Disposable absorbent insert for reusable outer shell

Abstract

A disposable absorbent insert for a reusable outer shell includes a liquid-impermeable backsheet having first and second side edges, a liquid-permeable absorbent core between the topsheet and backsheet, and a nonwoven outer cover layer overlying the backsheet to form the outer surface of the insert. The insert has a pair of leg cuffs extending longitudinally and symmetrically positioned along the longitudinal side edges. The leg cuffs include side portions of the outer cover layer folded along a longitudinal fold line to divide the side portions of the outer cover layer into first and second portions that together form leg cuff folds, and a plurality of spaced apart pretensioned elastic elements extending longitudinally inward of the leg cuff folds and attached between the first and second portions of the leg cuff folds.

Description

[Technical Field]

[0001] SUMMARY The present disclosure relates to a disposable absorbent insert for a reusable outer shell and to a wearable absorbent article including a reusable shell and a disposable absorbent insert. [Background technology]

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

[0003] Conventional disposable absorbent articles in the form of diapers are typically designed with an absorbent core sandwiched between a topsheet and a backsheet. The article is arranged along a longitudinal axis and a transverse axis extending perpendicular to the longitudinal axis. Furthermore, the article can be divided into a front section, a rear section, and a crotch section. The diaper is designed with a waist section that encircles the wearer and is integral with the core, and further includes internal leg gathers (i.e., standing gathers) and external leg gathers to prevent edge leakage from the article.

[0004] Disposable absorbent inserts are used with reusable outer shells and are typically of simpler design than disposable diapers because they are intended to be used with an outer disposable or reusable shell or cover. There is a general desire for absorbent inserts to provide the same level of comfort, absorbent capacity, and leak safety as conventional diapers. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. 2021 / 037352 Brochure Summary of the Invention [Means for solving the problem]

[0006] The present disclosure provides a disposable absorbent insert according to claim 1 and a wearable absorbent article comprising a reusable shell and a disposable absorbent insert according to claim 25. Further embodiments are set out in the dependent claims and the description below.

[0007] Disclosed herein is a disposable absorbent insert for a reusable outer shell, the insert having a predetermined longitudinal and transverse extent, longitudinal side edges, and transverse side edges, and having a front portion, a rear portion, and a crotch portion positioned between the front and rear portions. The disposable absorbent insert includes a liquid-impermeable backsheet having a backsheet first side edge and a backsheet second side edge, an absorbent core disposed between a liquid-permeable, user-facing topsheet and the liquid-impermeable backsheet, and a nonwoven outer cover layer overlying the backsheet and forming the outer surface of the insert. The insert has a pair of leg cuffs extending longitudinally and symmetrically arranged along the longitudinal side edges. Each leg cuff includes a side portion of the outer cover layer folded back upon itself along a fold line extending longitudinally and dividing the side portion of the outer cover layer into a first portion and a second portion, the first and second portions together forming a leg cuff fold. The leg cuff further includes a plurality of spaced apart pre-tensioned elastic elements extending longitudinally inward of the leg cuff fold and attached between the first and second portions of the leg cuff fold.

[0008] The absorbent core can include an absorbent component surrounded by a core cover that includes upper and lower sides.

[0009] The leg cuffs of the insert can prevent bodily fluids that may have escaped absorption in the insert's absorbent core from soiling the leg surrounds of a reusable shell used in combination with the disposable insert, increasing the number of times the reusable outer shell can be used before it needs to be laundered, which is a major benefit of two-piece diaper systems that include a disposable inner portion and a reusable outer portion.

[0010] The leg cuffs of the insert as disclosed herein are clearly defined, neat, and distinct features that are easily identified by visual inspection of the absorbent insert. In prior art inserts, the leg elastics are typically positioned between the laterally extending side portions of the topsheet and backsheet, or between the standing gather material and the side portions of the backsheet. Such an arrangement results in frilled, loose, inelastic side edge portions laterally outward of the elastic elements. When donning a shell equipped with an insert having such inelastic side portions, it is necessary to ensure that the side portions are folded in order to avoid the insert being applied to the wearer with the elastic side portions folded over the absorbent main body portion, which could lead to a poor fit and ultimately to leakage of body fluids from the insert.

[0011] The insert as disclosed herein is gentle on the skin and comfortable to wear because all body-contacting surfaces of the article are constructed of a soft nonwoven material. The leg cuffs are particularly soft because the pre-tensioned elastic elements in the leg cuffs are positioned inside the leg cuff folds, providing the leg cuffs with folded outer edges. The multiple, spaced apart pre-tensioned elastic elements cause the nonwoven material in the leg cuff folds to contract and form soft, airy, evenly distributed wrinkles on the surface of the leg cuff. The wrinkled, elastic portions of the leg cuffs act as cushioning distance means between the wearer's body and the elastic elements.

[0012] The side portions of the outer cover layer may extend transversely outwardly from the corresponding backsheet side edges.

[0013] All or substantially all of the plurality of elastic elements in each leg cuff may be disposed in an outer portion of the leg cuff that is transversely outer than (i.e., free from) the liquid-impermeable backsheet.

[0014] The nonwoven outer cover layer can be a single layer of nonwoven material.

[0015] The leg cuffs can be leak-resistant. The nonwoven outer cover layer forming the leg cuffs can be made of a material that provides properties such as high breathability and barrier properties to prevent any leakage and soiling of the reusable outer shell. This is particularly advantageous when the insert does not have standing gathers. The nonwoven layer can be made of a co-formed lamina of a nonwoven material, such as an SMS (spunbond / meltblown / spunbond) nonwoven material or an SS (spunbond / spunbond) nonwoven material. The thermoplastic polymer material in the nonwoven layer can be polypropylene, or a bicomponent fiber of polypropylene and polyethylene, or a combination of such materials. The outer cover layer can also include two layers of hydrophobic nonwoven material.

[0016] Alternatively, the nonwoven material used for the outer cover material can include one or more spunbond layers and, optionally, one or more meltblown layers. The nonwoven material can be made from thermoplastic polymer fibers or filaments. The nonwoven material can be formed by any of a variety of different processes, such as spunbonding, airlaying, meltblowing, or a bonded carded web formation process.

[0017] The nonwoven materials used can be renewable or recyclable. The nonwoven materials can be bio-based.

[0018] The leg cuffs are highly breathable because they are primarily composed of nonwoven material. The liquid-impermeable backsheet can extend into the leg cuffs at the inner portion of each leg cuff by up to 50% of the width of the leg cuff, for example, up to 40% of the width of the leg cuff, or up to 30% of the width of the leg cuff. The liquid-impermeable backsheet can extend into the leg cuffs by a larger portion of the width of each leg cuff for smaller-sized articles than for larger-sized articles.

[0019] An elastic element of the plurality of elastic elements can be attached between the first and second portions of the leg cuff fold by an adhesive.

[0020] According to one embodiment, a first portion of the side portion of the outer cover layer can be a lower portion of the leg cuff fold when viewed from the topsheet, and a second portion of the side portion of the outer cover layer can be an upper portion of the leg cuff fold when viewed from the topsheet. In such an arrangement, the outer-facing side of the insert is soft and continuous without edges, seams, or joints. In such an arrangement, the second portion of the side portion includes a longitudinal edge of the outer cover layer, and the longitudinal edge of the second portion of the side portion is an inner end that can be secured between the topsheet and the backsheet.

[0021] The plurality of elastic elements in each leg cuff may comprise at least three elastic elements, preferably at least four elastic elements, which may be spaced apart transversely by 1 mm to 8 mm, preferably 3 mm to 8 mm.

[0022] The elastic element can be an elastic thread, a string or an elastic band, preferably an elastic thread.

[0023] The one or more elastic elements disposed in the inner portion of the leg cuff fold can have a greater tensile resistance than the one or more elastic elements disposed in the outer portion of the leg cuff fold, and the one or more elastic elements in the inner portion of the leg cuff fold can have a higher linear density (dtex) than the linear density of the one or more elastic elements disposed in the outer portion of the leg cuff fold.

[0024] The leg cuff folds can extend along the entire longitudinal length of the insert.

[0025] The plurality of elastic elements can be disposed along at least the entire longitudinal length of the crotch area, with the longitudinal length of the plurality of elastic elements being less than the total longitudinal length of the insert. As such, the folded side portions of the nonwoven outer cover layer are elasticated only in portions of the insert intended to be positioned adjacent the wearer's legs during use. The leg cuff folds are partially devoid of elastic elements in the front and rear portions, thereby providing the insert with softer front and rear portions that better conform to the wearer's waist when placed and worn within the reusable outer shell.

[0026] Additionally, the insert can include first longitudinally extending standing gathers and second longitudinally extending standing gathers. The standing gathers are disposed transversely inside the leg cuffs toward the longitudinal centerline of the insert and are positioned to be at least partially raised during use of the insert. The standing gathers are attached to the topsheet. The standing gathers, in addition to the leg cuffs, further improve the leak safety of the absorbent insert.

[0027] The insert can have a pair of nonwoven barrier cuff strips extending longitudinally and symmetrically arranged with one barrier cuff strip on each side of the longitudinal centerline. Each nonwoven barrier cuff strip can include a standing gathered portion forming first and second standing gathers, respectively, each standing gather defined between a longitudinally extending free standing gathered edge and a longitudinally extending standing gathered hinge line. The barrier cuff strips are attached to the topsheet along the standing gathered hinge lines.

[0028] The nonwoven material in the nonwoven barrier strips can be the same as that described herein in connection with the outer cover layer, and can be different from the nonwoven material of the outer cover material from which the leg cuff folds are formed.

[0029] The standing gathers may have one or more pre-tensioned elastic elements disposed along the free standing gather edge.

[0030] The nonwoven barrier cuff strip may include a leg cuff portion, the leg cuff portion of the nonwoven barrier cuff strip being defined between the standing gathered hinge line and an outer leg cuff edge of the nonwoven barrier cuff strip, the outer leg cuff edge of the nonwoven barrier cuff strip being parallel to the fold line of the leg cuff fold, and the leg cuff portion of the nonwoven barrier cuff strip overlapping at least one elastic element of the plurality of elastic elements.

[0031] Each leg cuff can be positioned outwardly of the standing gathered portion of the corresponding barrier cuff strip.

[0032] The leg cuff folds can have free edges defined by fold lines, with the leg cuff width in the transverse direction being between the fold line and the standing gathered hinge line at the leg cuff folds.

[0033] The leg cuff portion of each nonwoven barrier cuff strip can be attached to a corresponding leg cuff fold with the leg cuff portion of the nonwoven barrier cuff strip overlapping all or substantially all of the plurality of elastic elements in the leg cuff fold.

[0034] In such an arrangement, the leg cuffs include, on the inside of the wearer-facing side of the article, leg cuff portions of the nonwoven barrier cuff strips, which form an additional gatherable cushioning layer of the leg cuffs. Thus, under the influence of contractile forces from the elastic elements distributed across the width of each leg cuff, the leg cuff portions of the nonwoven barrier cuff strips, together with the nonwoven material at the leg cuff folds, form soft and voluminous yet still highly conforming leg cuffs.

[0035] In inserts as disclosed herein, the leg cuff portions of the nonwoven barrier cuff strips can be attached to the leg cuff folds by adhesive that is uniformly distributed over the attachment area between the nonwoven barrier cuff strips and the leg cuff folds, or by a uniformly distributed thermobond or ultrasonic bond. Thus, the adhesive is uniformly distributed over the attachment area between the leg cuff portions of the nonwoven barrier cuff strips and the upper portions of the side portions of the outer cover layer. The adhesive can be applied by any suitable technique, such as slot coating or spray coating.

[0036] The outer leg cuff edges of the nonwoven barrier cuff strips can be positioned at or inward of the fold lines in the leg cuff folds when viewed in the cross direction.

[0037] The leg cuff portions of the nonwoven barrier cuff strips can be attached to the second portions of the side portions of the outer cover layer by adhesive, the adhesive being uniformly distributed over the attachment area between the leg cuff portions of the nonwoven barrier cuff strips and the second portions of the side portions of the outer cover layer.

[0038] The width of each leg cuff is in the range of 20 millimeters to 60 millimeters, and the elastic elements of the plurality of elastic elements in each leg cuff are distributed over an area of ​​the leg cuff having a width in the transverse direction that is at least 40% of the width of the leg cuff, preferably at least 50% of the width of the leg cuff.

[0039] The nonwoven barrier cuff strips can be a single layer of nonwoven material.

[0040] A first portion of the side portion of the outer cover layer can be contiguous with a central portion of the outer cover layer, which central portion of the outer cover layer overlaps the backsheet, and a second portion of the side portion of the outer cover layer is a folded-over portion of the side portion of the outer cover layer.

[0041] The insert can be provided with fastening elements for fastening the insert to the reusable outer shell, and the reusable outer shell can be provided with corresponding fastening elements to facilitate fastening of the insert. Suitable fastening elements can include, for example, hook or loop material, push buttons, and tape.

[0042] The fastening elements may be strips of loop material attached to the garment-facing side of the outer cover layer near the transverse side edges of each of the front and rear portions of the insert.

[0043] The fastener element can be a hook member, including any hook-type material with a hook surface structure, or a hook attachment zone, including any loop surface structure (i.e., a system known as a VELCRO® system). The "hook" can have many different shapes that are adapted to engage with the loop portion of a hook and loop fastening system (known as a VELCRO® system).

[0044] The strip of loop material can extend across 50-100% of the transverse sides of the insert. The longitudinal extent of the strip of loop material can be from 10 mm to 50 mm, such as from 10 mm to 35 mm. The longitudinal extent of the strip of loop material can be greater in the rear portion of the insert than in the front portion. The strip of loop material can have the same free transverse side edges as the topsheet and backsheet materials. The strip of loop material can have the same free transverse side edges as the insert. The insert with the strip of loop material attached to the backsheet can further include any other features of the insert as described above and disclosed herein.

[0045] The strip of loop material on the garment-facing side of the backsheet provides improved attachment of the insert into a reusable shell that is provided with hook portions on the inside of its front and rear portions, such as those disclosed herein. The advantage of an insert having strips of loop material in its front and rear portions with the same free transverse side edges as the insert itself is that it provides improved, tight attachment of the insert into the reusable shell during use.

[0046] Alternatively, the outer cover layer itself can be of a material that facilitates fastening of the insert to the reusable outer shell, i.e., a material that provides secure attachment of the insert to hook material elements provided on the user-facing side of the outer shell.

[0047] The present disclosure relates to a disposable absorbent insert for a reusable outer shell. The insert thus lacks side flaps located at the waist edge of the front section and side flaps located at the waist edge of the rear section. Such side flaps are present in disposable diapers, and are provided with fasteners for fastening the disposable diaper in a pant-like manner around the waist of a wearer. The disposable absorbent insert is not intended to be fastened to the waist of a wearer without an outer shell, and therefore lacks any such fastening means.

[0048] Moreover, the insert lacks a waist belt, which is present on conventional pant-type disposable diapers and forms a continuous waistband around the wearer's body.

[0049] The insert may have a rectangular shape.The absorbent core may have a rectangular shape.

[0050] The insert may be provided with a waist elastic member at the transverse front edge of the insert's front portion and / or at the transverse back edge of the insert's rear portion. The waist elastic member may include a stretchable material or elastic yarn extending in the transverse direction. The waist elastic member may improve fit around the wearer's waist. The insert may be provided with a waist gasketing element in the form of a barrier pocket at the front and / or rear portions of the insert. The barrier pocket may be attached to the insert along its longitudinal edges and the front or rear edges, respectively, for example, to open toward the crotch portion and thereby form a pocket. Such a waist gasketing element may improve leak safety around the wearer's waist.

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

[0052] A wearable absorbent article including a reusable outer shell worn by a wearer can include a disposable absorbent insert including a strip of loop material attached to the garment-facing side of the backsheet near the transverse side edges of each of the front and rear portions of the insert, as disclosed above.

[0053] The present disclosure will be described in more detail below with reference to the figures shown in the accompanying drawings. [Brief explanation of the drawings]

[0054] [Figure 1]FIG. 2 is a plan view of a stretched absorbent article in the form of an insert, viewed from the side intended to face the wearer during use. [Figure 2] 2 is a cross-section through the insert of FIG. 1 taken along line II-II of FIG. 1; [Figure 3] 1A-1C show a wearable absorbent article including a reusable shell and a disposable insert. [Figure 4] FIG. 2 is another plan view of a stretched absorbent article in the form of an insert, viewed from the side intended to face the wearer during use. [Figure 5] 2 is a cross-section through the insert of FIG. 3 taken along line II-II of FIG. 3; [Figure 6] FIG. 6 shows details of a leg cuff as shown in FIGS. 4 and 5. [Figure 7] 5 shows an alternative cross section through the diaper of FIG. 1 taken along line II-II of FIG. 4. DETAILED DESCRIPTION OF THE INVENTION

[0055] It should be understood by those skilled in the art that the following is a description of exemplary embodiments only, and is not intended as a limitation on the broader aspects of the present disclosure.

[0056] Different aspects of the absorbent insert as disclosed herein are described more fully below with reference to the enclosed drawings, and the embodiments disclosed herein should not be construed as being limited to the claimed absorbent insert.

[0057] It should be understood that the drawings are schematic and that individual components, such as layers of material, are not necessarily drawn to scale.

[0058] The disposable absorbent insert 1 is shown in Figure 1 in an unfolded, flat condition, with all elastic elements and components in a stretched state. Figure 1 shows the insert 1 from the inner, wearer-facing surface. Any measurements of distances and dimensions are taken with the insert in a fully stretched, ungathered condition, as shown in Figure 1.

[0059] The insert 1 has a longitudinal direction L and a transverse direction T.

[0060] The insert 1 has a first waist edge 2, a second waist edge 4, and first and second side edges 6, 8. The first waist edge 2 of the insert 1 shown in FIG. 1 is the back waist edge, and the second waist edge 4 of the absorbent insert 1 is the front waist edge. The first and second waist edges 2, 4 extend in a transverse direction T of the absorbent insert 1, and the side edges 6, 8 extend in a longitudinal direction L of the absorbent insert 1. The absorbent insert 1 can be divided in the longitudinal direction L into a front portion 3, a rear portion 5, and a crotch portion 7 located between the front portion 3 and the rear portion 5.

[0061] The insert 1 includes a liquid-permeable topsheet 9 and a liquid-impermeable backsheet 10. An absorbent core 11 is disposed between the topsheet 9 and the backsheet 10. The topsheet 9 has a topsheet first side edge 9' and a topsheet second side edge 9", as shown in Figures 1 and 2, and the backsheet 10 has a backsheet first side edge 10' and a backsheet second side edge 10".

[0062] The insert 1 further includes a nonwoven outer cover layer 18 overlying the backsheet 10 and forming the outer surface of the insert 1 .

[0063] The insert 1 includes a pair of leg cuffs 31, 32 extending in a longitudinal direction L and arranged symmetrically along the first and second side edges 6, 8.

[0064] As shown in FIG. 2 , the leg cuffs 31, 32 each include an outer cover layer side portion 33, 34 extending transversely outwardly of the corresponding backsheet side edge 10′, 10″, the side portion 33, 34 of the outer cover layer 18 folded back upon itself along fold lines 36, 38 extending in the longitudinal direction L to divide the side portion 33, 34 of the outer cover layer 18 into a first portion 33′, 34′ and a second portion 33″, 34″, which together form leg cuff folds 35, 37 having free edges defined by the fold lines 36, 38, such that a leg cuff width W is defined in the transverse direction T between the free edges of the leg cuff fold lines 36, 38 and the inner ends 47, 48 of the side portions 33, 34.

[0065] First portions 33', 34' of the side portions 33, 34 of the outer cover layer 18 are shown in FIG. 2 as being contiguous with the central portion 18' of the outer cover layer 18, which central portion 18' of the outer cover layer 18 overlapping the backsheet 10. Second portions 33", 34" of the side portions 33, 34 of the outer cover layer 18 are folded-over portions of the side portions 33, 34 of the outer cover layer 18.

[0066] In the embodiment shown in FIGS. 1-6 , first portions 33′, 34′ of the side portions 33, 34 of the outer cover layer 18 constitute lower portions of the leg cuff folds 35, 37 when viewed in the direction from the topsheet 9, and second portions 33″, 34″ of the side portions 33, 34 of the outer cover layer 18 constitute upper portions of the leg cuff folds 35, 37 when viewed in the direction from the topsheet 9. The upper portions of the leg cuff folds 35, 37 are folded over the lower portions of the leg cuff folds 35, 37 and secured between the topsheet 9 and the backsheet 10. Thus, the topsheet 9 and the backsheet 10 are directly connected to each other along the side edges of the absorbent core 11, as seen in FIG. 2 , and are directly connected to the folded portions of the outer cover layer secured between the topsheet 9 and the backsheet 10. The folded portions of the outer cover layer include inner edges 47, 48. The garment-facing side of the backsheet is attached directly to the central portion of the outer coversheet.

[0067] As described herein, the side portions 33, 34 of the outer cover layer 18 can alternatively be folded such that a first portion 33', 34' of the side portions 33, 34 of the outer cover layer 18, which is contiguous with the central portion 18' of the outer cover layer 18, constitutes the upper portion of the leg cuff folds 35, 37 when viewed in a direction away from the topsheet, and the folded-over second portion 33", 34" constitutes the lower portion of the leg cuff folds 35, 37 when viewed in a direction away from the topsheet 9. In this configuration, as shown in FIG. 7, the side portions 33, 34 of the outer cover layer 18 are folded back onto themselves on the side of the insert 1 that faces the outer garment.

[0068] A plurality of spaced apart pre-tensioned elastic elements 41, 42 are disposed within each leg cuff fold 35, 37. The elastic elements 41, 42 extend in the longitudinal direction L inside the leg cuff fold 35, 37 and are attached, for example by adhesive, between the first portion 33', 34' and the second portion 33", 34" of the leg cuff fold 35, 37.

[0069] The width of the leg cuffs 31, 32 can be in the range of 20 to 60 millimeters, and the elastic elements of the plurality of elastic elements 41, 42 can be distributed over an area of ​​each leg cuff having a width that is at least 40% of the width of the leg cuff, preferably at least 50% of the width of the leg cuff. The width of the stretchable portion of the leg cuffs 31, 32 can be in the range of 20 to 40 millimeters.

[0070] The elastic elements of the plurality of elastic elements 41, 42 in each leg cuff 31, 32 may be suitably attached between the first and second portions 33', 34'; 33", 34" of the leg cuff folds 35, 37 by adhesive. The adhesive may be applied to the elastic elements and / or to one or both of the first and second portions 33, 34 of the leg cuff folds 35, 37. Alternatively, the elastic elements may be anchored in the leg cuff folds 35, 37 by heat welding or ultrasonic welding, as disclosed, for example, in U.S. Patent No. 5,627,999.

[0071] The elastic elements can be elastic threads, bands, strings, etc. All of the elastic elements can be of the same type and have the same elastic properties. Alternatively, one or more elastic elements disposed in the outer portions of the leg cuff folds 35, 37 can have a greater tensile resistance than one or more elastic elements disposed in the inner portions of the leg cuff folds 35, 37.

[0072] The one or more elastic elements in the outer portions of the leg cuff folds 35, 37 may have a linear density (dtex) that is higher than the linear density of the one or more elastic elements disposed in the inner portions of the leg cuff folds 35, 37.

[0073] The absorbent insert 1 of Figures 1 and 4 further includes an optional waist elastic member 19. The waist elastic member 19 is positioned at the rear waist edge 2 and extends laterally along only a portion of the rear waist edge 2. Any type of waist elastic can be used as known in the art. Additionally, the absorbent insert 1 can also include a waist elastic member 20 in the front portion 3 of the absorbent insert 1.

[0074] Fastening elements in the form of strips of loop material 50, 51 are attached to the garment-facing side of the backsheet 18 near the transverse side edges 2, 4 of each of the front and rear portions 3, 5 of the insert 1, as shown in Figures 1, 3, and 4. The strips of loop material 50, 51 extend over 50-100% of the transverse sides of the insert 1. The longitudinal extent of each strip of loop material is 10 mm to 50 mm. The longitudinal extent of the strips of loop material 50, 51 can be greater in the rear portion 5 of the insert 1 than in the front portion 3.

[0075] The continuous production of absorbent articles is well known in the art. A method for producing a disposable absorbent insert 1 for use with a reusable outer shell 100 can include conveying a continuous precursor of the absorbent insert 1 having longitudinal and transverse extents, the precursor having a continuous topsheet material 9 and a continuous liquid-impermeable backsheet material 10, with a plurality of absorbent cores 11 regularly distributed between the topsheet 9 and backsheet 10 materials, and the precursor having a continuous outer cover layer material 18. The method disclosed herein then further regularly provides strips of loop material 50, 51 on the outward-facing sides of the outer cover layer material 18 so as to bridge the contours of two immediately adjacent interconnected inserts 1 each containing an absorbent core 11, and the method cuts the strips of loop material 50, 51, the topsheet 9, the backsheet 10, and the outer cover layer 18 material in a single cutting operation to separate the connected inserts 1, thereby obtaining a single insert 1 having strips of loop material 50, 51 near the transverse side edges 2, 4 of the front portion 3 and the rear portion 5 of the insert 1, respectively.

[0076] Figure 3 discloses an absorbent insert 1 within a reusable outer shell 2. The reusable shell 2 has longitudinal and transverse side edges and inner and outer surfaces. Figure 3 is an illustration of the reusable shell 100 as viewed from the inner surface that faces the user when worn. The reusable outer shell is provided with complementary fastening elements 50', 51'.

[0077] The reusable outer shell 2 is an outer shell that can be reused multiple times. The reusable outer shell can be a washable outer shell that can be washed multiple times without substantial shrinkage or other damage. The outer shell can be made from a washable material, such as a washable fabric. The outer shell can be made from one or more of the following materials: polyester, viscose, polyamide, and / or cotton. The outer shell can be a stretchable outer shell, i.e., made from a stretchable material. The outer shell can be an elastic shell, elastic in the longitudinal direction L and / or the transverse direction T of the outer shell.

[0078] In one example for releasably attaching the absorbent insert 1 to the outer shell 100, the outer shell 100 includes front and rear hook members 50' and 51' that are disposed on the inner surface of the outer shell 100 and are arranged to be attached to front and rear loop members or strips of loop material 50, 51 that are attached to the garment-facing side of the outer cover layer 18 of the insert 1.

[0079] Furthermore, as can be seen in Figure 3, the wide elastic leg cuffs 31, 32 are lofty and shape stable, and automatically correct position when the outer shell and insert are applied to the wearer.

[0080] As seen in Figures 4 and 5, inserts such as those seen in Figures 1, 2, and 3 can further be provided with standing gathers 29, 30. A pair of nonwoven barrier cuff strips 21, 22 are arranged extending in the longitudinal direction L, symmetrically arranged with one barrier cuff strip 21, 22 on each side of a longitudinal centerline Lc perpendicular to the transverse centerline Lt, and each nonwoven barrier cuff strip 21, 22 includes a standing gathered portion 21', 22'. The standing gathered portions 21', 22' of the nonwoven barrier cuff strips 21, 22 are defined between free standing gathered edges 23, 24 extending in the longitudinal direction L and standing gathered hinge lines 25, 26 extending in the longitudinal direction L. A pair of raised elastic standing gathers 29, 30, including the standing gathered portions 21', 22' of the barrier cuff strips 21, 22, are disposed on the topsheet 9. Thus, the standing gathered portions 21', 22' of the barrier cuff strips 21, 22 form part of the standing gathers 29, 30.

[0081] Each barrier cuff strip 21, 22 is attached directly to the topsheet 9 along a standing gather hinge line 25, 26 and has one or more pre-tensioned elastic elements 27, 28 disposed along the free standing gathered edge 23, 24. The one or more elastic elements can be elastic strings, threads, or bands applied at intervals along the free standing gathered edge 23, 24. In absorbent inserts as disclosed herein, the number of elastic elements 27, 28 disposed along the standing gathered edge 23, 24 is typically one, two, or three. The elastic elements 27, 28 are typically disposed parallel to one another with a spacing of 2 to 5 millimeters, with the outermost elastic elements disposed at the free standing gathered edge 23, 24.

[0082] Each leg cuff 31, 32 is disposed outwardly of the standing gathered portion 21', 22' of the corresponding barrier cuff strip 21, 22.

[0083] Each leg cuff 31, 32 further includes a leg cuff portion 21", 22" of a corresponding nonwoven barrier strip 21, 22. The leg cuff portion 21", 22" of the nonwoven barrier cuff strip 21, 22 is defined between the standing gathered hinge lines 25, 26 and outer leg cuff edges 43, 44 of the nonwoven barrier cuff strip 21, 22. The outer leg cuff edges 43, 44 of the nonwoven barrier cuff strip 21, 22 are parallel to the fold lines 36, 38 of the leg cuff folds 35, 37 and overlap at least one of the plurality of elastic elements 41, 42. In the illustrated embodiment, the leg cuff portions 21", 22" of the nonwoven barrier strips 21, 22 overlap all of the elastic elements 41, 42 in the leg cuff folds 35, 37, and the outer leg cuff edges 43, 44 of the leg cuff portions 21", 22" are aligned with the fold lines 36, 38 in the side portions 33, 34 of the outer cover layer 18. It should be understood that the outer leg cuff edges 43, 44 of the leg cuff portions 21", 22" do not have to be aligned with the fold lines 36, 38, but can be positioned inward of the fold lines 36, 38 in the side portions 33, 34 of the outer cover layer 18.

[0084] Figure 6 shows a simplified detail of a portion of the leg cuff 32 of Figure 5 located along the second side edge. A plurality of elastic elements 42, represented by five individual elastic elements, are arranged in the leg cuff fold 37 with a spacing d between the individual elastic elements. The elastic elements are shown with equal spacing between all elastic elements. However, the spacing may be different in different portions of the leg cuff 32. By way of example, the spacing between the individual elastic elements may be smaller in an outer portion of the leg cuff 32 near the fold line 38 than in an inner portion of the leg cuff 32 nearer the standing gathered hinge line 26.

[0085] The leg cuff portion 22" of the nonwoven barrier cuff strip 22 overlaps all of the elastic elements 42 in the leg cuff fold 37, but is attached to the second, upper portion 34" of the leg cuff fold 37 only in areas of the second portion 34" of the leg cuff fold 37 that correspond to the locations of four of the elastic elements 42 that are located a distance from the fold line 38. The leg cuff portion 22" of the nonwoven barrier cuff strip 22 is attached to the second portion 34" of the leg cuff fold 37 by adhesive 46, leaving the outermost portions of the leg cuff portion 22" of the nonwoven barrier cuff strip 22 unattached to the leg cuff fold 37. As such, the adhesive is not located immediately adjacent to the side edges of the absorbent insert 1. The adhesive attachment between the leg cuff fold and the leg cuff portion 22″ of the nonwoven barrier cuff strip 22 can increase the structural stability of the leg cuff 32 by increasing the bending resistance of the leg cuff. It should be understood that the adhesive area 46 can also extend to the fold line 38 in the leg cuff fold 37.

[0086] As shown in FIG. 6 (which is a highly schematic exploded view of leg cuff 32), the outermost elastic element of the plurality of elastic elements 42 is positioned at fold line 38 so that there is no excess material outside the outermost elastic element. This may be the ideal positioning of the outermost elastic element. However, due to manufacturing tolerances, the positioning of the outermost elastic element in an actual absorbent insert 1 may deviate somewhat from the position shown in FIG. 6.

[0087] As disclosed herein, the leg cuff portion 22" of the nonwoven barrier cuff strip 22 can be attached to the leg cuff fold 37 by adhesive, the adhesive being uniformly distributed across the attachment area between the barrier cuff strip 22 and the upper portion 34" of the leg cuff fold 37 to create a uniform attachment between the leg cuff portion 22" of the nonwoven barrier cuff strip 22 and the leg cuff fold 37 such that contractile forces from the spaced-apart pre-tensioned elastic elements 42 in the leg cuff fold 37 are transferred to the leg cuff portion 22" of the nonwoven barrier cuff strip 22 in a substantially equal manner across the entire attachment area. As the elastic elements contract, the leg cuff portion 22" of the nonwoven barrier cuff strip 22 gathers with the material at the leg cuff fold 37 to form soft corrugations in the leg cuff 32 in a controlled and orderly manner.

[0088] 6, the second portion 34" of the leg cuff fold 37 is secured to the backsheet 10 at an inner edge 48 of the second portion 34" of the leg cuff fold 37 along the backsheet side edge 10". The inner edge 48 is also disposed below the topsheet 9. As can be seen in FIGS. 2 and 6, the inner edges 47, 48 of the second portions 33", 34" of the side portions 33, 34 are inserted between the topsheet 9 and the backsheet 10 and secured therebetween. The attachment is by adhesive. However, it should be understood that the leg cuff portion 22" of the nonwoven barrier strip 22 may alternatively be attached by thermal welding or ultrasonic welding. In the embodiment shown in FIG. 3, all of the elastic elements of the plurality of elastic elements 42 are disposed in a portion of the leg cuff fold 37 where the backsheet 10 is not present. While this may be the desired arrangement to provide maximum breathability to the leg cuffs 32, the backsheet 10 may alternatively extend into the leg cuffs 32 so that it overlaps the innermost elastic element of the plurality of elastic elements 42.

[0089] In the configuration shown in FIG. 7 , the leg cuffs 31, 32 each include an outer cover layer side portion 33, 34 extending transversely outwardly of the corresponding backsheet side edge 10′, 10″, and the outer cover layer side portion 33, 34 is folded back upon itself along fold lines 36, 38 extending in the longitudinal direction L to divide the outer cover layer side portion 33, 34 into a first portion 33′, 34′ and a second portion 33″, 34″. , 34″ together form leg cuff folds 35, 37 having free edges defined by fold lines 36, 38, with a leg cuff width W defined in the transverse direction T between the free edges of the leg cuff fold lines 36, 38 and the standing gathered hinge lines 25, 26. First portions 33′, 34′ of the side portions 33, 34 of the outer cover layer 18 are contiguous with a central portion 18′ of the outer cover layer 18, which central portion 18′ of the outer cover layer 18 overlapping the backsheet 10.

[0090] As shown in FIG. 7 , first portions 33′, 34′ of the side portions 33, 34 of the outer cover layer 18 constitute upper portions of the leg cuff folds 35, 37 when viewed in the direction from the topsheet 9, and second portions 33″, 34″ of the side portions 33, 34 of the outer cover layer 18 constitute lower portions of the leg cuff folds 35, 37 when viewed in the direction from the topsheet 9. The lower portions of the leg cuff folds 35, 37 are folded under the upper portions of the leg cuff folds 35, 37 and attached to the outer cover layer 18.

[0091] The following paragraphs describe the absorbent core, topsheet, and backsheet as suitable for all of the examples described above.

[0092] The absorbent core 11 is disposed between the topsheet 9 and the backsheet 10 and is positioned to absorb liquids (e.g., urine or other bodily fluids) that pass through the topsheet 9. The absorbent core 11 can be a single-layer structure or a layered structure. The absorbent core 11 can comprise any conventional material suitable for absorbing excreted bodily wastes, such as cellulosic fluff pulp, tissue layers, highly absorbent polymers (superabsorbents), absorbent foam materials including hydrogel foam materials, or nonwoven materials. The absorbent core can also include non-absorbent components (e.g., reinforcing elements, shaping elements, binders, etc.). Various types of liquid-accepting and liquid-distribution materials can also be included in the core.

[0093] The absorbent core 11 can be a three-dimensionally shaped core with different amounts of absorbent material in different portions of the core. The core can be provided with features such as embossing, fluid acquisition cavities, and fluid distribution channels. The properties of the absorbent core, such as density, amount of absorbent material, and absorbent capacity, can also be varied in different portions of the absorbent core. The absorbent core 11 can include a core cover that sandwiches the absorbent material between an upper core cover layer and a lower core cover layer. Such a core cover can be a tissue or nonwoven material and is provided in addition to the topsheet 9 and backsheet 10.

[0094] The liquid-permeable topsheet 9 can include or be composed of a nonwoven material. Other suitable topsheet materials include tow fibers, porous foams, apertured plastic films and laminates, and combinations of such materials. Materials best suited as topsheet materials are soft and non-irritating to the skin, are easily penetrated by body fluids, and exhibit low rewet of absorbed body fluids.

[0095] The liquid-impermeable backsheet 10 can be any conventional liquid-impermeable material, such as a thin plastic film (e.g., polyethylene or polypropylene film), etc. The backsheet material can be breathable to allow vapors to escape from the absorbent body portion while still preventing liquids from passing through the backsheet material. [Explanation of symbols]

[0096] 1 absorbent insert 2 First waist edge 3 Front part 4 Second waist edge 5 Rear part 6 first side edge 7 Crotch area 8 second side edge 9 Topsheet 9' first side edge of topsheet 9" second side edge of topsheet 10 Back Seat 10' first side edge of backsheet 10" second side edge of backsheet 11 absorbent core 18 outer cover layer 18' center section 19 Waist elastic member 20 waist elastic member 21 Nonwoven Barrier Cuff Strips 21' standing gathered part 21" leg cuff 22 Nonwoven Barrier Cuff Strips 22' standing gathered part 22" leg cuff 23 Free standing gathered edge 24 Free standing gathered edge 25 Standing gathered hinge line 26 Standing gathered hinge line 27 Elastic Elements 28 Elastic Elements 29 Standing Gather 30 Standing Gather 31 Leg cuff 32 Leg cuff 33 Side part 33' First part 33” Second part 34 Side part 34' First part 34” Second Part 35 Leg cuff fold 36 Folding line 37 Leg cuff fold 38 Folding lines 41 Elastic Elements 42 Elastic Elements 43 outer leg cuff edge 44 outer leg cuff edge 46 Adhesive 47 Inner end 48 Inner end 50 strips of loop material, fastener elements 50' Complementary fastener element, front hook member 51 Strip of loop material, fastener element 51' Complementary fastener element, rear hook member 100 outer shell d-spacing L Longitudinal direction Lt Transverse Centerline Lc longitudinal center line T transverse direction W Leg cuff width

Claims

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

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

3. 3. A disposable absorbent insert (1) according to claim 1 or 2, wherein all of the plurality of elastic elements in each leg cuff (31, 32) are arranged in the outer portion of the leg cuff (31, 32) transversely outside the liquid-impermeable backsheet (10).

4. 4. The disposable absorbent insert (1) according to any one of claims 1 to 3, wherein the elastic elements (41, 42) of the plurality of elastic elements are attached between the first and second portions (33', 33", 34', 34") of the leg cuff folds (35, 37) by adhesive.

5. 5. The disposable absorbent insert (1) according to any one of claims 1 to 4, wherein the first portions (33', 34') of the side portions (33, 34) of the outer cover layer (18) are continuous with the central portion (18') of the outer cover layer (18), the central portion (18') of the outer cover layer (18) overlapping the backsheet (10), and the second portions (33", 34") of the side portions of the outer cover layer (18) are folded-over portions of the side portions (33, 34) of the outer cover layer (18).

6. 6. A disposable absorbent insert (1) according to any one of claims 1 to 5, wherein the plurality of elastic elements (41, 42) in each leg cuff (31, 32) is constituted by at least three elastic elements, preferably at least four elastic elements.

7. 7. A disposable absorbent insert (1) according to any one of claims 1 to 6, wherein the elastic elements (41, 42) are spaced apart in the transverse direction (T) by 1 mm to 8 mm, preferably by 3 mm to 8 mm.

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

9. 9. A disposable absorbent insert (1) according to any one of claims 1 to 8, wherein the first portions (33', 34') of the side portions (33, 34) of the outer cover layer (18) are lower portions of the leg cuff folds (35, 37) when viewed in a direction from the top sheet (9), and the second portions (33", 34") of the side portions (33, 34) of the outer cover layer (18) are upper portions of the leg cuff folds (35, 37) when viewed in a direction from the top sheet (9).

10. 10. The disposable absorbent insert (1) of claim 9, wherein the second portions (33", 34") of the side portions (33, 34) comprise the longitudinal edges of the outer cover layer (18), and the longitudinal edges of the second portions (33", 34") of the side portions (33, 34) are inner ends (47, 48) fixed between the topsheet (9) and the backsheet (10).

11. 11. The disposable absorbent insert (1) according to any one of claims 1 to 10, wherein the absorbent insert (1) comprises a first longitudinally extending standing gather (29) and a second longitudinally extending standing gather (30).

12. The disposable absorbent insert (1) according to claim 11, wherein said standing gathers (29, 30) are attached to said topsheet (9).

13. The absorbent insert (1) further comprises a pair of nonwoven barrier cuff strips (21, 22), which extend in the longitudinal direction (L) and are symmetrically arranged with one barrier cuff strip (21, 22) on each side of a longitudinal centerline (Lc), and each nonwoven barrier cuff strip (21, 22) has a standing gathered portion (21) that forms the first and second standing gathers (29, 30), respectively.

13. The disposable absorbent insert (1) according to claim 11 or 12, comprising free standing gathers (29, 30) extending in the longitudinal direction (L), each free standing gather edge (23, 24) being defined between a free standing gather edge (23, 24) extending in the longitudinal direction (L) and a standing gather hinge line (25, 26) also extending in the longitudinal direction (L), and the barrier cuff strips (21, 22) are attached to the topsheet (9) along the standing gather hinge line (25, 26).

14. 14. The disposable absorbent insert (1) according to claim 13, wherein the standing gathers (29, 30) have one or more pre-tensioned elastic elements (27, 28) arranged along the free standing gather edges (23, 24).

15. 15. The disposable absorbent insert (1) of claim 13 or 14, wherein the nonwoven barrier cuff strips (21, 22) include leg cuff portions defined between the standing gathered hinge lines (25, 26) and outer leg cuff edges (43, 44) of the nonwoven barrier cuff strips (21, 22), the outer leg cuff edges (43, 44) of the nonwoven barrier cuff strips (21, 22) being parallel to the fold lines (36, 38) of the leg cuff folds (35, 37), and the leg cuff portions (21″, 22″) of the nonwoven barrier cuff strips (21, 22) overlap at least one elastic element of the plurality of elastic elements (41, 42).

16. 16. A disposable absorbent insert (1) according to any one of claims 11 to 15, wherein the leg cuff folds (35, 37) have free edges defined by the fold lines (36, 38), and the leg cuff width (W) is between the fold lines (36, 38) in the leg cuff folds (35, 37) and the standing gathered hinge lines (25, 26) in the transverse direction (T).

17. 17. The disposable absorbent insert (1) of claim 15 or 16, wherein the leg cuff portion (21", 22") of each nonwoven barrier cuff strip (21, 22) is attached to the corresponding leg cuff fold (35, 37) in a manner such that the leg cuff portion (21", 22") of the nonwoven barrier cuff strip (21, 22) overlaps all of the plurality of elastic elements (41, 42) in the leg cuff fold (35, 37).

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

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

20. 20. The disposable absorbent insert (1) according to any one of claims 1 to 19, wherein the absorbent insert (1) is provided with fastening elements (50, 51) for fastening the absorbent insert (1) to a reusable outer shell (100).

21. 21. A disposable absorbent insert (1) as described in claim 20, wherein the fastening elements (50, 51) are strips of loop material attached to the garment-facing side of the outer cover layer (18) near the transverse side edges (2, 4) of each of the front and rear portions (3, 5) of the absorbent insert (1).

22. 22. A disposable absorbent insert (1) according to any one of claims 1 to 21, wherein the absorbent insert (1) lacks side flaps located at the waist edge of the front portion and lacks side flaps located at the waist edge of the rear portion.

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

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

25. A wearable absorbent article (101) comprising a reusable outer shell (100) worn by a wearer and a disposable absorbent insert (1) according to any one of claims 1 to 24.

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