Disposable absorbent insert for reusable housing

Abstract

A disposable absorbent insert for a reusable housing, comprising: a liquid impermeable backsheet having a backsheet first side edge and a backsheet second side edge; an absorbent core disposed between a liquid permeable and user facing topsheet and a liquid impermeable backsheet; and a non-woven outer cover layer covering the backsheet and forming an outer surface of the insert. The insert has a pair of leg cuffs extending in the longitudinal direction and symmetrically arranged along longitudinal side edges. Each leg cuff comprises a side portion of an outer cover layer folded back onto itself along a fold line extending in the longitudinal direction and dividing the side portion of the outer cover layer into a first portion and a second portion, the first portion and the second portion together forming a leg cuff fold, and a plurality of spaced apart pre-tensioned elastic elements arranged between the first portion and the second portion. A plurality of spaced apart pre-tensioned resilient elements extend longitudinally inside the leg cuff fold and are attached between the first and second portions of the leg cuff fold.

Description

Technical Field

[0001] The present disclosure relates to disposable absorbent inserts for use with reusable shells and wearable absorbent articles including a reusable shell and a disposable absorbent insert. Background Art

[0002] Wearable and disposable absorbent articles are well known, for example in the form of diapers, incontinence garments, feminine garments, inserts, etc. Absorbent articles are used to absorb, distribute and store various types of body exudates while providing a high level of comfort and dryness to the wearer during use.

[0003] Conventional disposable absorbent articles in the form of diapers are usually designed with an absorbent core sandwiched between a top sheet and a back sheet. The article is arranged along a longitudinal axis and a transverse axis, and the transverse axis extends in a perpendicular direction relative to the longitudinal axis. In addition, the article can be divided into a front part, a back part and a crotch part. The diaper is designed to have a waist portion integral with the core for enclosing the wearer, and also includes an inner leg gatherer (i.e., an upright gatherer) and an outer leg gatherer to avoid leakage from the edge of the article.

[0004] A disposable absorbent insert is intended for use with a reusable outer shell and is generally of simpler design than a disposable diaper, as it is intended for use with an outer disposable or reusable outer shell or cover. It is generally desirable to achieve the same level of comfort, absorbent capacity, and leakage safety in an absorbent insert as in a conventional diaper. Summary of the invention

[0005] The present disclosure provides a disposable absorbent insert according to claim 1 and a wearable absorbent article comprising a reusable shell and a disposable absorbent insert according to claim 25. Further embodiments are set out in the dependent claims and in the following description.

[0006] Disclosed herein is a disposable absorbent insert for a reusable shell, the insert having a longitudinal and transverse extension, longitudinal side edges and transverse side edges, and having a front portion, a rear portion and a crotch portion located between the front portion and the rear portion. The disposable absorbent insert comprises a liquid-impermeable backsheet having a first side edge of the backsheet and a second side edge of the backsheet, an absorbent core disposed between a liquid-permeable top sheet facing a user and the liquid-impermeable backsheet, and a nonwoven outer cover layer covering the backsheet and forming the outer surface of the insert. The insert has a pair of leg cuffs extending in the longitudinal direction and symmetrically arranged along the longitudinal side edges. Each leg cuff comprises a side portion of an outer cover layer, the side portion of the outer cover layer being folded back onto itself along a fold line, the fold line extending in the longitudinal direction and dividing the side portion of the outer cover layer into a first portion and a second portion, the first portion and the second portion together forming a leg cuff fold. The leg cuff also comprises a plurality of spaced apart pre-tensioned elastic elements extending longitudinally inside the leg cuff fold and attached between the first portion and the second portion of the leg cuff fold.

[0007] The absorbent core may comprise an absorbent component enclosed by a core cover, the core cover comprising an upper side and a lower side.

[0008] The leg cuffs of the insert prevent body fluids that may have escaped and absorbed in the absorbent core of the insert from soiling the surrounding leg portions of a reusable outer shell used in combination with a disposable insert. This increases the number of uses that the reusable outer shell can be used before needing to be washed, which is a great benefit of a two-piece diaper system comprising a disposable inner portion and a reusable outer portion.

[0009] The leg cuffs of the insert as disclosed herein are well-defined, neat and distinct features that are easily identified by visual inspection of the absorbent insert. In prior art inserts, the leg elastics are typically arranged between the laterally extending sides of the top sheet and the back sheet or between the upright gather material and the sides of the back sheet. This arrangement results in hemmed, floppy, inelastic side edge portions on the transverse outsides of the elastic elements. When donning an outer shell having an insert with such inelastic sides, it is necessary to ensure that the sides are folded out to avoid the insert being applied to the wearer with the elastic sides folded over the absorbent body, which can result in poor fit and ultimately lead to leakage of body fluids from the insert.

[0010] The insert as disclosed herein is skin-friendly and comfortable to wear because all body contacting surfaces of the article are composed of soft nonwoven material. The leg cuff is particularly soft because the pre-tensioned elastic elements in the leg cuff are arranged within the leg cuff folds, thereby providing the leg cuff with a folded outer edge. A plurality of spaced-apart pre-tensioned elastic elements cause the nonwoven material in the leg cuff folds to shrink and form soft, airy and evenly distributed wrinkles on the surface of the leg cuff. The elasticized portion of the folds of the leg cuff acts as a buffer distance means between the wearer's body and the elastic elements.

[0011] The side portions of the outer cover may extend in a transverse direction beyond the respective side edges of the chassis.

[0012] All or substantially all of the plurality of elastic elements in each leg cuff may be arranged in an outer portion of the leg cuff laterally outwardly of the liquid impermeable backsheet, ie free of the liquid impermeable backsheet.

[0013] The nonwoven outer cover may be a single layer of nonwoven material.

[0014] The leg cuffs can be leakproof. The nonwoven outer covering layer forming the leg cuffs can be a material that provides similar large air permeability and barrier properties to avoid any leakage and contamination of the reusable shell. If there is no upright gathering piece on the insert, this is particularly advantageous. The nonwoven layer can be made of a co-formed thin layer of a nonwoven material such as SMS (spunbond / meltblown / spunbond) nonwoven material or SS (spunbond / spunbond) nonwoven material. The thermoplastic polymer material in the nonwoven layer can be a bicomponent fiber of polypropylene or polypropylene and polyethylene, or a combination of such materials. The outer covering layer can also include two layers of hydrophobic nonwoven materials.

[0015] Alternatively, the nonwoven material for the outer cover material may include one or more spunbond layers and optionally one or more meltblown layers. The nonwoven material may be made of thermoplastic polymer fibers or filaments. The nonwoven material may be formed by any of a variety of different processes, such as spunbond, airlaid, meltblown or bonded carded web forming processes.

[0016] The nonwoven material used may be renewable or recyclable.The nonwoven material may be bio-based.

[0017] The leg cuffs are highly breathable because they are primarily composed of nonwoven material. The liquid impermeable backsheet may extend into the leg cuffs in the inner portion of each leg cuff up to 50% of the leg cuff width, such as up to 40% of the leg cuff width or up to 30% of the leg cuff width. The liquid impermeable backsheet may extend into the leg cuffs to a greater portion of the width of each leg cuff in smaller sized articles than in larger sized articles.

[0018] An elastic element of the plurality of elastic elements may be attached between the first portion and the second portion of the leg cuff fold by an adhesive.

[0019] According to one aspect, the first part of the side of the outer cover layer may be the lower part of the leg cuff fold as seen in the direction of the top sheet, and the second part of the side of the outer cover layer may be the upper part of the leg cuff fold as seen in the direction of the top sheet. In this arrangement, the outwardly facing side of the insert is soft and continuous without any edges, seams or joints. If so arranged, the second part of the side includes the longitudinal edge of the outer cover layer, and the longitudinal edge of the second part of the side is the inner end that can be fixed between the top sheet and the back sheet.

[0020] The plurality of elastic elements in each leg cuff may consist of at least 3 elastic elements, preferably at least 4 elastic elements.The elastic elements may be spaced apart in the transverse direction by 1 mm to 8 mm, preferably 3 mm to 8 mm.

[0021] The elastic element may be an elastic thread, a cord or an elastic band, preferably an elastic thread.

[0022] The one or more elastic elements arranged in the inner part of the leg cuff fold may have a greater stretch resistance than the one or more elastic elements arranged in the outer part of the leg cuff fold, and the linear density (dtex) of the one or more elastic elements in the inner part of the leg cuff fold may be higher than the linear density of the one or more elastic elements arranged in the outer part of the leg cuff fold.

[0023] The leg cuff fold may extend along the entire longitudinal length of the insert.

[0024] The plurality of elastic elements may be arranged at least along the entire longitudinal length of the crotch region, and the longitudinal length of the plurality of elastic elements is less than the total longitudinal length of the insert. Thus, the folded side portions of the nonwoven outer cover are elasticized only at portions of the insert that are intended to be arranged adjacent to the legs of the wearer during use. The leg cuff folds are partially free of elastic elements in the front and back portions, thereby providing the insert with softer front and back portions that will better adapt to the waist of the wearer once placed in the reusable shell and worn.

[0025] Furthermore, the insert may comprise a first vertical gathering piece extending longitudinally and a second vertical gathering piece extending longitudinally. The vertical gathering pieces are arranged transversely inside the leg cuffs, towards the longitudinal centerline of the insert, and are arranged to at least partially rise during use of the insert. The vertical gathering pieces are attached to the top sheet. In addition to the leg cuffs, the vertical gathering pieces further improve the leakage safety of the absorbent insert.

[0026] The insert may have a pair of nonwoven barrier cuff strips extending in the longitudinal direction and symmetrically arranged with one barrier cuff strip on each side of the longitudinal centerline. Each nonwoven barrier cuff strip may include upright gatherer parts forming first and second upright gatherers, respectively, each upright gatherer being defined between a longitudinally extending free upright gatherer edge and a longitudinally extending upright gatherer hinge line. The barrier cuff strips are connected to the top sheet along the upright gatherer hinge line.

[0027] The nonwoven material in the nonwoven barrier strip may be the same as described herein in connection with the outer cover.The nonwoven material in the nonwoven barrier strip may be different from the nonwoven material of the outer cover material forming the leg cuff folds.

[0028] The upstanding gathering member may have one or more pre-tensioned elastic elements disposed along the free upstanding gathering member edge.

[0029] The nonwoven barrier cuff strip may include a leg cuff portion, and the leg cuff portion of the nonwoven barrier cuff strip is defined between the upright gathering piece hinge line and the outer leg cuff edge of the nonwoven barrier cuff strip, wherein the outer leg cuff edge of the nonwoven barrier cuff strip is parallel to the fold line in the leg cuff fold portion, and the leg cuff portion of the nonwoven barrier cuff strip covers at least one elastic element of the plurality of elastic elements.

[0030] Each leg cuff may be disposed outboard of the upstanding gather member portion of the corresponding barrier cuff strip.

[0031] The leg cuff fold may have a free edge defined by a fold line and a leg cuff width in the transverse direction between the fold line in the leg cuff fold and the upstanding gatherer hinge line.

[0032] The leg cuff portion of each nonwoven barrier cuff strip may be attached to a corresponding leg cuff fold, wherein the leg cuff portion of the nonwoven barrier cuff strip covers all or substantially all of the plurality of elastic elements in the leg cuff fold.

[0033] In such an arrangement, the leg cuffs include a leg cuff portion of a nonwoven barrier cuff strip at the inner side of the article facing the wearer, which forms an additional gatherable cushioning layer for the leg cuffs. Thus, under the influence of the contraction forces from the elastic elements distributed over the width of each leg cuff, the leg cuff portion of the nonwoven barrier cuff strip together with the nonwoven material in the leg cuff folds form a soft, bulky but highly body-conforming leg cuff.

[0034] In an insert as disclosed herein, the leg cuff portion of the nonwoven barrier cuff strip may be attached to the leg cuff fold using an adhesive evenly distributed on the attachment area between the nonwoven barrier cuff strip and the leg cuff fold or using an evenly distributed thermal bond or ultrasonic bond. Thus, the adhesive is evenly distributed on the attachment area between the leg cuff portion of the nonwoven barrier cuff strip and the upper portion of the side of the outer cover layer. The adhesive may be applied by any suitable technique, such as slot coating or spray coating.

[0035] The outer leg cuff edge of the nonwoven barrier cuff strip may be arranged at or inside the fold line in the leg cuff fold as seen in the cross-machine direction.

[0036] The leg cuff portion of the nonwoven barrier cuff strip may be attached to the second portion of the side portion of the outer cover with an adhesive that is evenly distributed over the attachment area between the leg cuff portion of the nonwoven barrier cuff strip and the second portion of the side portion of the outer cover.

[0037] The width of each leg cuff is in the range of 20 mm to 60 mm, and the elastic elements of the plurality of elastic elements in each leg cuff are distributed over an area of ​​the leg cuff whose width in the transverse direction is at least 40%, preferably at least 50% of the width of the leg cuff.

[0038] The nonwoven barrier cuff strip may be a single layer of nonwoven material.

[0039] The first portion of the side of the outer cover layer may be contiguous with a central portion of the outer cover layer, the central portion of the outer cover layer overlying the backsheet, and wherein the second portion of the side of the outer cover layer is a folded portion of the side of the outer cover layer.

[0040] The insert may be provided with fastening elements to fasten the insert to the reusable shell. The reusable shell may also be provided with corresponding fastening elements to facilitate fastening of the insert. Suitable fastening elements may, for example, include hook or loop materials, buttons and straps.

[0041] The fastening elements may be strips of loop material attached to the garment-facing side of the outer cover near the front and rear lateral side edges of the insert, respectively.

[0042] The fastening element may be a hook member comprising any hook-type material having a hook surface structure, or a hook attachment area comprising any loop surface structure, i.e., a hook member known as a The "hook" can have many different shapes that are suitable for engaging with the loop portion of a hook-and-loop fastening system, known as system.

[0043] The strip of loop material may extend over 50% to 100% of the lateral sides of the insert. The longitudinal extension of the strip of loop material may be 10 mm to 50 mm, such as 10 mm to 35 mm. The longitudinal extension of the strip of loop material may be greater in the rear portion of the insert than in the front portion of the insert. The strip of loop material may have free lateral side edges of the same material as the top sheet and the back sheet. The strip of loop material may have the same free lateral side edges as the insert. The insert having the strip of loop material attached to the back sheet may also include any other features of the insert as disclosed above and herein.

[0044] The strips of loop material on the garment-facing side of the backsheet provide improved attachment of the insert into a reusable shell provided with hook patches on the inside of its front and rear portions, such as disclosed herein. The advantage of an insert having strips of loop material in its front and rear portions, having the same free lateral side edges as the insert itself, is that it will provide improved and tight attachment of the insert in the reusable shell when in use.

[0045] Alternatively, the outer cover layer itself may be a material that facilitates fastening of the insert to the reusable shell, ie a material that provides for secure attachment of the insert to the hook material elements provided on the user-facing side of the shell.

[0046] The present disclosure relates to a disposable absorbent insert for a reusable shell. The insert therefore lacks side flaps arranged at the waist edge of the front and side flaps arranged at the waist edge of the rear. Such side flaps are present on disposable diapers and are provided with fasteners for fastening the disposable diaper in a trouser-like manner around the waist of the wearer. The disposable absorbent insert is not intended to be fastened to the waist of the wearer without the shell and therefore lacks any such fastening means.

[0047] Furthermore, the insert lacks a waistband, which is present on conventional pant-type disposable diapers and forms a continuous waistband around the wearer's body.

[0048] The insert may have a rectangular shape.The absorbent core may have a rectangular shape.

[0049] The insert may be provided with a waist elastic member at the transverse front edge of the front portion and / or the transverse rear edge of the rear portion of the insert. The waist elastic member may include an elasticized material or elastic thread extending in the transverse direction. The waist elastic member may improve the fit around the wearer's waist.

[0050] The insert may be provided with a waist gasketing element in the form of a barrier pocket in the front and / or rear part of the insert. The barrier pocket is attached to the insert along its longitudinal edges and the front or rear edge, respectively, so as to open towards the crotch, thereby forming a pocket. Such a waist gasketing element may improve leakage safety around the waist of the wearer.

[0051] The present disclosure also relates to a wearable absorbent article comprising a reusable shell worn by a wearer and a disposable absorbent insert as described herein. The reusable shell may be made of a garment-like fabric, may be underwear-like and may be washable.

[0052] A wearable absorbent article comprising a reusable shell worn by a wearer may include a disposable absorbent insert comprising strips of loop material attached to the garment-facing side of a backsheet near the front and rear lateral side edges of the insert, respectively, as described above. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The present disclosure will now be described in more detail with reference to the figures shown in the accompanying drawings, in which:

[0054] Figure 1 shows a plan view of a stretched-out absorbent article in the form of an insert, seen from the side intended to face the wearer during use;

[0055] Figure 2 Shown along Figure 1 The line II-II in the Figure 1 A cross section of an insert in;

[0056] Figure 3 A wearable absorbent article comprising a reusable outer shell and a disposable insert is shown;

[0057] Figure 4 shows another plan view of a stretched-out absorbent article in the form of an insert, seen from the side intended to face the wearer during use;

[0058] Figure 5 Shown along Figure 3 The line II-II in the Figure 3 A cross section of an insert in;

[0059] Figure 6 Shows Figure 4 and Figure 5 Details of the leg cuffs shown; and

[0060] Figure 7 Shown along Figure 4 The line II-II in the Figure 1 Alternative cross-section of a diaper in. DETAILED DESCRIPTION

[0061] Those of ordinary skill in the art will appreciate that the following is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the present disclosure.

[0062] Various aspects of the absorbent insert as disclosed herein will be described more fully below with reference to the accompanying drawings.The embodiments disclosed herein should not be construed as being limited to the claimed absorbent insert.

[0063] It should be understood that the drawings are schematic and that various components, such as material layers, are not necessarily drawn to scale.

[0064] Disposable absorbent insert 1 in Figure 1 It is shown in an unfolded and flat state, with all elastic elements and components in an extended state. Figure 1 The insert 1 is shown from the inner surface facing the wearer. Any measurements of distances and dimensions are made with the insert in the position shown. Figure 1 The device is shown in the fully extended, non-folded position.

[0065] The insert 1 has a longitudinal direction L and a transverse direction T.

[0066] The insert 1 has a first waist edge 2 and a second waist edge 4 and a first and a second side edge 6 , 8 . Figure 1 The first waist edge 2 of the insert 1 shown is a rear waist edge, and the second waist edge 4 of the absorbent insert 1 is a front waist edge. The first and second waist edges 2, 4 extend in the transverse direction T of the absorbent insert 1, and the side edges 6, 8 extend in the longitudinal direction L of the absorbent insert 1. The absorbent insert 1 can be divided in the longitudinal direction L into a front part 3, a rear part 5 and a crotch part 7 located between the front part 3 and the rear part 5.

[0067] Insert 1 comprises a liquid permeable top sheet 9 and a liquid impermeable back sheet 10. An absorbent core 11 is disposed between the top sheet 9 and the back sheet 10. The top sheet 9 has a top sheet first side edge 9' and a top sheet second side edge 9", and the back sheet 10 has a back sheet first side edge 10' and a back sheet second side edge 10", such as Figure 1 and 2 shown.

[0068] The insert 1 further comprises a nonwoven outer cover layer 18 covering the backsheet 10 and forming the outer surface of the insert 1 .

[0069] The insert 1 comprises a pair of leg cuffs 31 , 32 extending in the longitudinal direction L and arranged symmetrically along the first and second side edges 6 , 8 .

[0070] like Figure 2As shown, each of the leg cuffs 31, 32 includes a side portion 33, 34 of the outer covering layer, which extends in the transverse direction to the outside of the corresponding side edge 10', 10" of the backsheet, and the side portions 33, 34 of the outer covering layer 18 are folded back onto themselves along folding lines 36, 38, which extend in the longitudinal direction L and divide the side portions 33, 34 of the outer covering layer 18 into a first portion 33', 34' and a second portion 33", 34", and the first and second portions 33', 33", 34', 34" together form a leg cuff fold 35, 37, and the leg cuff fold 35, 37 has a free edge defined by the fold lines 36, 38 and a leg cuff width W in the transverse direction T defined between the free edge of the leg cuff fold lines 36, 38 and the inner ends 47, 48 of the side portions 33, 34.

[0071] The first portions 33', 34' of the side portions 33, 34 of the outer cover layer 18 are Figure 2 18 is shown adjacent to the central portion 18' of the outer cover layer 18, which covers the backsheet 10. The second portions 33", 34" of the side portions 33, 34 of the outer cover layer 18 are folded over portions of the side portions 33, 34 of the outer cover layer 18.

[0072] exist Figure 1-6 In the illustrated embodiment, as seen in the direction from the top sheet 9, first portions 33', 34' of the side portions 33, 34 of the outer cover layer 18 constitute lower portions of the leg cuff folds 35, 37, and as seen in the direction from the top sheet 9, second portions 33", 34" of the side portions 33, 34 of the outer cover layer 18 constitute upper portions of the leg cuff folds 35, 37. The upper portions of the leg cuff folds 35, 37 are folded back onto the top of the lower portions of the leg cuff folds 35, 37 and fixed between the top sheet 9 and the back sheet 10. Thus, the top sheet 9 and the back sheet 10 are directly connected to each other along the side edges of the absorbent core 11 and to the folded-in portions of the outer cover layer fixed between the top sheet 9 and the back sheet 10, as shown in FIG. Figure 2 The tucked-in portion of the outer cover layer comprises inner ends 47, 48. The garment-facing side of the backsheet is directly attached to the central portion of the outer cover sheet.

[0073] As described herein, the side portions 33, 34 of the outer cover layer 18 can optionally be folded so that the first portion 33', 34' of the side portions 33, 34 of the outer cover layer 18 (which is adjacent to the central portion 18' of the outer cover layer 18) constitutes the upper portion of the leg cuff fold 35, 37 (as seen in the direction from the top sheet), and the folded back second portion 33", 34" constitutes the lower portion of the leg cuff fold 35, 37 (as seen in the direction from the top sheet 9). In this configuration, as Figure 7 As shown, the side portions 33 , 34 of the outer cover layer 18 are folded back on themselves on the outer side of the insert 1 facing the garment.

[0074] A plurality of spaced apart pre-tensioned elastic elements 41, 42 are arranged in each leg cuff fold 35, 37. The elastic elements 41, 42 extend in the longitudinal direction L inside the leg cuff fold 35, 37 and are attached between the first and second portions 33', 34' of the leg cuff fold 35, 37, for example by adhesive.

[0075] The width of the leg cuffs 31, 32 may be in the range of 20 mm to 60 mm, and the elastic elements of the plurality of elastic elements 41, 42 may be distributed over an area of ​​at least 40% of the width of the leg cuff in each leg cuff, preferably at least 50% of the width of the leg cuff. The width of the elasticized portion of the leg cuffs 31, 32 may be in the range of 20 mm to 40 mm.

[0076] The elastic elements of the plurality of elastic elements 41, 42 in each leg cuff 31, 32 may suitably be attached between the first portion 33', 34' and the second portion 33", 34" of the leg cuff fold 35, 37 by means of an adhesive. The adhesive may be applied to the elastic elements, and / or to one or both of the first and second portions 33, 34 of the leg cuff fold 35, 37. Alternatively, the elastic elements may be anchored in the leg cuff fold 35, 37 by means of heat welding or ultrasonic welding, for example as disclosed in WO2021 / 037352A1.

[0077] The elastic elements may be elastic threads, bands, cords, etc. All elastic elements may be of the same type and have the same elastic properties. Optionally, one or more elastic elements arranged in the outer portion of the leg cuff folds 35, 37 may have a greater resistance to stretching than one or more elastic elements arranged in the inner portion of the leg cuff folds 35, 37.

[0078] The linear density (dtex) of the elastic element or elements in the outer portion of the leg cuff fold 35 , 37 may be higher than the linear density of the elastic element or elements arranged in the inner portion of the leg cuff fold 35 , 37 .

[0079] Figure 1 and 4 The absorbent insert 1 in the embodiment of the present invention further comprises an optional waist elastic member 19. The waist elastic member 19 is located at the rear waist edge 2 and extends in the lateral direction only along a portion of the rear waist edge 2. As known in the art, any type of waist elastic member can be used. In addition, the absorbent insert 1 can include a waist elastic member 20 also at the front 3 of the absorbent insert 1.

[0080] Fastening elements in the form of strips of loop material 50, 51 are attached to the garment-facing side of the chassis 18 adjacent the lateral side edges 2, 4 of the front 3 and rear 5 portions of the insert 1, respectively. Figure 1 ,3 and 4. The strips of loop material 50, 51 extend over 50-100% of the lateral sides of the insert 1. The longitudinal extension of each strip of loop material is 10 to 50 mm. The longitudinal extension of the strips of loop material 50, 51 may be greater in the rear portion 5 of the insert 1 than in the front portion 3.

[0081] The continuous production of absorbent articles is well known in the art. A method for producing a disposable absorbent insert 1 for use with a reusable shell 100 may include delivering a continuous precursor of an absorbent insert 1 having an extension in the longitudinal and transverse directions, the precursor having a continuous top sheet material 9 and a continuous liquid-impermeable bottom sheet material 10, and having a plurality of absorbent cores 11 regularly distributed between the top sheet 9 and the bottom sheet 10 materials. The precursor also has a continuous outer cover material 18. The method as disclosed herein then further regularly provides loop material strips 50, 51 to the outwardly facing side of the outer cover material 18 so that it bridges the contours of two adjacent and interconnected inserts 1 each including an absorbent core 11, and cuts the loop material strips 50, 51 and the top sheet 9, bottom sheet 10 and outer cover 18 materials in one cutting operation to separate the connected inserts 1, thereby obtaining a single insert 1 having loop material strips 50, 51 near the lateral side edges 2, 4 of the front 3 and rear 5 of the insert 1, respectively.

[0082] Figure 3 An absorbent insert 1 is disclosed in a reusable shell 2. The reusable shell 2 has longitudinal and transverse side edges and inner and outer surfaces. Figure 3 is an illustration of the reusable outer shell 100 as seen from the inner surface facing the user when worn. The reusable outer shell is provided with complementary fastener elements 50', 51'.

[0083] The reusable shell 2 is a shell that can be reused multiple times. The reusable shell can be a washable shell that can be washed multiple times without unnecessary shrinkage or other damage. The shell can be made of a washable material, such as a washable fabric. The shell can be made of one or more of the following materials: polyester, viscose, polyamide and / or cotton. The shell can be a stretchable shell, i.e., made of a stretchable material. The shell can be an elastic shell that is elastic in the longitudinal direction L and / or the transverse direction T of the shell.

[0084] In one embodiment, in order to releasably attach the absorbent insert 1 to the shell 100, the shell 100 includes a front hook component 50' and a rear hook component 51', which are arranged on the inner surface of the shell 100 and are attached to the front and rear ring members or loop material strips 50, 51 attached to the clothing-facing side of the outer covering layer 18 of the insert 1.

[0085] As in Figure 3 As further seen in FIG. 1 , the wide, elastic leg cuffs 31 , 32 are bulky and form-stable and automatically assume the correct position when the shell and insert are applied to the wearer.

[0086] like Figure 4 and Figure 5 As shown, Figure 1 , 2 and Figure 3 The insert shown may also be provided with upright gatherers 29, 30. A pair of nonwoven barrier cuff strips 21, 22 are arranged to extend in the longitudinal direction L and are symmetrically arranged with one barrier cuff strip 21, 22 on each side of a longitudinal centerline Lc perpendicular to the transverse centerline Lt, each nonwoven barrier cuff strip 21, 22 comprising an upright gatherer portion 21', 22'. The upright gatherer portions 21', 22' of the nonwoven barrier cuff strips 21, 22 are defined between free upright gatherer edges 23, 24 extending in the longitudinal direction L and upright gatherer hinge lines 25, 26 extending in the longitudinal direction L. A pair of raised elasticized upright gatherers 29, 30 comprising the upright gatherer portions 21', 22' of the barrier cuff strips 21, 22 are arranged on the top sheet 9. Thus, the upstanding gatherer portions 21 ′, 22 ′ of the barrier cuff strips 21 , 22 form part of the upstanding gatherer 29 , 30 .

[0087] Each barrier cuff strip 21, 22 is directly attached to the top sheet 9 along a standing gatherer hinge line 25, 26 and has one or more pre-tensioned elastic elements 27, 28 arranged along the free standing gatherer edge 23, 24. The one or more elastic elements may be elastic cords, strings or bands applied at intervals along the free standing gatherer edge 23, 24. In the absorbent insert disclosed herein, the number of elastic elements 27, 28 arranged along the standing gatherer edge 23, 24 is typically 1, 2 or 3. The elastic elements 27, 28 are typically arranged parallel to each other at a spacing of 2 to 5 mm, with the outermost elastic elements being arranged at the standing gatherer edge 23, 24.

[0088] Each leg cuff 31 , 32 is arranged outside the upright gatherer portion 21 ′, 22 ′ of the corresponding barrier cuff strip 21 , 22 .

[0089] Each leg cuff 31, 32 also includes a leg cuff portion 21", 22" of a corresponding nonwoven barrier strip 21, 22. The leg cuff portions 21", 22" of the nonwoven barrier strips 21, 22 are defined between upright gathering piece hinge lines 25, 26 and outer leg cuff edges 43, 44 of the nonwoven barrier strips 21, 22. The outer leg cuff edges 43, 44 of the nonwoven barrier strips 21, 22 are parallel to the fold lines 36, 38 in the leg cuff folds 35, 37 and cover at least one elastic element of the plurality of elastic elements 41, 42. In the embodiment shown in the drawings, the leg cuff portions 21", 22" of the nonwoven barrier strips 21, 22 cover all elastic elements of the plurality of elastic elements 41, 42 in the leg cuff folds 35, 37, and the outer leg cuff edges 43, 44 of the leg cuff portions 21", 22" coincide with the fold lines 36, 38 in the side portions 33, 34 of the outer cover layer 18. It should be understood that the outer leg cuff edges 43 , 44 of the leg cuff portions 21 ″, 22 ″ may not coincide with the fold lines 36 , 38 and may be disposed inboard of the fold lines 36 , 38 in the sides 33 , 34 of the outer cover 18 .

[0090] Figure 6 The second side edge is shown Figure 5 37. A plurality of elastic elements 42, represented by five individual elastic elements, are arranged in the leg cuff fold 37 with a spacing d between the individual elastic elements. The elastic elements are shown with equal spacing between all elastic elements. However, in different parts of the leg cuff 32, the spacing may be different. By way of example, the spacing between the individual elastic elements may be smaller in an outer portion of the leg cuff 32, near the fold line 38, than in an inner portion of the leg cuff 32, closer to the upright gather hinge line 26.

[0091] The leg cuff portion 22″ of the nonwoven barrier cuff strip 22 covers all elastic elements of the plurality of elastic elements 42 in the leg cuff fold 37, but is attached to the upper second portion 34″ of the leg cuff fold 37 only in the area below the second portion 34″ of the leg cuff fold 37, which corresponds to the positions of four elastic elements of the plurality of elastic elements 42 arranged at a certain distance from the fold line 38. The leg cuff portion 22″ of the nonwoven barrier cuff strip 22 is attached to the second portion 34″ of the leg cuff fold 37 by an adhesive 46, so that the outermost portion of the leg cuff portion 22″ of the nonwoven barrier cuff strip 22 is not attached to the leg cuff fold 37. In this way, no adhesive is arranged in close proximity to the side edge of the absorbent insert 1. The adhesive attachment between the leg cuff fold and the leg cuff portion 22″ of the nonwoven barrier cuff strip 22 can increase the structural stability of the leg cuff 32 by increasing the bending resistance of the leg cuff. It should be understood that the adhesive area 46 can extend all the way to the fold line 38 in the leg cuff fold 37.

[0092] As shown in the highly schematic exploded view of the leg cuff 32 Figure 6 As shown, the outermost elastic element of the plurality of elastic elements 42 is positioned at fold line 38 so that there is no excess material outside the outermost elastic element. This may be an ideal positioning of the outermost elastic element. However, due to production tolerances, the positioning of the outermost elastic element in an actual absorbent insert 1 may deviate slightly from Figure 6 Position shown.

[0093] As disclosed herein, the leg cuff portion 22" of the nonwoven barrier cuff strip 22 can be attached to the leg cuff fold 37 using an adhesive that is evenly distributed over the attachment area between the barrier cuff strip 22 and the upper portion 34" of the leg cuff fold 37, thereby forming a uniform attachment between the leg cuff portion 22" of the nonwoven barrier cuff strip 22 and the leg cuff fold 37, so that the contraction force from the spaced-apart pre-tensioned elastic elements 42 in the leg cuff fold 37 is transmitted to the leg cuff portion 22" of the nonwoven barrier cuff strip 22 over the entire attachment area in a substantially equal manner. Therefore, when the elastic element contracts, the leg cuff portion 22" of the nonwoven barrier cuff strip 22 is gathered together with the material in the leg cuff fold 37 and forms soft ripples in the leg cuff 32 in a controlled and neat manner.

[0094] Also like Figure 6 As shown, the second portion 34" of the leg cuff fold 37 is fixed to the backsheet 10 along the backsheet side edge 10" at the inner end 48 of the second portion 34" of the leg cuff fold 37. The inner end 48 is also arranged below the topsheet 9. Figure 2 and Figure 6 As shown, the inner ends 47, 48 of the second portions 33″, 34″ of the side portions 33, 34 are inserted between the top sheet 9 and the back sheet 10 and fixed therebetween. Attachment is performed by adhesive 50. However, it should be understood that the leg cuff portion 22″ of the nonwoven barrier strip 22 may alternatively be attached by heat welding or ultrasonic welding. Figure 3 In the illustrated embodiment, all of the plurality of elastic elements 42 are arranged in the portion of the leg cuff fold 37 where the chassis 10 is not present. While this may be a desired arrangement to provide the leg cuff 32 with maximum breathability, the chassis 10 may alternatively extend into the leg cuff 32 such that it overlaps the innermost elastic element of the plurality of elastic elements 42.

[0095] exist Figure 7In the configuration shown, the leg cuffs 31, 32 each include a side portion 33, 34 of the outer cover layer that extends in the transverse direction outside the corresponding side edge 10', 10" of the backsheet, and the side portions 33, 34 of the outer cover layer 18 are folded back onto themselves along fold lines 36, 38 that extend in the longitudinal direction L and divide the side portions 33, 34 of the outer cover layer 18 into a first portion 33', 34' and a second portion 33", 34", the first and second portions 33', 33" ; 34', 34" together form a leg cuff fold 35, 37, which has a free edge defined by a fold line 36, 38 and a leg cuff width W in the transverse direction T defined between the free edge of the leg cuff fold line 36, 38 and the upright gathering portion hinge line 25, 26. The first parts 33', 34' of the side parts 33, 34 of the outer covering layer 18 are adjacent to the central part 18' of the outer covering layer 18, and the central part 18' of the outer covering layer 18 covers the backsheet 10.

[0096] like Figure 7 As shown, as seen in the direction from the top sheet 9, the first parts 33', 34' of the side parts 33, 34 of the outer cover layer 18 constitute the upper parts of the leg cuff folds 35, 37, and as seen in the direction from the top sheet 9, the second parts 33", 34" of the side parts 33, 34 of the outer cover layer 18 constitute the lower parts of the leg cuff folds 35, 37. The lower parts of the leg cuff folds 35, 37 are folded back below the upper parts of the leg cuff folds 35, 37 and attached to the outer cover layer 18.

[0097] The following paragraphs describe the absorbent core, topsheet and backsheet which are applicable to all the embodiments described above.

[0098] Absorbent core 11 is arranged between top sheet 9 and back sheet 10, and is arranged to absorb liquid, such as urine or other body fluids, that has passed through top sheet 9. Absorbent core 11 can be a single layer structure or can be a layered structure. Absorbent core 11 can include any conventional material suitable for absorbing the body excreta discharged, such as cellulose fluff pulp, tissue paper layer, high absorbent polymer (superabsorbent), absorbent foam material including hydrogel foam material, nonwoven material etc. Absorbent core can include non-absorbent parts, such as reinforcing element, forming element, adhesive etc. Various types of liquid receiving and liquid distribution materials can also be included in the core.

[0099] The absorbent core 11 can be a three-dimensionally shaped core with different amounts of absorbent material in different parts of the core. The core can be provided with features such as embossing, fluid collection chambers, and fluid distribution channels. The properties of the absorbent core, such as density, the amount of absorbent material, and the absorption capacity, can also vary in different parts of the absorbent core. The absorbent core 11 can include a core cover, sandwiching the absorbent material between an upper core cover layer and a lower core cover layer. Such a core cover can be a tissue material or a nonwoven material provided in addition to the top sheet 9 and the back sheet 10.

[0100] Liquid-permeable top sheet 9 may comprise or be made of nonwoven material. Other suitable top sheet materials include tow fibers, porous foams, open-cell plastic films and laminates and combinations of such materials. The material most suitable as top sheet material is soft and non-irritating to the skin, is easily penetrated by body fluids, and shows low rewetting of the body fluids absorbed.

[0101] The liquid impermeable backsheet 10 may be any conventional liquid impermeable material, such as a thin plastic film, such as a polyethylene or polypropylene film. The backsheet material may be breathable to allow vapor to escape from the absorbent body while still preventing liquid from passing through the backsheet material.

Claims

1. A disposable absorbent insert (1) for a reusable shell (100), the insert (1) having an extension in the longitudinal direction (L) and in the transverse direction (T), longitudinal side edges (6, 8) and transverse side edges, and having a front part (3), a rear part (5) and a crotch part (7) located between the front part (3) and the rear part (5), and comprising: - a liquid-impermeable backsheet (10) having a backsheet first side edge (10') and a backsheet second side edge (10"); - an absorbent core (11) arranged between a liquid-permeable top sheet (9) facing the user and a liquid-impermeable back sheet (10), - a nonwoven outer cover layer (18) covering the backsheet (10) and forming the outer surface of the insert (1); Characterized in that the insert (1) has - a pair of leg cuffs (31, 32) extending in the longitudinal direction (L) and arranged symmetrically along the longitudinal side edges (6, 8), and wherein Each leg cuff (31, 32) comprises: - a side portion (33, 34) of the outer covering layer (18) folded back on itself along a folding line (36, 38), said folding line extending in the longitudinal direction (L) and dividing the side portion (33, 34) of the outer covering layer (18) into a first portion (33', 34') and a second portion (33", 34"), the first and second portions (33', 33", 34', 34") together forming a leg cuff fold (35, 37), - a plurality of spaced apart pre-tensioned elastic elements (41, 42) extending in the longitudinal direction (L) inside the leg cuff fold (35, 37) and attached between the first portion (33', 34') and the second portion (33", 34") of the leg cuff fold (35, 37).

2. The disposable absorbent insert (1) according to claim 1, wherein: The side portions (33, 34) of the outer cover layer extend in the transverse direction (T) beyond the respective side edges (10', 10") of the backsheet.

3. A disposable absorbent insert (1) according to claim 1 or 2, wherein all or substantially all of the multiple elastic elements in each leg cuff (31, 32) are arranged in an outer part of the leg cuff (31, 32) located laterally outside the liquid-impermeable backing film (10).

4. A disposable absorbent insert (1) according to any of the preceding claims, wherein the elastic elements of the plurality of elastic elements (41, 42) are attached between the first portion (33', 34') and the second portion (33", 34") of the leg cuff fold (35, 37) by an adhesive.

5. A disposable absorbent insert (1) according to any one of the preceding claims, wherein: A first portion (33', 34') of the side portion (33, 34) of the outer covering layer (18) is adjacent to a central portion (18') of the outer covering layer (18), the central portion (18') of the outer covering layer (18) covering the backsheet (10), and wherein a second portion (33", 34") of the side portion of the outer covering layer (18) is a folded portion of the side portion (33, 34) of the outer covering layer (18).

6. A disposable absorbent insert (1) according to any one of the preceding claims, wherein the plurality of elastic elements (41, 42) in each leg cuff (31, 32) consists of at least 3 elastic elements, preferably at least 4 elastic elements.

7. A disposable absorbent insert (1) according to any one of the preceding claims, wherein: The elastic elements (41, 42) are spaced 1 mm to 8 mm apart in the transverse direction (T), preferably 3 mm to 8 mm apart.

8. A disposable absorbent insert (1) according to any one of the preceding claims, wherein: The plurality of elastic elements (41, 42) are arranged at least along the entire longitudinal length of the crotch region (7), and the longitudinal length of the plurality of elastic elements (41, 42) is smaller than the total longitudinal length of the insert (1).

9. A disposable absorbent insert (1) according to any one of the preceding claims, wherein the first part (33', 34') of the side parts (33, 34) of the outer covering layer (18) as seen from the direction of the top sheet (9) is the lower part of the leg cuff fold (35, 37), and the second part (33", 34") of the side parts (33, 34) of the outer covering layer (18) as seen from the direction of the top sheet (9) is the upper part of the leg cuff fold (35, 37).

10. The disposable absorbent insert (1) according to claim 9, wherein: The second portion (33", 34") of the side portion (33, 34) comprises the longitudinal edge of the outer covering layer (18), and wherein the longitudinal edge of the second portion (33", 34") of the side portion (33, 34) is the inner end (47, 48) fixed between the top sheet (9) and the back sheet (10).

11. A disposable absorbent insert (1) according to any one of the preceding claims, wherein the insert (1) comprises a longitudinally extending first upstanding gathering member (29) and a longitudinally extending second upstanding gathering member (30).

12. The disposable absorbent insert (1) according to claim 11, wherein The upright gathering members (29, 30) are attached to the top sheet (9).

13. A disposable absorbent insert (1) according to any one of claims 11-12, wherein the insert (1) also includes a pair of non-woven barrier cuff strips (21, 22), which extend in the longitudinal direction (L) and are symmetrically arranged with one barrier cuff strip (21, 22) on each side of the longitudinal center line (Lc), each non-woven barrier cuff strip (21, 22) including upright gathering piece portions (21', 22') forming a first upright gathering piece (29) and a second upright gathering piece (30), respectively, each upright gathering piece (29, 30) being defined between a free upright gathering piece edge (23, 24) extending along the longitudinal direction (L) and an upright gathering piece hinge line (25, 26) extending along the longitudinal direction (L), and wherein the barrier cuff strips (21, 22) are attached to the top sheet (9) along the upright gathering piece hinge line (25, 26).

14. The disposable absorbent insert (1) according to claim 13, wherein: The upright gathering piece (29, 30) has one or more pre-tensioned elastic elements (27, 28) arranged along the free upright gathering piece edge (23, 24).

15. A disposable absorbent insert (1) according to any one of claims 13-14, wherein the non-woven barrier cuff strip (21, 22) includes a leg cuff portion defined between the upright gathering piece hinge line (25, 26) and the outer leg cuff edge (43, 44) of the non-woven barrier cuff strip (21, 22), the outer leg cuff edge (43, 44) of the non-woven barrier cuff strip (21, 22) is parallel to the folding line (36, 38) in the leg cuff folding portion (35, 37), and the leg cuff portion (21", 22") of the non-woven barrier cuff strip (21, 22) covers at least one elastic element of the multiple elastic elements (41, 42).

16. A disposable absorbent insert (1) according to any one of claims 11-15, wherein the leg cuff folding portion (35, 37) has a free edge defined by the folding line (36, 38) and a leg cuff width (W) in the transverse direction (T) between the folding line (36, 38) in the leg cuff folding portion (35, 37) and the upright gathering portion hinge line (25, 26).

17. A disposable absorbent insert (1) according to any one of claims 15-16, wherein the leg cuff portion (21", 22") of each non-woven barrier cuff strip (21, 22) is attached to a corresponding leg cuff fold (35, 37), wherein the leg cuff portion (21", 22") of the non-woven barrier cuff strip (21, 22) covers all or substantially all of the multiple elastic elements (41, 42) in the leg cuff fold (35, 37).

18. A disposable absorbent insert (1) according to any one of claims 13-17, wherein the nonwoven barrier cuff strips (21, 22) are a single layer of nonwoven material.

19. The disposable absorbent insert (1) according to any one of the preceding claims, wherein the nonwoven outer cover layer (18) is a single layer of nonwoven material.

20. A disposable absorbent insert (1) according to any one of the preceding claims, wherein the insert (1) is provided with fastening elements (50, 51) to fasten the insert (1) to a reusable housing (100).

21. A disposable absorbent insert (1) according to claim 20, wherein the fastening elements (50, 51) are strips of loop material, which are attached to the garment-facing side of the outer covering layer (18) near the lateral side edges (2, 4) of the front (3) and the rear (5) of the insert (1), respectively.

22. A disposable absorbent insert (1) according to any one of the preceding claims, wherein the insert (1) has no side flaps arranged at the waist edge of the front part and has no side flaps arranged at the waist edge of the rear part.

23. The disposable absorbent insert (1) according to any one of the preceding claims, wherein the insert (1) is free of a waistband.

24. The disposable absorbent insert (1) according to any one of the preceding claims, wherein the insert (1) has a rectangular shape.

25. A wearable absorbent article (101) comprising a reusable shell (100) to be worn by a wearer and a disposable absorbent insert (1) according to any one of the preceding claims.

Images