Absorbent article with improved fit and conformity

Abstract

An absorbent article includes a backsheet extending in a longitudinal direction; and at least one ear attached to the backsheet and extending outwardly from the backsheet. The at least one ear is formed of a fabric adapted to be stretched such that the at least one ear has a stretching direction. The at least one ear is attached to the backsheet such that the tensile direction of the at least one ear is oriented at an oblique tensile angle relative to the longitudinal direction when the absorbent article is oriented in a tiled deployed position and in an uncollapsed state.

Description

Technical Field

[0001] The present technology relates to absorbent articles intended to be worn, and more particularly, but not limited to, diapers having an improved geometry for better fitting and conforming to a wearer. Background Art

[0002] Many absorbent articles intended for personal wear, such as diapers, training pants, feminine hygiene products, adult incontinence products, bandages, medical garments, etc., are designed to have absorbent properties sufficient to absorb moisture from liquid body excretions, including urine, menstrual fluid, blood, etc., and wick them away from the wearer to reduce skin irritation caused by long-term exposure to a moist environment. For example, a diaper is typically arranged and secured on a wearer and positioned to absorb excretions and contain excrement using a set of primary fastening tabs, such as adhesive tabs or mechanical (e.g., hook or loop) fastening system tabs.

[0003] Diapers are generally classified as disposable or reusable. Disposable diapers have dominated the market for decades and are typically available in custom sizes based on weight and height to fit children at different stages of growth. Once a child outgrows a smaller diaper, a diaper in the next size range must be purchased.

[0004] In contrast to the single-use nature of disposable diapers, reusable diapers can be fully or partially reusable, such that their overall structure can be reused repeatedly and are generally designed to fit children at different stages of growth. Reusable cloth diapers predate disposable diapers, but they are generally ill-fitting, bulky, and often not effective at containing liquids and other waste. Improvements have been made to reusable diapers to address the drawbacks of traditional cloth diapers. For example, many reusable diapers include a durable outer shell in which a disposable or reusable absorbent component is provided, which can be removed and replaced and is capable of better absorbing and containing body fluids. Additionally, reusable diapers have been shaped to better conform to the body structure of the wearer and generally include elastics in the waistband and leg openings to more effectively prevent leakage. Even with such improvements, existing reusable diapers still have problems with fit, comfort, and performance when compared to disposable diapers. Such problems stem in part from the desire to provide reusable diapers sized to be generally suitable for fitting wearers at different stages of growth. Thus, further improvements are needed to allow reusable diapers to adapt to children, especially as they grow. Summary of the Invention

[0005] As used in this patent, the terms "invention", "the invention", "this invention" and "the present invention" are intended to generally refer to all subject matters of this patent and the following patent claims. Statements containing these terms should be understood not to limit the subject matter described herein or the meaning or scope of the following patent claims. The embodiments of the invention covered by this patent are defined by the following claims rather than the present description. The present description is a high-level overview of various embodiments of the invention and introduces some concepts further described in the following detailed description section. The present description is not intended to identify the key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0006] According to certain embodiments, an absorbent article includes a backsheet that extends in a longitudinal direction; and at least one ear portion attached to the backsheet and extending outwardly from the backsheet. The at least one ear portion is formed of a fabric adapted to stretch such that the at least one ear portion has a stretching direction. The at least one ear portion is attached to the backsheet such that when the absorbent article is oriented in a flat, unfolded position and in an unshrunk state, the stretching direction of the at least one ear portion is oriented at an inclined stretching angle relative to the longitudinal direction.

[0007] According to certain embodiments, an absorbent article includes a backsheet that extends in a longitudinal direction and has a first lateral side and an opposite second lateral side. A first ear portion is attached to the first lateral side and extends outwardly from the first lateral side, and a second ear portion is attached to the second lateral side and extends outwardly from the second lateral side. The first ear portion and the second ear portion are each formed of a fabric adapted to stretch in at least one of the longitudinal or transverse directions such that the first ear portion has a first ear portion stretching direction and the second ear portion has a second ear portion stretching direction, wherein each of the first ear portion stretching direction and the second ear portion stretching direction is parallel to one of the longitudinal or transverse directions of the fabric. The first ear portion is attached to the first lateral side such that when the absorbent article is oriented in a flat, unfolded position and in an unshrunk state, the first ear portion stretching direction is oriented at a first ear portion stretching angle relative to the longitudinal direction; and the second ear portion is attached to the second lateral side such that when the absorbent article is oriented in a flat, unfolded position and in an unshrunk state, the second ear portion stretching direction is oriented at a second ear portion stretching angle relative to the longitudinal direction. In some embodiments, the first ear portion stretching angle and the second ear portion stretching angle are between 40° and 80°, inclusive of the end values.

[0008] According to certain embodiments, a method for manufacturing an absorbent article includes providing a backsheet that extends in a longitudinal direction and includes lateral sides, and providing ear portions formed from a fabric adapted to be stretched in at least one of the longitudinal or transverse directions of the fabric such that the ear portions have a stretching direction parallel to one of the longitudinal or transverse directions of the fabric. The method further includes attaching the ear portions to the lateral sides of the backsheet such that when the absorbent article is oriented in a flat laid-out position and in an unshrunk state, the stretching direction of the ear portions is oriented at an inclined angle with respect to the longitudinal direction.

[0009] The various specific embodiments described in this disclosure may include additional systems, methods, features, and advantages that are not necessarily explicitly disclosed herein but will be apparent to those of ordinary skill in the art upon examination of the following detailed description and the drawings. It is intended that all such systems, methods, features, and advantages be included within this disclosure and be protected by the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The features and components of the following drawings are illustrated to emphasize the general principles of this disclosure. For consistency and clarity, corresponding features and components throughout the drawings may be designated by matching reference numerals.

[0011] Figure 1 is a top plan view of the inner side of an absorbent article oriented in a flat laid-out position and in an unshrunk state according to one embodiment.

[0012] Figure 1A is in Figure 1 an enlarged cross-sectional view taken at the inserted circle 1A in.

[0013] Figure 2 is Figure 1 a top plan view of the opposite outer side of the absorbent article.

[0014] Figure 3 is Figure 1 a top plan view of the absorbent article, wherein elastic members are provided along some edges.

[0015] Figure 4 is an absorbent article positioned on a wearer Figure 3 front perspective view.

[0016] Figure 5 is an absorbent article positioned on a wearer Figure 3 side perspective view.

[0017] Figure 6 is an absorbent article positioned on a wearer Figure 3 back perspective view. DETAILED DESCRIPTION

[0018] Aspects and embodiments of the present invention will be described in the context of reusable absorbent articles such as reusable diapers or semi-reusable diapers formed from a semi-durable backsheet, which are intended to be discarded after multiple uses and cleanings (as opposed to disposable diapers intended for single use and reusable diapers intended for indefinite use). However, it will be apparent that the present invention can also be used with other articles such as disposable diapers, training pants for children, incontinence garments, etc., which can be constructed to be reusable or disposable. Generally, reusable articles such as reusable clothing have reusable components and absorbent components (which can be reusable or disposable). In contrast, disposable articles such as disposable clothing are intended for limited use and are not intended to be washed or otherwise cleaned for reuse. For example, disposable diapers are discarded after being soiled by the wearer.

[0019] Figure 1 is a plan view of an embodiment of an absorbent article (particularly diaper 10) of the present invention in a flat, unfolded position and in an unshrunk state (i.e., substantially all wrinkles and contractions caused by elastic elements are removed). Diaper 10 extends generally in a lateral direction x and a longitudinal direction y. Diaper 10 can have any desired shape or profile such as rectangular, I-shaped, hourglass-shaped, or T-shaped. For a T-shaped diaper, the crossbar of the "T" can include the front waist region of the diaper or alternatively can include the back waist region of the diaper. The size or proportion of diaper 10 can be customized according to the size of the wearer to be protected, or alternatively, the diaper can be adjustable to generally fit wearers of different sizes.

[0020] In the illustrated embodiment, diaper 10 includes a backsheet 12 and ears 14. Generally, the outer edge of backsheet 12 defines a perimeter that has generally laterally extending end edges connected by generally longitudinally extending side edges. The side edges define leg openings for diaper 10 and are optionally curved and contoured.

[0021] In the longitudinal direction y, backsheet 12 has a front waist region 20, a back waist region 22, and an intermediate region 24 that connects front waist region 20 and back waist region 22 and provides a crotch for placement between the wearer's legs. As Figures 4 to 6 shown and in use, intermediate region 24 is configured to be positioned to cover the wearer's crotch, and front waist region 20 and back waist region 22 are configured to at least partially encircle the wearer's waist.

[0022] In an exemplary embodiment, the end edges include a front end edge 16a and a rear end edge 16b. The end edges 16a, 16b are shown as straight, but optionally, they can be curved. The side edges include laterally opposite front side edges 18a, laterally opposite rear side edges 18b, and laterally opposite intermediate side edges 18c connecting the front side edges 18a and the rear side edges 18b. In some embodiments, the front side edge 18a extends between the intermediate side edge 18c and the front end edge 16a, and the rear side edge 18b extends between the intermediate side edge 18c and the rear end edge 16b. In some embodiments, the rear side edge 18b tapers inwardly from the intermediate side edge 18c toward the rear end edge 16b. However, it should be noted that Figure 1 merely representative, and the number and orientation of the end edges 16a, 16b and the side edges 18a to 18c can vary depending on the particular article and its size and shape. The elastomeric member 19 (see Figure 3 ) can be positioned to extend near or along any of the end edges 16a, 16b and / or the side edges 18a to 18c. The elastomeric member 19 tightens and holds the diaper 10 on the wearer to better conform the diaper to the wearer and prevent diaper leakage.

[0023] Although the backsheet 12 can be formed as a single layer, in some embodiments, the backsheet is formed of at least two layers. In any case and in some embodiments, the backsheet 12 is formed of a fabric (e.g., woven, non-woven, knitted, etc.) or other durable material such that the diaper 10 can be cleaned (e.g., washed) and reused without damage.

[0024] By way of example only, in some embodiments, the backsheet 12 is formed of a shell fabric 26 having an exposed outer surface 28 and a lining fabric 30 having an exposed inner surface 32. The shell fabric 26 and the lining fabric 30 can be attached to each other in different ways. In one non-limiting example, the shell fabric 26 and the lining fabric 30 are joined via sewing or an adhesive along at least a portion of the end edges 16a, 16b and / or the side edges 18a to 18c.

[0025] In some embodiments, the outer shell fabric 26 is substantially liquid-impermeable to prevent moisture from penetrating through the backsheet 12. Suitable materials include, but are not limited to, waterproof materials, water-resistant materials, coating materials, laminated materials, etc., and in some embodiments, can be woven materials, knitted materials, or non-woven materials. Polymer materials (such as polyester, polyurethane, and / or elastomeric film laminates) may be particularly suitable. The lining fabric 30 is positioned closer to the wearer or in direct contact with the wearer and can thus be formed of materials or in a manner that imparts comfort but is still very durable. Such materials can be woven, knitted, or non-woven, and can include, but are not limited to, polymer materials (e.g., polyester, polyurethane, etc.) and natural and synthetic cellulose materials (e.g., cotton, rayon, acetate, triacetate, and lyocell). In some embodiments, the lining fabric 30 is a flannel or microflannel material. In some embodiments, the lining fabric 30 can be a fabric that is capable of stretching.

[0026] One or more portions of the backsheet 12 can include a reinforcing fabric element 38. By way of example only and with reference to Figure 1 , the reinforcing fabric element 38 has been provided in the back waist region 22, but can be provided in alternative and / or additional regions of the backsheet 12. Although the reinforcing fabric element 38 can be a non-stretch material, in some embodiments, the reinforcing fabric element 38 is formed of a stretch fabric that enhances the conformability and fit of the diaper around the wearer. For example, the reinforcing fabric element 38 can be a woven or knitted fabric that is capable of stretching and recovering in at least one (or both) of the longitudinal or transverse directions of the fabric. In some embodiments, the reinforcing fabric element 38 is formed of natural and synthetic cellulose materials (e.g., cotton, rayon, acetate, triacetate, and lyocell) to impart comfort, of nylon materials to impart abrasion resistance and durability, and / or of elastomeric materials (e.g., spandex (elastane), ethylene-olefin copolymer, rubber, etc.) to impart stretch characteristics. In one particular non-limiting embodiment, the reinforcing fabric element 38 is a fabric formed of 60% rayon, 33% nylon, and 7% spandex (e.g., ).

[0027] The absorbent member 40 (in Figure 1(schematically shown in) disposed on at least a portion of the backsheet 12 and / or within at least a portion of the backsheet to be available for absorbing exudates and moisture and wicking the exudates and the moisture away from the wearer. The absorbent member 40 can be formed in any number of shapes and sizes and can include superabsorbent materials, short fibers, adhesives, etc. and combinations thereof, as known in the art. For example, the absorbent member 40 can be formed of any suitable material or material assembly, including but not limited to those materials or material assemblies disclosed in the following patents: U.S. Patent No. 9,011,403, issued April 21, 2015, and titled "Absorbent Insert"; U.S. Patent No. 6,710,225, issued March 23, 2004, and titled "Layered Absorbent Structure with a Zoned Basis Weight"; U.S. Patent Application Serial No. 16 / 086,033, published September 17, 2020, as US2020 / 0289342 and titled "Absorbent Cores and Methods for Forming Absorbent Cores"; and PCT / US2020 / 047736, published March 3, 2022, as WO 2022 / 046030 and titled "Absorbent Structures and Methods for Manufacturing Absorbent Structures", the entire contents of each of these patents being incorporated herein by reference. In the context of a reusable diaper, the absorbent member 40 can be a disposable insert that is removed after use and replaced with a new disposable insert within the backsheet 12, a reusable insert that is cleaned after use and subsequently replaced within the backsheet 12, and / or permanently bonded to or within the backsheet 12 such that both the backsheet 12 and the associated absorbent member 40 are cleaned and reused after use. The absorbent member 40 can be retained within the backsheet 12 in numerous ways, such as by insertion into a pocket within the backsheet 12 or via mechanical retention features or chemical retention features (e.g., hook-and-loop fasteners, snaps, adhesives, etc.).

[0028] The opposing ear portions 14 are attached to the back waist region 22 of the backsheet 12 at one or more attachment points to extend outwardly from the backsheet 12. The ear portions 14 can be attached to the backsheet 12 using any suitable mechanical attachment method or chemical attachment method (including but not limited to sewing / stitching, adhesion, melting, etc.).

[0029] As Figure 1AAs best seen, in some embodiments, the ear 14 is attached to the rear side edge 18b of the backsheet 12 along a bond line 42 that extends along a bond line axis z oriented at a bond angle α relative to the longitudinal direction y of the diaper 10. In some embodiments, the bond angle α extends at an inclined angle relative to the longitudinal direction y (i.e., at an angle greater than 0° and less than 90°). In some embodiments, the bond angle α is between 5° and 85°, inclusive; between 10° and 80°, inclusive; between 15° and 75°, inclusive; between 15° and 70°, inclusive; between 20° and 65°, inclusive; between 20° and 60°, inclusive; between 20° and 55°, inclusive; between 20° and 50°, inclusive; between 20° and 45°, inclusive; between 20° and 40°, inclusive; between 20° and 35°, inclusive; between 20° and 30°, inclusive; between 15° and 40°, inclusive; between 15° and 35°, inclusive; and between 15° and 30°, inclusive.

[0030] For the purposes of this disclosure, the bond angle α (and the stretch angle β described below) is measured when the diaper 10 is in a flat, unfolded position and in an unshrunk state (i.e., substantially all of the wrinkles and shrinkage caused by the elastic members are physically removed or removed by stretching), such as Figure 1 and Figure 2 shown. Conventionally, the ears are attached to the diaper backsheet along a bond line that extends parallel to the longitudinal direction of the backsheet. Subsequent shrinkage of the elastic members in the diaper (such as along the side edges and waistbands) pulls the backsheet inward, creating the appearance that the bond line extends at an inclined angle relative to the longitudinal direction, but in reality the bond line does not extend as such.

[0031] The ear 14 can be made of any suitable material, but in some embodiments, it is made of a woven or knitted fabric that is capable of stretching and recovering in at least one (or both) of the longitudinal or transverse directions of the fabric. For example, in some embodiments, the ear fabric is formed from one or more natural and synthetic cellulose materials (e.g., cotton, rayon, acetate, triacetate, and lyocell) to impart comfort, from nylon materials to impart abrasion resistance and durability, and / or from elastomeric materials (e.g., spandex (elastic material), ethylene-olefin copolymer, rubber, etc.) to impart stretch properties. In one particular non-limiting embodiment, the ear fabric is formed from 60% rayon, 33% nylon, and 7% spandex (e.g., ). In some embodiments, the stretch fabric used to form the ear 14 is the same as the stretch fabric that can form the reinforcing fabric element 38.

[0032] In some embodiments, the lug 14 is attached such that the stretch direction s (i.e., the orientation of the stretch of the lug 14, which is typically the longitudinal and / or transverse direction of the lug fabric) extends at a stretch angle β relative to the longitudinal direction y. In some embodiments, the stretch angle β extends at an inclination angle (i.e., greater than 0° and less than 90°) relative to the longitudinal direction y. In some embodiments, the stretch angle β is between 5° and 85°, inclusive; between 10° and 80°, inclusive; between 15° and 80°, inclusive; between 20° and 80°, inclusive; between 25° and 80°, inclusive; between 30° and 80°, inclusive; between 40° and 80°, inclusive; between 40° and 75°, inclusive; between 40° and 70°, inclusive; between 45° and 75°, inclusive; between 45° and 70°, inclusive; between 50° and 75°, inclusive; and between 50° and 70°, inclusive.

[0033] In some embodiments, the stretch angle β is substantially perpendicular to the bond line axis z, but this is not required. In some embodiments, the lug 14 is oriented such that the greatest or most significant stretch direction of the fabric (e.g., the transverse direction) extends at a stretch angle β relative to the longitudinal direction y.

[0034] The fastening tab 50 provided with fastening features can be attached to the lug 14 located distally of the backsheet 12. The fastening tab 50 can be formed of any material and, in some embodiments, can be formed of the same material as the backsheet 12 or of a stretch material such as that used to form the lug 14. Any type of fastening feature can be provided on the fastening tab 50 to cooperate with complementary fastening features on the backsheet 12 to fasten the diaper 10 around the wearer's waist. Examples include but are not limited to hook-and-loop fasteners, adhesives, snaps, clamps, buttons, hook closures, magnets, adhesive fasteners, sticky fasteners, mechanical fasteners, male / female mating parts, combinations thereof, and / or other suitable desired features. It may be preferred that the fastening features do not form a permanent bond but allow the diaper 10 to be repeatedly fastened to the wearer. In one non-limiting embodiment, the fastening feature is formed by the engagement of a hook (or loop) with a fastening patch 52 of a fastening tape 54 formed by a loop (or hook) on the exposed outer surface 28 of the front waist region 20 of the backsheet 12 to allow adjustable positioning of the fastening patch 52 on the fastening tape 54 to accommodate wearers of different sizes. In some embodiments, the diaper 10 does not include a separate fastening tab 50. Instead, the fastening feature (e.g., the fastening patch 52) is provided directly on the lug 14.

[0035] In use, the diaper 10 is positioned between the wearer's legs, with the front waist region 20 adjacent to the front of the wearer and the back waist region 22 adjacent to the back of the wearer. The ear portions 14 can be stretched to wrap around a portion of the wearer (e.g., laterally around the hips), and the diaper 10 is secured via securing features (e.g., securing patches 52 and securing straps 54) such that the back waist region 22 is secured to the front waist region 20 of the backsheet 12 to hold the diaper 10 on the wearer. The stretchability of the ear portions 14 allows for adjustability of the waist size of the diaper, such that the waist size of the diaper can be customized according to the wearer's waist size to provide a contoured fit around the wearer. The ability of the diaper 10 to conform to the wearer's profile is further enhanced by the angular relationship between the stretch direction s of the ear portions 14 and the longitudinal direction y of the diaper 10. As described above, traditionally, the ear portions are attached to the diaper backsheet along a bond line extending parallel to the longitudinal direction of the diaper and are stretched directly outward (i.e., at a 90° angle) relative to the longitudinal direction of the diaper (to the extent of ear portion stretch). While this design allows the ear portions to extend laterally around the hips, it does not account for the upwardly curved nature of the hips. By attaching the stretchable ear portions 14 to the backsheet 12 such that the stretch direction s is inclined relative to the longitudinal direction y, the ear portions 14 are allowed to stretch upward as well as outward from the backsheet 12. In this way, the ear portions 14 can extend upward, over, and around the hips (rather than only laterally around the hips) to better conform the diaper 10 to the wearer's hip profile and to more effectively stretch the elastics around the wearer's hips, legs, and waist to provide a tighter seal between the diaper 10 and the wearer. This results in a better and more comfortable fit, which in turn results in less sagging (downward movement) and consequent diaper leakage. As Figures 4 to 6 As best seen, the ear portions extend upward and over the wearer's hips so as to at least partially cover the lateral sides of the wearer's hips.

[0036] Embodiments of the present invention also relate to a method for manufacturing an absorbent article (such as, but not limited to, the embodiments of the diaper 10 described above), the absorbent article having a backsheet and at least one ear formed from a fabric stretched in at least one stretching direction. According to the method, the ear is attached to the backsheet such that the stretching direction (and in some embodiments, the maximum stretching direction) of the ear extends at a stretching angle (and in some embodiments, at the stretching angle β disclosed above) that is inclined with respect to the longitudinal direction of the backsheet. In some embodiments of the method, the ear is attached to the backsheet along a bonding line that extends along a bonding line axis, the bonding line axis being oriented at a bonding angle (and in some embodiments, at the bonding angle α disclosed above) that is inclined with respect to the longitudinal direction. In some embodiments, the ear is attached such that the stretching direction is substantially perpendicular to the bonding line axis. The method may also include incorporating a securing feature into the diaper. In some embodiments, the securing feature is provided on a securing tab that is attached to the ear opposite the backsheet or is provided directly on the ear itself.

[0037] Example

[0038] A set of exemplary embodiments are provided below (including at least some exemplary embodiments expressly designated as "Examples" that provide additional descriptions of various example types in accordance with the concepts described herein). These Examples are not meant to be mutually exclusive, exhaustive, or limiting; and the present invention is not limited to these Examples, but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0039] Example 1. An absorbent article, the absorbent article comprising: a backsheet that extends in a longitudinal direction and includes a front portion, a rear portion, an intermediate portion connecting the front portion and the rear portion, a first lateral side, an opposite second lateral side, an outer surface, and an opposite inner surface; and at least one ear attached to the first lateral side of the backsheet and extending outwardly from the first lateral side of the backsheet, wherein the at least one ear is formed from a fabric adapted to stretch such that the at least one ear has a stretching direction; and wherein the at least one ear is attached to the first lateral side such that when the absorbent article is oriented in a flat, unfolded position and in an uncontracted state, the stretching direction of the at least one ear is oriented at an inclined stretching angle with respect to the longitudinal direction.

[0040] Example 2. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the at least one ear portion includes a first ear portion and a second ear portion, each of the first ear portion and the second ear portion being formed of the fabric and having the stretching direction, wherein the first ear portion and the second ear portion are respectively attached to the first lateral side and the second lateral side such that when the absorbent article is oriented in the flat unfolded position and in the unshrunk state, the stretching direction of each of the first ear portion and the second ear portion is oriented at an inclined angle with respect to the longitudinal direction.

[0041] Example 3. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the fabric has a longitudinal direction and a transverse direction, and wherein the stretching direction is parallel to one of the longitudinal direction or the transverse direction.

[0042] Example 4. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the inclined stretching angle is between 40° and 80°, including the end values.

[0043] Example 5. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the at least one ear portion is attached to the backsheet along a bond line having a bond line axis, and wherein when the absorbent article is oriented in the flat unfolded state and in the unshrunk state, the bond line axis extends at an inclined bond angle with respect to the longitudinal direction.

[0044] Example 6. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the inclined bond angle is between 20° and 50°, including the end values.

[0045] Example 7. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the stretching direction is substantially perpendicular to the bond line axis.

[0046] Example 8. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the at least one ear portion is attached to the rear portion of the backsheet.

[0047] Example 9. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the fabric includes a woven or knitted fabric containing elastic fibers.

[0048] Example 10. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, further comprising an absorbent component positioned on or within the backsheet.

[0049] Example 11. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the absorbent article comprises a diaper.

[0050] Example 12. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the diaper is a reusable diaper, and wherein the backsheet is adapted to be washed and reused.

[0051] Example 13. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, further comprising a first fastening feature and a second fastening feature, wherein the first fastening feature is associated with the at least one ear, and the second fastening feature is disposed on the outer surface of the front portion of the backsheet, wherein the first fastening feature and the second fastening feature are configured to cooperate with each other to fasten the absorbent article to a wearer.

[0052] Example 14. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, further comprising a fastening tab attached to the at least one ear, wherein the first fastening feature is disposed on the fastening tab.

[0053] Example 15. An absorbent article, the absorbent article comprising: a backsheet extending in a longitudinal direction and including a front portion, a rear portion, an intermediate portion connecting the front portion and the rear portion, a first lateral side, an opposite second lateral side, an outer surface, and an opposite inner surface; a first ear attached to the first lateral side and extending outwardly from the first lateral side; and a second ear attached to the second lateral side and extending outwardly from the second lateral side, wherein the first ear and the second ear are each formed of a fabric adapted to stretch in at least one of the longitudinal or transverse directions, such that the first ear has a first ear stretch direction, and the second ear has a second ear stretch direction, wherein each of the first ear stretch direction and the second ear stretch direction is parallel to one of the longitudinal or transverse directions of the fabric; wherein the first ear is attached to the first lateral side such that when the absorbent article is oriented in a flat, unfolded position and in an unshrunk state, the first ear stretch direction is oriented at a first ear stretch angle relative to the longitudinal direction; wherein the second ear is attached to the second lateral side such that when the absorbent article is oriented in the flat, unfolded position and in the unshrunk state, the second ear stretch direction is oriented at a second ear stretch angle relative to the longitudinal direction; and wherein the first ear stretch angle and the second ear stretch angle are between 40° and 80°, inclusive.

[0054] Example 16. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the first ear portion is attached to the backsheet along a first bonding line, and the second ear portion is attached to the backsheet along a second bonding line, wherein when the absorbent article is oriented in the flat unfolded position and in the unshrunk state, each of the first bonding line and the second bonding line extends at an inclined bonding line angle with respect to the longitudinal direction.

[0055] Example 17. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the stretching direction of the first ear portion is substantially perpendicular to the first bonding line, and the stretching direction of the second ear portion is substantially perpendicular to the second bonding line.

[0056] Example 18. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the first ear portion and the second ear portion are attached to the rear portion of the backsheet.

[0057] Example 19. The absorbent article according to any one of the foregoing or subsequent examples or combinations of examples, wherein the absorbent article comprises a diaper, and the diaper further comprises an absorbent component positioned on or within the backsheet.

[0058] Example 20. A method for manufacturing an absorbent article, the method comprising: providing a backsheet extending in a longitudinal direction and including lateral sides; providing an ear portion formed from a fabric adapted to be stretched in at least one of the longitudinal or transverse directions of the fabric such that the ear portion has a stretching direction parallel to the one of the longitudinal or transverse directions of the fabric; and attaching the ear portion to the lateral side of the backsheet such that when the absorbent article is oriented in the flat unfolded position and in the unshrunk state, the stretching direction of the ear portion is oriented at an inclined angle with respect to the longitudinal direction.

[0059] The various aspects, embodiments, specific implementations or features of the described embodiments may be used alone or in any combination. It should be understood that various elements from the concepts of the drawings may be combined without departing from the spirit or scope of the present invention.

[0060] Unless otherwise specified herein or clearly contradicted by the context, in the context of describing the present invention (especially in the context of the appended claims), the use of the terms "a" and "an" and "the" and similar referents shall be construed to cover both the singular and the plural. Directional references such as "above", "below", "top", "bottom", "left", "right", "front", and "rear" are intended to refer to the orientation shown and described in the figure (or figures) to which the components and directions are referred. Unless otherwise specified, the terms "comprising", "having", "including", and "containing" shall be construed as open-ended terms (i.e., meaning "including but not limited to"). Unless otherwise specified herein, the recitation of numerical ranges herein is only intended to be a shorthand method of referring individually to each separate value or gradient falling within the range, and each separate value is incorporated into the specification as if it were recited individually herein. Unless otherwise specified herein or clearly contradicted by the context, all methods described herein can be performed in any suitable order. Unless otherwise required, the use of any and all examples or exemplary language (e.g., "such as") herein is only intended to better illustrate embodiments of the present invention and does not limit the scope of the present invention. No language in the specification should be construed as indicating that any non-claimed element is essential for the practice of the present invention.

[0061] As used herein, the term "substantially" means the complete or near-complete range or degree of an action, characteristic, property, state, structure, item, or result. For example, a "substantially" enclosed object means that the object is completely enclosed or nearly completely enclosed. In some cases, the exact allowable degree of deviation from absolute completeness may depend on the particular context. However, near-completion will have the same overall result as if absolute and complete completion were achieved.

[0062] Preferred embodiments of the present invention are described herein, including the best mode known to the inventors for practicing the present invention. The present invention is susceptible to various modifications and alternative configurations, and certain exemplary embodiments of the present invention are shown in the drawings and have been described in detail above. Variations of those preferred embodiments within the spirit of the present invention will be apparent to those of ordinary skill in the art after reading the foregoing description. The inventors expect skilled artisans to appropriately employ these variations, and the inventors intend to practice the present invention in a manner different from that specifically described herein. Accordingly, it is to be understood that the present invention is not intended to be limited to the particular forms disclosed, but rather, the present invention includes all modifications and equivalents of the subject matter recited in the appended claims as permitted by applicable law. Additionally, unless otherwise specified herein or clearly contradicted by the context, the present invention covers any combination of the above elements in all possible variations thereof.

[0063] For purposes of explanation, the foregoing description uses specific terms to provide a thorough understanding of the described embodiments. However, it will be apparent to one of ordinary skill in the art that specific details are not required in order to practice the described embodiments. Accordingly, the foregoing description of specific embodiments is presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in light of the above teachings.

Claims

1. An absorbent article, the absorbent article comprising: a backsheet that extends in a longitudinal direction and includes a front portion, a rear portion, an intermediate portion connecting the front portion and the rear portion, a first lateral side, an opposite second lateral side, an outer surface, and an opposite inner surface; and at least one ear portion attached to the first lateral side of the backsheet and extending outwardly from the first lateral side of the backsheet, wherein: the at least one ear portion is formed of a fabric adapted to stretch such that the at least one ear portion has a stretching direction; and the at least one ear portion is attached to the first lateral side such that when the absorbent article is oriented in a flat, unfolded position and in an unshrunk state, the stretching direction of the at least one ear portion is oriented at an inclined stretching angle relative to the longitudinal direction.

2. The absorbent article according to claim 1, wherein the at least one ear portion includes a first ear portion and a second ear portion, each of the first ear portion and the second ear portion being formed of the fabric and having the stretching direction, wherein the first ear portion and the second ear portion are attached to the first lateral side and the second lateral side, respectively, such that when the absorbent article is oriented in the flat, unfolded position and in the unshrunk state, the stretching direction of each of the first ear portion and the second ear portion is oriented at an inclined angle relative to the longitudinal direction.

3. The absorbent article according to claim 1, wherein the fabric has a longitudinal direction and a transverse direction, and wherein the stretching direction is parallel to one of the longitudinal direction or the transverse direction.

4. The absorbent article according to claim 1, wherein the inclined stretching angle is between 40° and 80°, inclusive of the end values.

5. The absorbent article according to claim 1, wherein the at least one ear portion is attached to the backsheet along a bond line having a bond line axis, wherein when the absorbent article is oriented in the flat, unfolded position and in the unshrunk state, the bond line axis extends at an inclined bond angle relative to the longitudinal direction.

6. The absorbent article according to claim 5, wherein the inclined bond angle is between 20° and 50°, inclusive of the end values.

7. The absorbent article according to claim 5, wherein the stretching direction is substantially perpendicular to the bond line axis.

8. The absorbent article according to claim 1, wherein the at least one ear portion is attached to the rear portion of the backsheet.

9. The absorbent article according to claim 1, wherein the fabric comprises a woven or knitted fabric containing elastic fibers.

10. The absorbent article according to claim 1, further comprising an absorbent component positioned on or within the backsheet.

11. The absorbent article according to claim 10, wherein the absorbent article comprises a diaper.

12. The absorbent article according to claim 11, wherein the diaper is a reusable diaper, and wherein the backsheet is adapted to be washed and reused.

13. The absorbent article according to claim 1 further comprises a first fastening feature and a second fastening feature, wherein the first fastening feature is associated with the at least one ear portion, and the second fastening feature is disposed on the outer surface of the front portion of the backsheet, wherein the first fastening feature and the second fastening feature are configured to cooperate with each other to fasten the absorbent article to a wearer.

14. The absorbent article according to claim 13 further comprises a fastening tab attached to the at least one ear portion, wherein the first fastening feature is disposed on the fastening tab.

15. An absorbent article, the absorbent article comprising: A backsheet that extends in a longitudinal direction and includes a front portion, a rear portion, an intermediate portion connecting the front portion and the rear portion, a first lateral side, an opposite second lateral side, an outer surface, and an opposite inner surface; A first ear portion attached to the first lateral side and extending outwardly from the first lateral side; and A second ear portion attached to the second lateral side and extending outwardly from the second lateral side, wherein: Each of the first ear portion and the second ear portion is formed of a fabric adapted to stretch in at least one of the longitudinal or transverse directions, such that the first ear portion has a first ear portion stretch direction, and the second ear portion has a second ear portion stretch direction, wherein each of the first ear portion stretch direction and the second ear portion stretch direction is parallel to one of the longitudinal or transverse directions of the fabric; The first ear portion is attached to the first lateral side such that when the absorbent article is oriented in a flat, unfolded position and in an unshrunk state, the first ear portion stretch direction is oriented at a first ear portion stretch angle relative to the longitudinal direction; The second ear portion is attached to the second lateral side such that when the absorbent article is oriented in the flat, unfolded position and in the unshrunk state, the second ear portion stretch direction is oriented at a second ear portion stretch angle relative to the longitudinal direction; and The first ear portion stretch angle and the second ear portion stretch angle are between 40° and 80°, inclusive of the end values.

16. The absorbent article according to claim 15, wherein the first ear portion is attached to the backsheet along a first bond line, and the second ear portion is attached to the backsheet along a second bond line, wherein when the absorbent article is oriented in the flat, unfolded position and in the unshrunk state, each of the first bond line and the second bond line extends at an inclined bond line angle relative to the longitudinal direction.

17. The absorbent article according to claim 16, wherein the first ear portion stretch direction is substantially perpendicular to the first bond line, and the second ear portion stretch direction is substantially perpendicular to the second bond line.

18. The absorbent article according to claim 15, wherein the first ear portion and the second ear portion are attached to the rear portion of the backsheet.

19. The absorbent article according to claim 15, wherein the absorbent article comprises a diaper, and the diaper further comprises an absorbent component positioned on or within the backsheet.

20. A method for manufacturing an absorbent article, the method comprising: providing a backsheet that extends in a longitudinal direction and includes lateral sides; providing an ear formed from a fabric adapted to be stretched in at least one of the longitudinal or transverse directions of the fabric such that the ear has a stretching direction parallel to the one of the longitudinal or transverse directions of the fabric; and attaching the ear to the lateral sides of the backsheet such that when the absorbent article is oriented in a flat laid-out position and in an unshrunk state, the stretching direction of the ear is oriented at an inclined angle with respect to the longitudinal direction.

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