Reusable absorbent carrier insert and disposable insert combinations, assemblies, and methods of assembly

Abstract

Embodiments relate to combinations, assemblies, and methods of assembly of reusable absorbent carrier inserts and disposable insert combinations that include reusable absorbent carrier inserts and disposable inserts. The reusable absorbent carrier insert includes a carrier portion and has a first capacity-to-thickness ratio. The disposable insert includes an absorbent material and has a second capacity-thickness ratio. The disposable insert is configured to be received and received within the carrier portion of the reusable absorbent carrier insert to form a reusable absorbent carrier insert and disposable insert combination. The first length is greater than the second length, the first width is greater than the second width, and the first capacity-thickness ratio is less than the second capacity-thickness ratio.

Description

Technical Field

[0001] The present disclosure relates generally to reusable absorbent carrier insert and disposable insert combinations and absorbent assemblies including the same, and particularly to systems and methods for forming reusable combinations and assemblies. Background Art

[0002] Infants and other incontinent individuals wear absorbent articles and components such as diapers or other absorbent pants to receive and contain urine and other body fluids such as feces. Such absorbent articles may include reusable absorbent inserts. However, although reusable absorbent inserts can be washed for reuse, they may require a long time to dry after such washing. Conventional reusable absorbent inserts may have disadvantages in terms of capacity and dryness compared to disposable articles using superabsorbent polymers. This disadvantage can be compensated by using multi-layer fabrics, which make the inserts thicker and therefore more bulky and less conformable when worn on an infant with a diaper outer cover, and also require a long time to dry after washing.

[0003] Based on the foregoing, there is a need for alternative absorbent inserts and assemblies and methods of use and manufacture that more effectively absorb body fluids and allow for reduced drying times after washing, as well as improved containment and dryness and improved fit. Summary of the invention

[0004] According to the subject matter of the present disclosure, a reusable absorbent carrier insert and a disposable insert combination includes a reusable absorbent carrier insert and a disposable insert. The reusable absorbent carrier insert includes a carrier portion, a first length measured along the central longitudinal axis of the reusable absorbent carrier insert, and a first width measured along the central lateral axis of the reusable absorbent carrier insert. The reusable absorbent carrier insert has a first capacity-thickness ratio. The disposable insert includes absorbent material, a second length measured along the central longitudinal axis of the disposable insert, and a second width measured along the central lateral axis of the disposable insert. The disposable insert has a second capacity-thickness ratio. The reusable absorbent carrier insert is configured to receive and hold the disposable insert. The disposable insert is configured to receive and be accommodated within the carrier portion of the reusable absorbent carrier insert to form a reusable absorbent carrier insert and disposable insert combination. The first length is greater than the second length, the first width is greater than the second width, and the first capacity-thickness ratio is less than the second capacity-thickness ratio.

[0005] In another embodiment, absorbent pants include an outer shell layer, the outer shell layer including an inner pocket, an inner portion, or a combination thereof; and a reusable absorbent carrier insert and a disposable insert combination, the reusable absorbent carrier insert and the disposable insert combination being configured to be received at least in one of the following: in the inner pocket of the outer shell layer of the absorbent pants, on top of the inner portion of the outer shell layer, or a combination thereof. The reusable absorbent carrier insert and the disposable insert combination include a reusable absorbent carrier insert and a disposable insert. The reusable absorbent carrier insert includes a carrier portion, a first length measured along the central longitudinal axis of the reusable absorbent carrier insert, and a first width measured along the central lateral axis of the reusable absorbent carrier insert, wherein the reusable absorbent carrier insert has a first capacity-thickness ratio. The disposable insert includes an absorbent material, a second length measured along the central longitudinal axis of the disposable insert, and a second width measured along the central lateral axis of the disposable insert, wherein the disposable insert has a second capacity-thickness ratio. The reusable absorbent carrier insert is configured to receive and hold the disposable insert. The disposable insert is configured to be received and contained within the carrier portion of the reusable absorbent carrier insert to form a reusable absorbent carrier insert and disposable insert combination. The first length is greater than the second length, the first width is greater than the second width, and the first volume-to-thickness ratio is less than the second volume-to-thickness ratio.

[0006] In yet another embodiment, a method of forming a reusable absorbent carrier insert and a disposable insert combination includes receiving a disposable insert including an absorbent material within a carrier portion of the reusable absorbent carrier insert, and accommodating the disposable insert in a self-locking configuration within the carrier portion when received. The reusable absorbent carrier insert has a first volume-to-thickness ratio, the disposable insert has a second volume-to-thickness ratio, and the first volume-to-thickness ratio is less than the second volume-to-thickness ratio. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The embodiments described in the drawings are illustrative and exemplary in nature and are not intended to limit the subject matter defined by the claims. The detailed description of the following exemplary embodiments can be understood when read in conjunction with the following drawings, in which similar structures are represented by similar reference numerals, and in which:

[0008] Figure 1 is an interior side view of an absorbent assembly according to one or more embodiments shown and described herein, showing an interior portion facing the wearer;

[0009] Figure 2 yes Figure 1 an exterior side view of an absorbent assembly showing an exterior portion facing away from a wearer;

[0010] Figure 3 yes Figure 1 An interior side view of an absorbent assembly of , showing a reusable absorbent carrier insert partially disposed within an interior pocket defined at one end of an outer shell layer of the absorbent assembly;

[0011] Figure 4 is an interior side view of another absorbent assembly according to one or more embodiments shown and described herein, showing a reusable absorbent carrier insert partially disposed within an interior pocket defined at a side edge of an outer shell layer of the absorbent assembly;

[0012] Figure 5A is a schematic diagram of a reusable absorbent carrier insert and a disposable insert combination including a belt having two open ends according to one or more embodiments shown and described herein;

[0013] Figure 5B is a schematic diagram of a reusable absorbent carrier insert and disposable insert combination including a pair of strips having two open ends according to one or more embodiments shown and described herein;

[0014] Fig. 6A is a schematic diagram of a reusable absorbent carrier insert and disposable insert combination including a pouch having a partially extending longitudinal cutout according to one or more embodiments shown and described herein;

[0015] Figure 6B is a schematic diagram of a reusable absorbent carrier insert and disposable insert combination including a pouch with a fully extended longitudinal cutout according to one or more embodiments shown and described herein;

[0016] Figure 7 is a schematic diagram of a reusable absorbent carrier insert and disposable insert combination including a strip having two open ends and a pouch having a partially extending longitudinal cutout according to one or more embodiments shown and described herein;

[0017] Figure 8 is a schematic diagram of a reusable absorbent carrier insert and disposable insert combination including a pouch having a pair of flaps according to one or more embodiments shown and described herein;

[0018] Fig. 9 is a schematic diagram of a reusable absorbent carrier insert and disposable insert combination including a pouch with a diagonal cutout according to one or more embodiments shown and described herein; and

[0019] Fig.10is a schematic illustration of a reusable absorbent carrier insert and disposable insert combination including a pouch having a partially extending longitudinal cut configured to be folded over the disposable insert according to one or more embodiments shown and described herein. DETAILED DESCRIPTION

[0020] Reference will now be made in detail to embodiments of reusable absorbent carrier inserts and disposable insert combinations and assemblies, examples of which are shown in the accompanying drawings. Embodiments herein relate to alternative absorbent insert combinations and assemblies and methods of use and manufacture to more effectively absorb body fluids and allow for reduced drying time after cleaning. Whenever possible, the same reference numerals are used throughout the drawings to represent the same or similar parts. Various embodiments of such absorbent patents, systems and methods will be described in more detail herein with specific reference to the accompanying drawings.

[0021] The reusable absorbent carrier insert can be made of various foldable and non-foldable configurations, and can be made of textile materials or fabrics, fleece fabrics, terry fabrics, micro-terry fabrics, cotton, bamboo-based, lyocell or a combination thereof. The material can be made of synthetic yarn or yarn of natural origin, including but not limited to PET, PLA, cotton, bamboo, hemp, lyocell. In addition, the material can have any fabric structure, including but not limited to knitting, weaving or non-woven. Durable multiple layers can be fastened together such as by lock seams, tapes, glues, mechanical bonding or similar fastening objects. The layers of the reusable absorbent carrier insert can be made of textile materials or fabrics, such as terry fabrics, micro-terry fabrics, cotton, bamboo-based, lyocell or a combination thereof. In an embodiment, the reusable absorbent carrier insert can be made of one or more fabric types, such as but not limited to the types provided by weaving, knitting, crocheting, felting or other non-woven types. Some fabric types achieved through weaving, knitting, and warp knitting may include, but are not limited to, terry cloth, waffle fabric, jacquard fabric, jersey, 3D fabric, etc. Material types may include, but are not limited to, (1) natural fibers, such as cotton, linen, silk, wool, minerals, etc.; (2) artificial fibers, such as polyester, polypropylene, recombinant cellulose (such as viscose and / or lyocell), etc., or (3) combinations thereof, and / or may include (4) specialty fibers, such as microfibers, hollow fibers, etc.

[0022] The "absorbent article" of the absorbent assembly described herein means a device for absorbing and containing body exudates, and more specifically means a device that is placed close to or adjacent to the body of the wearer for absorbing and containing various exudates discharged by the body. Exemplary absorbent articles include diapers, training pants, pull-on pants diapers (i.e., diapers with preformed waist openings and leg openings such as shown in U.S. Patent No. 6,120,487), refastenable diapers or pants diapers, incontinence briefs and underwear, diaper fasteners and liners, women's hygiene underwear such as panty liners, absorbent inserts, etc. Non-limiting examples of absorbent articles are disclosed in U.S. Patents 8,998,870, 9,089,456, 8,435,223, 9,011,402, 8,808,263, 8,759,605, 8,932,273, and 9,078,789.

[0023] "Absorbent insert" and "insert" and "reusable absorbent (carrier) insert" mean a component of a wearable absorbent article that is suitable for containing and / or absorbing urine, feces, menstrual fluids, or any combination thereof, and that is adapted to be installed and removed as a modular unit from the outer shell layer of the absorbent assembly described herein.

[0024] "Shell layer" or "outer cover" means the component of a wearable absorbent article that is the absorbent assembly and is adapted to be worn about the lower torso of the wearer and is adapted to support an absorbent insert and hold the insert close to the wearer's body. In various embodiments, the outer cover is reusable.

[0025] "Reusable" when referring to a component means that the component is adapted to function as new after initial use for its intended purpose without substantial destruction of any necessary portion of the component. For example, a reusable outer cover means that the outer cover is adapted to allow removal of at least a first insert and replacement thereof with at least a second insert without substantial destruction of any necessary portion of the outer cover to provide substantially like new functionality of the outer cover, and without requiring any repair or reconstruction after replacement of such inserts.

[0026] With respect to absorbent (which may be superabsorbent) articles, "disposable" means absorbent articles that are not generally intended to be washed or otherwise restored or reused as absorbent articles (i.e., they are intended to be discarded after a single use, and preferably can be recycled, composted, or otherwise discarded in an environmentally compatible manner). Disposable absorbent articles generally include adhesives between layers and / or elements to hold the article together (e.g., the ears, side panels, and belts are bonded to the base structure by adhesives, and the ears, side panels, belts, and layers of the base structure are bonded together using adhesives). Alternatively, heat and / or pressure bonding is used with or in place of adhesives. In this case, a portion of the material layer may become partially melted and pressed together so that once cooled, they are physically bonded together. Nonwovens (including, for example, polypropylene, polyethylene, etc.) adhesives (including, for example, styrene block copolymers (e.g., SIS, SBS)) and absorbent gelling materials (AGM) account for more than 50%, more than 75%, and generally more than 90% of the weight of the disposable absorbent article. And, the core including AGM is usually kept in the infrastructure in a way that will encapsulate and contain AGM under normal conditions. Such disposable (super) absorbent articles usually have an absorption capacity greater than about 100mL of fluid, and can have a capacity of up to about 500mL of fluid or more. Suturing (including using thread) and / or woven materials are usually not used to make disposable absorbent articles. If suturing or woven materials are used, they constitute a very small percentage of disposable absorbent articles. Some landing areas of disposable absorbent articles for fasteners may include woven materials, but other parts of disposable absorbent articles usually do not include woven materials. Absorbent materials may include superabsorbent polymers, mixtures of superabsorbent polymers and air felt, only air felt and / or foam. In some cases, absorbent materials may include at least 80%, at least 85%, at least 90%, at least 95%, at least 99%, or at most 100% superabsorbent polymers by weight of absorbent materials. In such cases, absorbent materials may be free of air felt, or at least mostly free of air felt--in such cases, superabsorbent materials may include AGM that can be held in place by adhesives such as thermoplastic adhesives.

[0027] In all respects, and with reference to Figures 1 to 4 , the absorbent assembly 20 includes an outer shell layer 21 having a front portion 11 and a rear portion 12 connected by a middle portion 14, the middle portion forming a crotch region between a front waist region defined by the front portion 11 and a rear waist region defined by the rear portion 12. The outer shell layer 21 may include a Figure 1 The inner piece and Figure 2 The outer sheet of the present invention has intermediate elastic strips 101 and 102. Non-limiting examples of outer shell layers are disclosed in US Pat. Nos. 9,387,138 and 8,435,223.

[0028] The shell layer 21 and / or its layers or portions may be made of any durable or semi-durable knitted, woven or nonwoven textile or textile-like material that is suitably compatible with the skin of the intended wearer, and may include an elastomeric material. In an embodiment, the reusable absorbent carrier insert 15, 245 described herein and / or its layers or portions may be made of any durable or semi-durable knitted, woven or nonwoven textile or textile-like material that is suitably compatible with the skin of the intended wearer, and may include an elastomeric material. The shell layer 21 may be formed of a single layer of durable or semi-durable material, or may have two or more layers in the front and / or back regions. Suitable examples are described in U.S. Application Serial Nos. 12 / 687,493; 12 / 687,412; 12 / 687,528; and 12 / 687,425 (all to Roe et al.). Non-limiting examples of fibers, nonwovens, and laminates of nonwovens and films that may be considered for use as semi-durable outer cover materials may be found in U.S. Patent Nos. 7,223,818; 7,211,531; 7,060,149; 6,964,720; 6,905,987; 6,890,872; 6,884,494; 6,878,64 7 and 5,518,801, and U.S. Published Application Nos. 2008 / 0319407; 2008 / 0045917; 2007 / 0293111; 2007 / 0287983; 2007 / 0287348; 2007 / 0249254; 2007 / 0203301 and 2005 / 0164587. In some embodiments, the inner, wearer-facing side and outer, garment-facing side surfaces of the shell layer 21 can be formed of the same material. However, because the functional requirements of the garment-facing surface and the wearer-facing surface are different, it may be desirable that the outer surface include different materials.

[0029] In a non-limiting example, the wearer-facing surface of the shell layer 21 may be formed by a first material or a first material combination (hereinafter collectively referred to as "first material"). The selected material may include hydrophilic fibers or fibers treated to be hydrophilic. This may be desirable in some cases to make the material forming the wearer-facing surface more easily absorb liquid or permeate liquid. This can be used to provide supplementary absorption in the shell layer 21 in the case of liquid exudates escaping the insert, thereby reducing the possibility that the shell layer 21 will leak. Alternatively, it can provide a way to communicate to the user that the liquid exudates have escaped the insert, that is, by causing the wetness to be transferred to the outer cover, so that the wearer senses the wetness and / or is visible on the outer surface. Alternatively, it can be used to provide a layer that tends to wick moisture away from the skin in order to obtain a drier, more comfortable feeling. Additionally or alternatively, it may be desirable to form the wearer-facing surface by a porous material to promote the transfer of exudates through the wearer-facing surface and transfer to the absorbent insert. In some non-limiting examples, the material may include fibers having hydrophobic properties, thereby providing enhanced liquid containment properties to the wearer-facing layer.

[0030] The garment-facing surface of the outer cover may be formed of a second material or a combination of second materials (hereinafter collectively referred to as "second material"). The selected material may include fibers having hydrophobic properties, thereby providing enhanced liquid-holding properties to such layers, or may include liquid-impermeable materials. However, in another example, in some cases, it may be desirable that the selected material include hydrophilic fibers or fibers treated to be hydrophilic so as to cause the material to absorb liquid more easily. This can be used to provide supplemental absorption within the outer cover in the event that liquid exudates escape the insert, or to provide a way to communicate to the user that liquid exudates have escaped the insert. Alternatively, in some cases, it may be desirable that the selected material have soft tactile properties so as to have a pleasant feel that is attractive to the user and / or wearer. The material may also be selected so as to have a desired appearance, including but not limited to coloring, gloss and / or texture.

[0031] The first material and the second material may differ in one of the group consisting of: texture, thickness, elasticity, opacity, water resistance, absorbency, breathability, and combinations thereof.

[0032] In a non-limiting example, the shell layer 21 can be reversible so that both surfaces are suitable for use as a wearer-facing surface and a garment-facing surface. For example, this can provide the wearer with a change in visible graphics or color, texture, and / or breathability to the skin, liquid wicking properties, etc. The layers or other elements of the shell layer 21 can be joined to each other via any suitable mechanism, including, for example, adhesives, mechanical bonds, ultrasonic bonds, stitching, stitching, hemming, trimming, etc.

[0033] In a non-limiting example, the elasticized waist feature of the shell layer 21 includes an elastic strand or ribbon joined to a nonwoven and / or textile layer. In another non-limiting example, the elasticized waist feature includes a laminate of one or more textile layers and / or nonwoven layers and one or more elastic films. If the elastic material is tightened before lamination, the elasticized waist element may include one or more wrinkles. In other non-limiting examples, the layers of the elastic laminate may be joined and subsequently activated under zero applied strain. In an alternative embodiment, the waist feature may be non-elastic. In such a configuration, the waist feature may provide additional anchoring around the waist of the wearer. In some embodiments, the elastic element is attached to the shell layer 21 only at or near one or both of its respective ends, for example, in a pouch, tube or envelope structure formed by an outer cover material-referred to herein as an "elastic drawstring". The shell layer 21 may also include anchoring supplements, strips or its system, as described in more detail in U.S. Patent No. 8,932,273.

[0034] Reference again Figure 1 , the inner portion facing the wearer may include an opening 13 defining an inner pocket 45A ( Figure 3 ) to receive a reusable absorbent (carrier) insert 15 ( Figure 3 )(exist FIG. 5A to FIG. 10 In the in-use configuration, the outer shell layer 21 may at least partially enclose the reusable absorbent insert 15, such as Figure 3 to Figure 4 As shown in , a pocket 45 is formed in which the absorbent insert is located during use. In an embodiment, the outer shell layer 21 may include a single layer including an inner side facing the wearer, and the reusable absorbent inert 15 is located on top of the inner side. As a non-limiting example, Figure 3 The reusable absorbent insert in FIG. 1 is shown as being partially disposed in an inner pocket 45A defined at one end of the front portion 11 of the outer shell layer of the absorbent assembly. The inner pocket 45A may be defined anywhere within the inner sheet, including, but not limited to, for example, at one end of the back portion 12, along a side edge (e.g., Figure 4 The inner sheet may be a fleece material made of polyester or a similar material. As described in further detail below, the reusable absorbent insert 15 may be made of multiple layers of cotton or a reusable liner.

[0035] Figure 2 The outer portion of the outer shell layer facing away from the wearer is shown. The elongated wings 126 and 127 ( Figure 1) are configured to be fastened to the fasteners 112, 113 and 114 of the front portion 11 when the shell layer is in a folded fastened configuration for the wearer. In an embodiment, the fasteners can be buckles or other suitable fastening mechanisms. Non-limiting examples of engageable fastening and receiving components include belt tabs, hook and loop fastening components, interlocking fasteners such as tabs and grooves, buckles, buttons, buckles and / or hermaphroditic fastening components. Some exemplary surface fastening systems are disclosed in the following U.S. Patents 3,848,594, 4,662,875, 4,846,815, 4,894,060, 4,946,527, 5,151,092 and 5,221,274.

[0036] As described above, in the configuration of use of the present invention, the shell layer 21 at least partially encapsulates the absorbent insert 15, forming a pocket 45, in which the absorbent insert is located during use. When the absorbent insert 15 is completely positioned in the pocket 45 by design, the surface of the shell layer 21 facing the wearer can cover at least about 60%, or at least about 75%, or at least about 80%, or at least about 90%, or about 60% to about 100% of the surface area of ​​the absorbent insert 15, and each 5% increment is listed for the range. In some non-limiting examples, the width of the surface of the shell layer 21 facing the wearer is greater than the width of the absorbent insert 15 on most or all of the length of the absorbent insert. Additionally or alternatively, when the absorbent insert 15 is completely positioned in the pocket 45 by design, the surface of the shell layer 21 facing the clothes can cover at least about 60%, or at least about 75%, or at least about 80%, or at least about 90%, or about 60% to about 100% of the surface area of ​​the absorbent insert 15, and each 5% increment is listed for the range. In some non-limiting examples, the width of the garment-facing surface of shell layer 21 is greater than the width of absorbent insert 15 over most or all of its length.

[0037] like Figure 1 and Figure 3 to Figure 4 As shown, the shell layer 21 includes one or more openings 13 capable of receiving the absorbent insert 15. The size and shape of the openings 13 are set to allow the user to insert the absorbent insert 15 into the bag 45. In various embodiments, the opening 13 includes a maximum longitudinal length Lo that is at least about 50%, or at least about 60%, or at least about 70%, or about 50% to about 100%, or about 55% to about 85%, or about 60% to about 75% of the length Lc of the shell layer 21, with each 5% increment listed for each range.

[0038] The one or more openings 13 may include at least one longitudinally extending opening that defines a pocket, such as the inner pocket 45B ( Figure 4). Longitudinally extending means that the opening extends more in the longitudinal dimension than in the lateral dimension. For the purpose of longitudinal extension, the longitudinal direction includes directions within 40 degrees of the maximum linear dimension in the xy plane of the shell layer 21. The longitudinally extending opening may be present in the crotch region. The longitudinally extending opening may extend into one or both of the front region and the back region.

[0039] The size and shape of the opening 13 are set so that once the absorbent insert 15 is inserted, the absorbent insert will be retained in the inner pocket 45. For example, the opening 13 can be smaller than the insert 15 in one or more dimensions. Additionally or alternatively, the second edge of the opening 13 can be spaced apart from the edge of the opening 13 so that there is less than 10 mm of void space above or below the absorbent insert 15 within the pocket 45 in the z-direction.

[0040] The opening 13 may be sealable so that it may be closed or repeatedly opened and reclosed. In a non-limiting example, the first edge and / or the second edge may include means for attaching to each other, including any of the above-mentioned fastening components and / or receiving components and a pressure sensitive adhesive. Additionally or alternatively, the first edge or the second edge can wrap around the longitudinal edge and be secured to an exterior surface.

[0041] Reference again Figure 3 to Figure 4 In one embodiment, the reusable absorbent insert 15 can be designed to contain and / or absorb body exudates and can be made of a pliable material, as will be further described below. The reusable absorbent insert 15 can be made of a washable material such as cloth, or made of a material suitable for composting such as cellulose. In other embodiments, the absorbent insert can be disposable and made of materials commonly found in disposable absorbent articles. The reusable absorbent insert 15 can have a top sheet and a back sheet that can be joined together. The absorbent core can be disposed between the top sheet and the back sheet.

[0042] The top sheet is typically a portion of the insert 15 that can be positioned to at least partially contact or be in close proximity to the wearer. Suitable top sheets can be made from a wide range of materials, such as porous foams; reticulated foams; open-cell plastic films; or woven or nonwoven webs of natural fibers (e.g., wood fibers or cotton fibers), synthetic fibers (e.g., polyester fibers or polypropylene fibers), or a combination of natural and synthetic fibers. The top sheet is typically compliant, soft-feeling, and non-irritating to the wearer's skin. Typically, at least a portion of the top sheet is liquid permeable, thereby allowing liquid to easily penetrate through the thickness of the top sheet. The top sheet may include one or more apertures.

[0043] As is known in the art, any portion of the topsheet may be coated with a lotion, antimicrobial agent or skin care composition. The topsheet may be fully or partially elasticized or may be shortened to provide a void space between the topsheet and the core. The topsheet, backsheet or any portion of the topsheet or backsheet may be embossed and / or matte finished to provide a more cloth-like appearance.

[0044] The backsheet is typically the outer lining portion of the insert 15 that forms its garment-facing surface and prevents exudates absorbed and contained within the insert 15 from wicking through the outer shell 21 and soiling the outer shell. The backsheet may include one or more nonwoven materials, films, elastomeric films, foams, strands, or a combination of these or other suitable materials with nonwoven materials or synthetic films. In a non-limiting example, the backsheet is a laminate of an elastomeric material (such as a film) and a nonwoven material.

[0045] In various embodiments, the backsheet is substantially water-impermeable. Suitable backsheet materials include nonwoven materials and / or films. The material of other suitable backsheets may include a breathable material that allows steam to escape from insert 15 while still preventing effluent from passing through the backsheet. Exemplary breathable materials may include materials such as woven webs, nonwoven webs, composite materials (such as nonwoven webs of film coatings) and microporous membranes.

[0046] Other suitable materials and / or manufacturing techniques can be used to provide a suitable backsheet, including but not limited to surface treatments, specific film selection and processing, specific filament selection and processing. The backsheet can be joined to the topsheet, absorbent core, or any other element of the insert 15 by any suitable attachment mechanism known in the art. For example, the attachment mechanism can include a continuous adhesive line or layer, a patterned adhesive layer, or a series of separate adhesive lines, spirals, or spots.

[0047] As described above, the insert 15 may have an absorbent core disposed within an envelope-like structure formed by the top sheet and the back sheet. The absorbent core may include a material suitable for absorption and for washing and reusing the insert. In non-limiting examples, the insert 15 may be formed of cotton, fleece, flannel, felt, nylon, polyester, terry cloth, and combinations thereof.

[0048] FIG. 5A to FIG. 10 Various embodiments of a reusable absorbent (carrier) insert 15 are shown, which is described herein as a reusable absorbent carrier insert 245, which is combined with a disposable insert 345 to form a reusable absorbent carrier insert and disposable insert combination 145. As described above, the reusable absorbent carrier insert 15, 245 (and thus the reusable absorbent carrier insert and disposable insert combination 145) is configured to be inserted into the interior pocket 45, 45A, 45B of the outer shell layer 21 of the absorbent assembly 20.

[0049] Therefore, in embodiments herein, and as will be described in more detail below, FIG. 5A to FIG. 10 The reusable absorbent carrier insert and disposable insert combination 145 includes a reusable absorbent carrier insert 245 and a disposable insert 345. The reusable absorbent carrier insert 245 includes a carrier portion 148, a first length measured along the central longitudinal axis of the reusable absorbent carrier insert 245, and a first width measured along the central lateral axis of the reusable absorbent carrier insert 245. The reusable absorbent carrier insert 245 also has a first capacity-to-thickness ratio. The carrier portion 148 of the reusable absorbent carrier insert 245 may include an elastomeric material. The carrier portion 148 of the reusable absorbent carrier insert 245 may be attached to the reusable absorbent carrier insert 245 via a fastening mechanism, which includes a lock seam, a flat seam, an adhesive, or a combination thereof. Prior to receiving the disposable insert 345, the carrier portion 148 of the reusable absorbent carrier insert 245 may include an outer portion facing outward and an inner portion facing inward.

[0050] The disposable insert 345 includes a superabsorbent material, a second length measured along a central longitudinal axis of the disposable insert 345, and a second width measured along a central lateral axis of the disposable insert 345. The disposable insert 345 has a second capacity-to-thickness ratio. The reusable absorbent carrier insert 245 is configured to receive and retain the disposable insert 345, such that the disposable insert 345 is configured to be received and contained within the carrier portion 148 of the reusable absorbent carrier insert 245 to form a reusable absorbent carrier insert and disposable insert combination 145. The superabsorbent material may include absorbent gelling material (AGM), and the reusable absorbent carrier insert may include one or more textile fabrics instead of AGM.

[0051] The first length is greater than the second length, the first width is greater than the second width, and the first capacity-to-thickness ratio of the reusable absorbent carrier insert 245 is less than the second capacity-to-thickness ratio of the disposable insert 345, such that the disposable insert 345 having a second capacity-to-thickness ratio greater than the first capacity-to-thickness ratio of the reusable absorbent carrier insert 245 is thinner than the reusable absorbent carrier insert 245. The thickness defines the thickness of the material when dry, and the capacity defines the bodily fluid storage capacity. In an embodiment, the reusable absorbent carrier insert and disposable insert combination 145 as described herein is thinner and has a greater capacity-to-thickness ratio than a single reusable absorbent insert having substantially the same capacity. When the reusable absorbent carrier insert and disposable insert combination 145 are in a wearing configuration, at least a portion of the reusable absorbent carrier insert 245 may be disposed between the disposable insert 345 and the skin surface of the wearer.

[0052] In an embodiment, the reusable absorbent carrier insert 245 is configured to be inserted into the interior pocket 45 of the outer shell layer 21 of the absorbent pants 20. Additionally or alternatively, as in FIG. 5A to FIG. 10 As shown in the embodiment of , the carrier portion 148 of the reusable absorbent carrier insert 245 may include at least one strip 150 having two open ends 152A, 152B, at least one pouch 160, or a combination thereof, each of which will be described in more detail further below. FIG. 6A to FIG. 10 As shown in the embodiment of FIG. 1 , the pouch 160 may include a longitudinal cut or a diagonal cut. FIG. 6A to FIG. 8 and Fig.10 As shown in the embodiment of FIG. 2 , the longitudinal cut extends at least partially across the reusable absorbent carrier insert 245. As shown in FIG. Fig. 9 , the diagonal cut extends at least partially across the reusable absorbent carrier insert 245. The method of forming the reusable absorbent carrier insert and disposable insert combination 145 described herein may include receiving a disposable insert 345 including superabsorbent material within a carrier portion 148 of the reusable absorbent carrier insert 245, and containing the disposable insert 345 in a self-locking configuration within the carrier portion 148 when received.

[0053] Figure 5AA reusable absorbent carrier insert and disposable insert combination 145A is depicted, wherein the reusable absorbent carrier insert 245 includes a belt 150 having two open ends 152A, 152B located on opposite ends of the belt 150. The reusable absorbent carrier insert 245 is configured to receive and hold a disposable insert 345 within the belt 150. The disposable insert 345 is configured to be received within an inner portion to form the reusable absorbent carrier insert and disposable insert combination 145A. The carrier portion 148 of the reusable absorbent carrier insert 245 includes at least the belt 150 having two open ends 152A, 152B, and the disposable insert 345 is configured to be received within at least the inner portion of the belt 150.

[0054] Figure 5B A reusable absorbent carrier insert and disposable insert combination 145B is depicted, which includes a reusable absorbent carrier insert 245 having a pair of bands 150A, 150B. The bands 150A, 150B each include two open ends. The disposable insert 345 is configured to be received within the inner portion to form the reusable absorbent carrier insert and disposable insert combination 145B. The carrier portion 148 of the reusable absorbent carrier insert 245 includes at least the bands 150A, 150B each having two open ends, and the disposable insert 345 is configured to be received within the inner portion of at least the bands 150A, 150B.

[0055] Fig. 6A A reusable absorbent carrier insert and disposable insert combination 145C is depicted that includes a reusable absorbent carrier insert 245 having a pouch 160A. The pouch 160A includes a partially extending longitudinal cut 162. The disposable insert 345 is configured to be received within the interior portion to form the reusable absorbent carrier insert and disposable insert combination 145C. The carrier portion 148 of the reusable absorbent carrier insert includes at least the pouch 160A, and the disposable insert 345 is configured to be received within the interior portion of at least the pouch 160A.

[0056] Figure 6BA reusable absorbent carrier insert and disposable insert combination 145D is depicted, which includes a reusable absorbent carrier insert 245 having a pouch 160 with a fully extended longitudinal cut 162. The fully extended longitudinal cut 162 is disposed between the ends of the pouches 160B, 160C. A disposable insert 345 is configured to be received within an interior portion to form the reusable absorbent carrier insert and disposable insert combination 145D. The carrier portion 148 of the reusable absorbent carrier insert includes at least the pouch 160, and the disposable insert 345 is configured to be received within an interior portion of at least the pouch 160, such as between the ends of the pouches 160B, 160C.

[0057] Figure 7 A reusable absorbent carrier insert and disposable insert combination 145E is depicted that includes a reusable absorbent carrier insert 245 having a band 150 and a pouch 160 as part of a carrier portion 148. Band 150 includes two open ends. Pouch 160 includes a partially extending longitudinal cut. A disposable insert 345 is configured to be received within the interior portion to form the reusable absorbent carrier insert and disposable insert combination 145E. The carrier portion 148 of the reusable absorbent carrier insert 245 includes at least a band 150 having two open ends, and the disposable insert 345 is configured to be received within the interior portion of at least the band 150. The carrier portion 148 of the reusable absorbent carrier insert includes at least the pouch 160, and the disposable insert 345 is configured to be received within the interior portion of at least the pouch 160. Figure 7 In the embodiment of the reusable absorbent carrier insert, the carrier portion 148 includes a belt 150 having at least two open ends and a pouch 160, and the disposable insert 345 is configured to be received within at least an interior portion of the belt 160.

[0058] Figure 8 A reusable absorbent carrier insert and disposable insert combination 145F is depicted that includes a reusable absorbent carrier insert 245 having a pouch 160. The pouch 160 includes a pair of flaps 160C, 160D. A disposable insert 345 is configured to be received within an interior portion to form the reusable absorbent carrier insert and disposable insert combination 145F. The carrier portion 148 of the reusable absorbent carrier insert includes at least the pouch 160, and the disposable insert 345 is configured to be received within an interior portion of at least the pouch 160, such as between the pair of flaps 160C, 160D. Figure 8In the embodiment of the present invention, the carrier portion 148 of the reusable absorbent carrier insert 245 includes at least a first wing 160C and a second wing 160D. The first wing 160C is longer than the second wing 160D in the vertical axis direction and is configured to overlap with the second wing 160D. The disposable insert 345 is configured to be received within the inner portion of the second wing 160D and covered by the first wing 160C.

[0059] Fig. 9 A reusable absorbent carrier insert and disposable insert combination 145G is depicted that includes a reusable absorbent carrier insert 245 having a pouch 160E. The pouch 160E includes a diagonal cutout 164. The disposable insert 345 is configured to be received within the interior portion to form the reusable absorbent carrier insert and disposable insert combination 145G. The carrier portion 148 of the reusable absorbent carrier insert includes at least the pouch 160E, and the disposable insert 345 is configured to be received within the interior portion of at least the pouch 160E.

[0060] Fig.10 A reusable absorbent carrier insert and disposable insert combination 145H is depicted that includes a reusable absorbent carrier insert 245 having a pouch 160F. The pouch 160F includes a partially extended longitudinal cut that is configured to be folded over the disposable insert 345. Thus, when the reusable absorbent carrier insert and disposable insert combination 145H is formed, the interior portion is folded over the disposable insert and faces outward. The carrier portion 148 of the reusable absorbent carrier insert includes at least the pouch 160F, and the disposable insert 345 is configured to be received within the interior portion of at least the pouch 160F when folded over the disposable insert 345.

[0061] Compared to separate reusable absorbent inserts in absorbent articles such as diapers, the embodiments of the reusable absorbent carrier insert and disposable insert combination 145 described herein can allow for longer use time while allowing durability and reusability and without increasing dry thickness (thickness). The disposable insert can increase the absorbent capacity of the insert combination without significantly increasing the dry thickness (thickness) of the insert combination. Therefore, it is possible to achieve an increase in use time while reducing the thickness under dry conditions and maintaining the typical thickness of the reusable absorbent insert under wet conditions with comparable capacity. In addition, compared to separate reusable absorbent inserts with similar capacity, the reusable absorbent carrier insert and disposable insert combination 145 allow the reusable absorbent carrier insert to use thinner cloth, thereby allowing comfortable fit, smaller volume, faster drying and overall effective drying of the skin (such as fluid locked in the AGM of the disposable insert) and increased mileage (e.g., longer use time). Therefore, the reusable absorbent carrier insert and disposable insert combination 145 can have a greater capacity-to-thickness ratio than a separate reusable absorbent insert with similar capacity. The capacity-thickness ratio and combined insert weight-capacity may be expressed using the measurements of "ml capacity" / "mm thickness" or "ml capacity" / "grams".

[0062] In an embodiment, the thickness mentioned may be under a pressure of 2.1 kPa (0.3 PSI) during measurement. AGM laminate at 435 g / m 2 AGM can have a thickness of approximately 1.5 mm with a g / cm 2 CRC (centrifugal retention capacity [g 吸收 / g AGM ]) and 1.09 + / - 0.5 g / cm 2 AAP (absorbency under 0.7 psi pressure [g 吸收 / g AGM ]) capacity. Compared to the reference cloth insert, this laminate can reduce rewet (collagen rewet at 3.4 psi) to 50% of the initial value and increase capacity. At moderate dry thickness increases (such as thickness ≤ 4 mm), the capacity can be easily increased within the limitations of the technology. In embodiments, at high FSR (free swell rate [g 吸收 / g AGM × s 吸收时间]), very high CRC (>30 g / g) and / or very low SFC (0-5) AGM can be found. With respect to AGM fibers, at various AGM fiber properties, such fibers (i.e., needle punched pure AGM fibers) can have up to 100% absorbent material in disposable inserts. Typically, for 400 g / m 2 For AGM fiber cores, the thickness can be 4mm-5mm. For foam inserts, the thickness can be 2mm, where two or more layers are utilized to achieve a 50% rewet reduction target of the initial cloth insert rewet.

[0063] 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 "about 40 mm".

[0064] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patent or patent application and any patent application or patent to which this application claims priority or the benefit of, is hereby incorporated by reference in its entirety. The citation of any document is not an admission that it is prior art to any of the present invention disclosed or claimed herein, or an admission that it, by itself or in combination with any one or more of the 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.

[0065] Although specific embodiments are illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. In addition, although various aspects of the claimed subject matter are described herein, such aspects need not be utilized in combination. All such changes and modifications within the scope of the claimed subject matter are therefore intended to be covered in the appended claims.

Claims

1. A reusable absorbent carrier insert and a disposable insert combination, the reusable absorbent carrier insert and the disposable insert combination include: a reusable absorbent carrier insert comprising a carrier portion, a first length measured along a central longitudinal axis of the reusable absorbent carrier insert, and a first width measured along a central lateral axis of the reusable absorbent carrier insert, wherein the reusable absorbent carrier insert has a first capacity-to-thickness ratio; and a disposable insert comprising an absorbent material, a second length measured along a central longitudinal axis of the disposable insert, and a second width measured along a central lateral axis of the disposable insert, wherein the disposable insert has a second volume-to-thickness ratio; wherein the reusable absorbent carrier insert is configured to receive and retain the disposable insert; wherein said disposable insert is configured to be received and contained within said carrier portion of said reusable absorbent carrier insert to form said reusable absorbent carrier insert and disposable insert combination; wherein the first length is greater than the second length; wherein the first width is greater than the second width; and Wherein the first capacity-to-thickness ratio is less than the second capacity-to-thickness ratio.

2. A reusable absorbent carrier insert and disposable insert combination according to claim 1, wherein the reusable absorbent carrier insert is configured to be inserted into an interior pocket of the outer shell layer of an absorbent pant, on top of the inner portion of the outer shell layer, or a combination thereof.

3. The reusable absorbent carrier insert and disposable insert combination of claim 1, wherein the carrier portion of the reusable absorbent carrier insert comprises an elastomeric material.

4. A reusable absorbent carrier insert and disposable insert combination according to claim 1, wherein the carrier portion of the reusable absorbent carrier insert comprises at least one band having two open ends, at least one pouch, or a combination thereof, wherein the at least one pouch comprises a longitudinal cut or a diagonal cut.

5. The reusable absorbent carrier insert and disposable insert combination of claim 4, wherein the longitudinal cut extends at least partially across the reusable absorbent carrier insert.

6. The reusable absorbent carrier insert and disposable insert combination of claim 4, wherein the diagonal cut extends at least partially across the reusable absorbent carrier insert.

7. A reusable absorbent carrier insert and disposable insert combination according to claim 1, wherein the carrier portion of the reusable absorbent carrier insert is attached to the reusable absorbent carrier insert via a fastening mechanism, the fastening mechanism comprising a lock edge, a flat seam, an adhesive or a combination thereof.

8. The reusable absorbent carrier insert and disposable insert combination of claim 1, wherein prior to receiving the disposable insert, the carrier portion of the reusable absorbent carrier insert comprises an exterior portion facing outwardly and an interior portion facing inwardly.

9. The reusable absorbent carrier insert and disposable insert combination of claim 8, wherein the inner portion is folded over the disposable insert and faces outward when the reusable absorbent carrier insert and disposable insert combination is formed.

10. The reusable absorbent carrier insert and disposable insert combination of claim 8, wherein the disposable insert is configured to be received within the interior portion to form the reusable absorbent carrier insert and disposable insert combination.

11. A reusable absorbent carrier insert and disposable insert combination according to claim 10, wherein the carrier portion of the reusable absorbent carrier insert includes at least one band having two open ends, and the disposable insert is configured to be received within the inner portion of the at least one band.

12. The reusable absorbent carrier insert and disposable insert combination of claim 10, wherein the carrier portion of the reusable absorbent carrier insert includes at least one pouch and the disposable insert is configured to be received within the interior portion of the at least one pouch.

13. A reusable absorbent carrier insert and disposable insert combination according to claim 10, wherein the carrier portion of the reusable absorbent carrier insert includes at least one band having two open ends and a pouch, and the disposable insert is configured to be received within the interior portion of the at least one band.

14. A reusable absorbent carrier insert and disposable insert combination according to claim 10, wherein the carrier portion of the reusable absorbent carrier insert includes at least a first wing and a second wing, the first wing being longer than the second wing and configured to overlap with the second wing, and the disposable insert is configured to be received within the inner portion of the second wing and covered by the first wing.

15. The reusable absorbent carrier insert and disposable insert combination of claim 1, wherein the absorbent material comprises absorbent gelling material (AGM) and the reusable absorbent carrier insert comprises one or more textile fabrics and does not comprise AGM.

16. The reusable absorbent carrier insert and disposable insert combination of claim 1, wherein at least a portion of the reusable absorbent carrier insert is disposed between the disposable insert and the skin surface of the wearer when the reusable absorbent carrier insert and disposable insert combination is in a wearing configuration.

17. An absorbent trousers, the absorbent trousers include: an outer shell layer, the outer shell layer comprising an inner pocket, an inner portion, or a combination thereof; and A reusable absorbent carrier insert and disposable insert combination configured to be received at least one of: in the interior pocket of the outer shell layer of the absorbent pants, on top of the interior portion of the outer shell layer, or a combination thereof, the reusable absorbent carrier insert and disposable insert combination comprising: a reusable absorbent carrier insert comprising a carrier portion, a first length measured along a central longitudinal axis of the reusable absorbent carrier insert, and a first width measured along a central lateral axis of the reusable absorbent carrier insert, wherein the reusable absorbent carrier insert has a first capacity-to-thickness ratio; and a disposable insert comprising an absorbent material, a second length measured along a central longitudinal axis of the disposable insert, and a second width measured along a central lateral axis of the disposable insert, wherein the disposable insert has a second volume-to-thickness ratio; wherein the reusable absorbent carrier insert is configured to receive and retain the disposable insert; wherein said disposable insert is configured to be received and contained within said carrier portion of said reusable absorbent carrier insert to form said reusable absorbent carrier insert and disposable insert combination; wherein the first length is greater than the second length; wherein the first width is greater than the second width; and Wherein the first capacity-to-thickness ratio is less than the second capacity-to-thickness ratio.

18. The absorbent pant of claim 17, wherein prior to receiving the disposable insert, the carrier portion comprises an outwardly facing outer portion and an inwardly facing inner portion.

19. The absorbent pant of claim 18, wherein when the reusable absorbent carrier insert and disposable insert combination is formed, the inner portion is folded over the disposable insert and faces outwardly.

20. The absorbent pant of claim 18 wherein when forming the reusable absorbent carrier insert and disposable insert combination, the disposable insert is received in the interior portion remaining facing inwardly.

21. A method of forming a combination of a reusable absorbent carrier insert and a disposable insert, the method include: receiving a disposable insert including an absorbent material within a carrier portion of a reusable absorbent carrier insert; as well as receiving the disposable insert in the carrier portion in a self-locking configuration when received; wherein the reusable absorbent carrier insert has a first capacity-to-thickness ratio, wherein the disposable insert has a second capacity-to-thickness ratio, and wherein the first capacity-to-thickness ratio is less than the second capacity-to-thickness ratio.

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