising:

[0174] Absorbing layer (232);

[0175] a liquid impermeable barrier layer (233) disposed beneath the absorbent layer, the barrier layer comprising an outwardly facing surface of the gusset assembly; and an edge barrier overlying a portion of the wearer-facing surface in the crotch portion proximate the peripheral edge and effectively continuing from the wearer-facing surface to the outwardly facing surface in the crotch region over and around the peripheral edge, wherein the edge barrier comprises one or more sections of liquid impermeable edge sealing strip material (235) joined to the barrier layer proximate the peripheral edge, or wherein the edge barrier comprises an extension of the barrier layer (233);

[0176] wherein the gusset component (230) is attached within the crotch portion (130) by a pattern of discrete adhesive deposits (236d).

[0177] 5. The absorbent pants according to example 4, wherein the average size of the adhesive deposits (236d) in the pattern is 0.25 mm 2 Up to 2.0mm 2 .

[0178] 6. A pair of pants according to any of Examples 4 or 5, wherein an area of ​​the outwardly facing surface of the gusset assembly that is completely surrounded by the peripheral edge but is longitudinally and laterally inboard of the peripheral edge is not attached to the crotch portion.

[0179] 7. Absorbent pant according to any of examples 4 to 6, wherein the adhesive deposits (236d) in the pattern have the form of substantially circular dots.

[0180] 8. The absorbent pant according to any of examples 5 to 7, wherein the pattern of adhesive deposits (236d) follows a path generally parallel to the leg opening edges and disposed inboard and proximate thereto.

[0181] 9. The absorbent pant of examples 4 to 8, wherein the pattern of adhesive deposits (236d) reflects a programmed contour that follows the path of the leg opening edges.

[0182] 10. The absorbent pant of any of Examples 4 to 9, wherein the adhesive deposit (236d) directly attaches one or both of the barrier layer (233) and edge barrier structure to the crotch portion (130).

[0183] 11. A durable absorbent pants, comprising:

[0184] Outer trousers structure, the outer trousers structure comprising:

[0185] A front waist portion (100), the front waist portion having a front waist edge (102);

[0186] a rear waist portion (120), the rear waist portion having a rear waist edge (122);

[0187] a crotch portion (130) having a front portion (132) connected to the front waist portion and a rear portion (136) connected to the rear waist portion; and left and right hip side portions (160) at which the front waist portion is connected to the rear waist portion to form a waist opening having a waist opening edge including the front waist edge and the rear waist edge, and forming left and right leg openings having left and right leg opening edges (104, 140, 124); and

[0188] A gusset (230) disposed at least partially in the crotch portion, the gusset having a wearer-facing surface, an outwardly facing surface, and a peripheral edge, and comprising:

[0189] Absorbing layer (232);

[0190] a liquid impermeable barrier layer (233) disposed beneath the absorbent layer, the barrier layer comprising an outwardly facing surface of the gusset assembly; and an edge barrier overlying a portion of the wearer-facing surface in the crotch portion proximate the peripheral edge and effectively continuing from the wearer-facing surface to the outwardly facing surface in the crotch region over and around the peripheral edge, wherein the edge barrier comprises one or more sections of liquid impermeable edge sealing strip material (235) joined to the barrier layer proximate the peripheral edge, or wherein the edge barrier comprises an extension of the barrier layer (233);

[0191] An extension flange 244e comprises a fabric material having a width, the entirety of which is bonded to the edge barrier structure, the flange extending laterally outward beyond the proximal side edge of the absorbent layer in the crotch portion, and the extension flange is attached to the outer pants structure.

[0192] 12. The absorbent pant according to any of the preceding examples, wherein the gusset (230) comprises an elastic stretch knit fabric.

[0193] 13. Absorbent pants according to any of the preceding examples, wherein the barrier layer (233) comprises an elastomeric film.

[0194] 14. The absorbent pant according to any of the preceding examples, wherein the edge barriers comprise an elastomeric film.

[0195] 15. An absorbent pants according to any of the preceding examples, comprising a supplementary elastic stretch knitted fabric finishing strip (237), wherein the absorbent pants comprises a supplementary elastic stretch knitted fabric finishing strip having a first strip portion attached to the triangular gusset at a first attachment location and a second strip portion attached to the front waist portion or the rear waist portion at a second attachment location, wherein the adhesive deposit is present at either or both of the first attachment location and the second attachment location.

[0196] 16. A durable absorbent pant comprising:

[0197] Outer trousers structure, the outer trousers structure comprising:

[0198] A front waist portion (100), the front waist portion having a front waist edge (102);

[0199] a rear waist portion (120), the rear waist portion having a rear waist edge (122);

[0200] a crotch portion (130) having a front portion (132) connected to the front waist portion and a rear portion (136) connected to the rear waist portion; and

[0201] left and right hip side portions (160), where the front waist portion and the rear waist portion meet to form a waist opening having a waist opening edge including the front waist edge and the rear waist edge, and forming left and right leg openings having left and right leg opening edges (104, 140, 124); and

[0202] A gusset (230) at least partially disposed in the crotch portion, the gusset having a wearer-facing surface, an outwardly facing surface, and a peripheral edge, the peripheral edge having front and rear edge portions in the front waist portion and the rear waist portion, respectively, and left and right crotch edge portions, and the gusset comprises:

[0203] Absorbing layer (232);

[0204] a liquid impermeable barrier layer (233) disposed beneath the absorbent layer, the barrier layer comprising an outwardly facing surface of the gusset assembly; and

[0205] an edge barrier overlying a portion of the wearer-facing surface in the crotch portion proximate the peripheral edge and effectively continuing from the wearer-facing surface to the outwardly facing surface in the crotch region over and around the peripheral edge, wherein the edge barrier comprises one or more sections of liquid-impermeable edge sealing strip material (235) joined to the barrier layer proximate the peripheral edge, or wherein the edge barrier comprises an extension of the barrier layer (233);

[0206] The gusset (230) is attached to the outer trouser structure in the front waist portion and the rear waist portion, respectively, but not in the crotch portion.

[0207] 17. The absorbent pants of example 16, wherein:

[0208] The gusset (230) is attached to the outer pant structure at the front and back seams (134, 138);

[0209] When in a relaxed condition, the gusset has a first length between the seams;

[0210] When in a relaxed condition, the outer pants structure has a second length between the seams; and

[0211] The first length is equal to or greater than the second length.

[0212] 18. The absorbent pants of example 16, wherein:

[0213] The gusset (230) is attached to the outer pant structure at the front and back seams (134, 138);

[0214] When in a relaxed condition, the gusset has a first length between the seams;

[0215] When in a relaxed condition, the outer pants structure has a second length between the seams; and

[0216] The first length is smaller than the second length.

[0217] The dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​cited. Instead, unless otherwise indicated, each such dimension is intended to represent the stated value and a functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" is intended to mean "approximately 40 mm".

[0218] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patent or application, is incorporated herein by reference in its entirety. Citation of any document is not an admission that it is prior art to any of the present invention disclosed or claimed herein, or that it, by itself or in combination with any one or more references, proposes, suggests, or discloses any such invention. In addition, to the extent that any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this invention shall govern.

[0219] Although specific embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the present invention. Therefore, it is intended that all such changes and modifications within the scope of the present invention be covered in the appended claims.

Claims

1. A durable absorbent pants, comprising: Outer trousers structure, the outer trousers structure comprising: A front waist portion (100), the front waist portion having a front waist edge (102); a rear waist portion (120), the rear waist portion having a rear waist edge (122); a crotch portion (130) having a front portion (132) connected to the front waist portion and a rear portion (136) connected to the rear waist portion; and left and right hip side portions (160), where the front waist portion and the rear waist portion meet to form a waist opening having a waist opening edge including the front waist edge and the rear waist edge, and forming left and right leg openings having left and right leg opening edges (104, 140, 124); and A gusset assembly (230) disposed at least partially in the crotch portion, the gusset assembly having a wearer-facing surface, an outwardly facing surface, and a peripheral edge, and comprising: Absorbing layer (232); a liquid impermeable barrier layer (233) disposed beneath the absorbent layer, the barrier layer comprising an outwardly facing surface of the gusset assembly; and an edge barrier overlying a portion of the wearer-facing surface in the crotch portion proximate the peripheral edge and effectively continuing from the wearer-facing surface to the outwardly facing surface in the crotch region over and around the peripheral edge, wherein the edge barrier comprises one or more sections of liquid-impermeable edge sealing strip material (235) joined to the barrier layer proximate the peripheral edge, or wherein the edge barrier comprises an extension of the barrier layer (233); wherein the gusset component (230) is attached within the crotch portion (130) by a pattern of discrete adhesive deposits (236d).

2. The absorbent according to claim 1, wherein the average size of the adhesive deposits (236d) in the pattern is 0.25 mm 2 Up to 2.0mm 2 .

3. A pair of pants according to any one of claims 1 or 2, wherein an area of ​​the outwardly facing surface of the gusset assembly which is completely surrounded by the peripheral edge but is longitudinally and laterally inboard of the peripheral edge is not attached to the crotch portion.

4. Absorbent pant according to any one of the preceding claims, wherein the adhesive deposits (236d) in the pattern have the form of substantially circular dots.

5. An absorbent pant according to any one of the preceding claims, wherein the pattern of adhesive deposits (236d) follows a path generally parallel to the leg opening edges and is disposed inside and close thereto.

6. Absorbent pant according to the preceding claim, wherein the pattern of said adhesive deposits (236d) reflects a programmed contour that follows the path of said leg opening edges.

7. Absorbent pant according to any one of the preceding claims, wherein the adhesive deposit (236d) directly attaches one or both of the barrier layer (233) and edge barrier to the crotch portion (130).

8. A durable absorbent pants, comprising: Outer trousers structure, the outer trousers structure comprising: A front waist portion (100), the front waist portion having a front waist edge (102); a rear waist portion (120), the rear waist portion having a rear waist edge (122); a crotch portion (130) having a front portion (132) connected to the front waist portion and a rear portion (136) connected to the rear waist portion; and left and right hip side portions (160), where the front waist portion and the rear waist portion meet to form a waist opening having a waist opening edge including the front waist edge and the rear waist edge, and forming left and right leg openings having left and right leg opening edges (104, 140, 124); and A gusset assembly (230) disposed at least partially in the crotch portion, the gusset assembly having a wearer-facing surface, an outwardly facing surface, and a peripheral edge, and comprising: Absorbing layer (232); a liquid impermeable barrier layer (233) disposed beneath the absorbent layer, the barrier layer comprising an outwardly facing surface of the gusset assembly; and an edge barrier overlying a portion of the wearer-facing surface in the crotch portion proximate the peripheral edge and effectively continuing from the wearer-facing surface to the outwardly facing surface in the crotch region over and around the peripheral edge, wherein the edge barrier comprises one or more sections of liquid-impermeable edge sealing strip material (235) joined to the barrier layer proximate the peripheral edge, or wherein the edge barrier comprises an extension of the barrier layer (233); An extension flange (244e) comprising a fabric material having a width, the entirety of which is bonded to the edge barrier, the flange extending laterally outward beyond the proximal side edge of the absorbent layer in the crotch portion, the extension flange being attached to the outer pant structure.

9. The absorbent pant according to any one of the preceding claims, wherein the gusset component (230) comprises an elastic stretch knit fabric.

10. Absorbent pant according to any one of the preceding claims, wherein the barrier layer (233) comprises an elastomeric film.

11. An absorbent pant according to any one of the preceding claims, wherein the edge barriers comprise an elastomeric film.

12. An absorbent pant according to any of the preceding claims, comprising a supplementary elastic stretch knitted fabric trimming strip (237), the supplementary elastic stretch knitted fabric trimming strip having a first strip portion attached to the triangular gusset assembly at a first attachment location and a second strip portion attached to the front waist portion or the rear waist portion at a second attachment location, wherein the adhesive deposit is present at either or both of the first attachment location and the second attachment location.

13. A durable absorbent pant comprising: Outer trousers structure, the outer trousers structure comprising: A front waist portion (100), the front waist portion having a front waist edge (102); a rear waist portion (120), the rear waist portion having a rear waist edge (122); a crotch portion (130) having a front portion (132) connected to the front waist portion and a rear portion (136) connected to the rear waist portion; and left and right hip side portions (160), where the front waist portion and the rear waist portion meet to form a waist opening having a waist opening edge including the front waist edge and the rear waist edge, and forming left and right leg openings having left and right leg opening edges (104, 140, 124); and A gusset assembly (230) at least partially disposed in the crotch portion, the gusset assembly having a wearer-facing surface, an outwardly facing surface, and a peripheral edge, the peripheral edge having front and rear edge portions in the front waist portion and the rear waist portion, respectively, and left and right crotch edge portions, and the gusset assembly comprising: Absorbing layer (232); a liquid impermeable barrier layer (233) disposed beneath the absorbent layer, the barrier layer comprising an outwardly facing surface of the gusset assembly; and an edge barrier overlying a portion of the wearer-facing surface in the crotch portion proximate the peripheral edge and effectively continuing from the wearer-facing surface to the outwardly facing surface in the crotch region over and around the peripheral edge, wherein the edge barrier comprises one or more sections of liquid-impermeable edge sealing strip material (235) joined to the barrier layer proximate the peripheral edge, or wherein the edge barrier comprises an extension of the barrier layer (233); The gusset assembly (230) is attached to the outer trouser structure in the front waist portion and the rear waist portion, respectively, and is not attached to the outer trouser structure along a portion near the leg opening edge.

14. The absorbent pants according to claim 13, wherein: The gusset assembly (230) is attached to the outer pant structure at the front and back seams (134, 138); When in a relaxed condition, the gusset assembly has a first length between the seams; When in a relaxed condition, the outer pants structure has a second length between the seams; and The first length is equal to or greater than the second length.

15. The absorbent pants of claim 13, wherein: The gusset assembly (230) is attached to the outer pant structure at the front and back seams (134, 138); When in a relaxed condition, the gusset assembly has a first length between the seams; When in a relaxed condition, the outer pants structure has a second length between the seams; and The first length is smaller than the second length.

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