Array of absorbent articles having lumbar gasket elements

Abstract

An array of personal hygiene articles (10), comprising at least a first article and a second article, wherein the second article is larger in size than the first article. Each article comprises a rear waist gasket element (70) between a pair of elastic rear ears (32). Each rear ear (42) has an innermost edge (420) having a length (60). The waist gasket element (70) has a length (70) measured along the longitudinal centerline. The ratio of the length (60) of the innermost edge of the rear ear to the length of the waist gasket element is in the range of 1.0 to 3.0 for at least the first and second articles. The length of the waist gasket element of the second article is at least 2 mm longer than the length of the waist gasket element of the first article. At least a third article having a size larger than the second article may be included in the array.

Description

Technical Field

[0001] The present disclosure relates to disposable absorbent articles such as diapers having a waist gasket element capable of containing bodily excretions such as feces. The absorbent article may be included in an array of articles of different sizes.

Background Art

[0002] Diapers and other similar personal hygiene absorbent articles are typically made from a chassis including a topsheet, a capture layer, an absorbent core, and a backsheet. Other components including elastic parts are attached to the chassis. To improve the fit around the legs of the wearer, most diapers have inner elastic leg cuffs and outer elastic leg cuffs disposed along their longitudinal edges. Tape-type diapers further have a set of rear side ear parts each equipped with a fastening tab that can be fastened to the front of the article, thus forming a waist opening around the waist of the wearer. These rear side ear parts are typically elastic components such as a laminate including an elastic film, and are attached to the chassis of the article at their innermost edges by an adhesive and / or mechanical coupling.

[0003] Some tape-type diapers have an elastic waistband disposed along their rear side waist edges. These elastic waistbands are typically made from a laminate including an elastic film or elastic strands sandwiched between two non-woven fabric layers. Such elastic waistbands are disposed within the chassis of the article or attached to the inner or outer side of the article. Such elasticized waistbands provide increased pressure between the skin and the article. This improves the containment of excretions in the rear side waist area. The elasticized waistband is particularly useful for closing the waist gap that can be formed when the wearer changes posture, such as when bending forward or lying supine as in the case of a sleeping infant.

[0004] More recently, lumbar gasket elements positioned adjacent to the rear edge of the diaper have been proposed. These lumbar gasket elements can be made from the same material as elastic waistbands and are positioned adjacent to the rear lumbar edge of the diaper. However, lumbar gasket elements, also called lumbar cuffs, differ from elastic waistbands in that they are positioned on the inside of the absorbent article and that the innermost edge of the lumbar gasket element is not attached to the diaper chassis but can instead be separated to some extent from the top sheet. The other edges of the lumbar gasket element are at least partially bonded to the diaper chassis. In this way, the lumbar gasket element can form a pocket capable of containing feces and / or reduce leakage of urine through the rear lumbar edge of the article.

[0005] Spine gasket elements can be attached to the inner surface of an article (typically the top sheet) using a variety of means, including mechanical attachment, adhesive attachment, heat attachment, and co-forming. Recent international publications assigned to P&G, 2020 / 242714, 2021 / 092606, 2020 / 242715, and 2021 / 092607, disclose a spine gasket element having at least a portion of a spine gasket element that is adhesively attached to the chassis and at least a portion of a spine gasket element that is mechanically attached to the chassis. Thus, the spine gasket element includes an adhesive zone, a first mechanical attachment portion in a non-adhesive zone, a second mechanical attachment portion in a second non-adhesive zone, and a freestanding edge portion.

[0006] Many absorbent items, particularly diapers, are developed as an array of items in different sizes, with each size corresponding to a different stage of the expected user's physical development. This is typically the case with infant diapers, where each size is typically indicated by a number, e.g., 0 or 1 for newborns and up to 6 or 7 for older toddlers. Sizes may also be indicated by other symbols, such as letters (e.g., XS, S, M, L, XL...) or descriptive terms ("newborn," "small," "medium," "large," "extra large,"...). Each size is further correlated to a given weight range. Manufacturers adapt items within such arrays of absorbent items by adapting the dimensions and absorbency of the absorbent items to the expected user. While the numbering and corresponding weight ranges may, of course, differ between manufacturers, such arrays of items with progressively larger sizes allow caregivers to easily switch from one item to the next as the infant grows.

[0007] Little attention has been paid until recently to how the dimensions of rear waist gasket elements should be adapted according to the size of the article to provide the greatest benefit. Rather, for cost reasons and rationalization, manufacturers have been encouraged to use standard-dimension waist gasket elements across a given array of articles. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] International Publication No. 2020 / 242714 [Patent Document 2] International Publication No. 2021 / 092606 [Patent Document 3] International Publication No. 2020 / 242715 [Patent Document 4] International Publication No. 2021 / 092607 [Overview of the project] [Means for solving the problem]

[0009] In one embodiment, the present invention relates to an array of personal hygiene articles. Each article comprises a chassis, a pair of rear ear sections extending outward from the chassis, and a waist gasket element disposed between the rear ear sections on the wearer-facing side of the chassis. The array comprises at least a first article having a first size and a second article having a second size, the second article being larger than the first article. The size of the articles may be indicated by markings such as numbers and / or by a weight range of a given target user. These markings are typically found on the packaging and / or on the article itself, for example, as printing on the backsheet. Each rear ear section has an innermost edge closest to the longitudinal centerline, and this innermost edge has a length measured in the longitudinal direction. The waist gasket element has a length measured in the longitudinal direction along the longitudinal centerline of the article.

[0010] In one aspect of the present invention, it has been found that the ratio of the length of the innermost edge of the rear ear portion to the length of the waist gasket element should be in the range of about 1.0 to about 3.0 for at least the first and second articles, and optionally for at least the third article in the array, and optionally for all articles included in the array. In a further aspect of the present invention, the length of the waist gasket element of the second article is at least 2 mm longer than the length of the waist gasket element of the first article. The length of the waist gasket element of the second article may be at least 4 mm longer than the length of the waist gasket element of the first article.

[0011] The waist gasket element may include a proximal edge attached to the chassis, a distal edge that can be partially upright away from the chassis, a first side edge, a second side edge, and an elastic material. At least a portion of the waist gasket element may be attached to the chassis with adhesive, or at least a portion of the waist gasket element may be mechanically attached to the chassis. The waist gasket element may include an adhesive zone, a first adhesive-free zone, and a second adhesive-free zone.

[0012] Disposable absorbent articles may also typically include a leg gasket system comprising a longitudinally extending inner leg cuff and a longitudinally extending outer leg cuff. [Brief explanation of the drawing]

[0013] [Figure 1] A simplified front perspective view of a partially fastened tape-type diaper with a rear lumbar gasket element. [Figure 2] This is a plan view of the surface of the absorbent material shown in Figure 1, facing the wearer, when it is laid flat. [Figure 3] This is a plan view from the wearer-facing (internal) side of the posterior lumbar region of the diaper, with the lumbar gasket element flattened and stretched. [Figure 4] This is a plan view of the posterior waist area of ​​the diaper, from the side facing the clothing (outside). [Figure 5] The image shows a diaper package. [Modes for carrying out the invention]

[0014] Overview of absorbent materials Figure 1 shows an exemplary absorbent article 10 according to this disclosure, shown in the form of a tape-type diaper. Figure 1 is a front perspective view of the absorbent article 10, with one rear ear portion 42a having a fastening tab 46a fastened to a landing zone 44 and the other rear ear portion 42b having its fastening tab (tag) 46b not yet fastened. Figure 2 is a plan view of the exemplary absorbent article 10 in a flattened state (i.e., with the elastic contraction portion flattened) with the wearer-facing side facing the observer. The absorbent article 10 in Figures 1 and 2 is shown for illustrative purposes only, as this disclosure can be used to manufacture a wide variety of diapers, including adult incontinence products, resealable pants, or other absorbent articles.

[0015] The absorbent article 10 includes a liquid-permeable top sheet 26, a liquid-impermeable back sheet 28, and an absorbent core 30 at least partially positioned between the top sheet 26 and the back sheet 28. The top sheet 26 forms the majority of the wearer-facing side of the article, and the back sheet 28 forms the majority of the clothing-facing side of the article. These layers, which will be further discussed below, together form at least partially the chassis of the article.

[0016] The absorbent article 10 includes a front waist region 12, a crotch region 14, and a rear waist region 16. Each of the front waist region 12, the crotch region 14, and the rear waist region 16 is one-third of the length of the absorbent article 10 when measured along the longitudinal centerline 50. The crotch region 14 extends between the front waist region 12 and the rear waist region 16. The absorbent article 10 includes a front edge 18, a rear edge 20 opposite the front edge 18, and longitudinally extending, transversely opposing side edges 22 and 24 that extend between the front edge 18 and the rear edge 20. The outer dimensions of the article are substantially defined by the chassis.

[0017] Typically, the diaper also includes a set of inner leg cuffs 32 having an elastified edge 33 that stands upright away from the chassis, and a set of outer leg cuffs 34 having an elastomer 35 integrated within the chassis. The absorbent article 10 includes a set of rear side ears 42 within the rear side waist region 16 that extend transversely from the rear side waist region 16 of the absorbent article 10. The rear side ears 42 may include fastening tabs 46. The rear side ears 42 may be fastened (using the fastening tabs 46) to a landing zone area or landing zone material 44 disposed on the clothing-facing portion of the front side waist region 12 of the absorbent article 10. The absorbent article 10 can also have front side ears 47 on each side of the front side waist region 12. The absorbent article 10 conceptually has a central longitudinal axis 50 that symmetrically divides the diaper into a left half and a right half. A transverse axis 48 that extends perpendicular to the central longitudinal axis 50 can also be conceptually defined. Other components typically found in diapers are not shown for simplicity but should be considered to exist for typical uses. Specifically, the absorbent article typically includes one or more capture layers disposed intermediate the topsheet 26 and the absorbent core 30, but is not further represented.

[0018] In other examples, the absorbent article may be in the form of pants having re-fastenable side seams. Suitable re-fastenable seams are disclosed in U.S. Patent Application Publication No. 2014 / 0005020 and U.S. Patent No. 9,421,137.

[0019] Top sheet The topsheet 26 is a part of the absorbent article 10 on the wearer-facing side that contacts the wearer's skin. The topsheet 26 can be conformable to the wearer's skin, have a soft feel, and be non-irritating. Further, at least a part or the whole of the topsheet can be liquid-permeable, whereby liquid body excreta can easily penetrate through its thickness. Suitable topsheets may be manufactured from a wide range of materials such as apertured plastic films, nonwoven fabrics, but other materials such as porous foams, reticulated foams, woven materials, knitted materials are also possible. The nonwoven fabric can include natural fibers (e.g., wood fibers or cotton fibers), synthetic fibers or filaments (e.g., polyester fibers or polypropylene fibers or bicomponent PE / PP fibers, or mixtures thereof), or combinations of natural and synthetic fibers. The topsheet can have one or more layers. Any part of the topsheet can be coated with a skin care composition, an antibacterial agent, a surfactant, and / or other beneficial agents. The topsheet can be hydrophilic or hydrophobic, or can have hydrophilic parts or hydrophilic layers and / or hydrophobic parts or hydrophobic layers. If the topsheet is hydrophobic, there will typically be pores so that body excreta can pass through the topsheet.

[0020] The topsheet 26 can be joined to the backsheet 28, the absorbent core 30, the inner leg cuff 32 and the outer leg cuff 34, and / or any other layer or component part of the article, as known to those skilled in the art.

[0021] Backsheet 28 The backsheet 28 is generally the portion of the absorbent article 10 positioned in close proximity to the clothing-facing side of the absorbent core 30. The backsheet 28 can be bonded to the topsheet 26, the outer cover material, the absorbent core 30, and / or any other layer of the absorbent article by any attachment method known to those skilled in the art. The backsheet 28 prevents, or at least inhibits, bodily waste absorbed and contained within the absorbent core 10 from soiling articles such as bed sheets, underwear, and / or clothing. The backsheet is typically liquid-impermeable or at least substantially liquid-impermeable. The backsheet may be, for example, a thin plastic film such as a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm, or may include such a film. Other suitable backsheet materials may include breathable materials that allow vapor to escape from the absorbent article while still preventing, or at least inhibiting, bodily waste from passing through the backsheet.

[0022] The outer cover material (sometimes referred to as the backsheet nonwoven fabric) can bond the backsheet 28 to its garment-facing side and cover the backsheet 28. The outer cover material forms at least a portion of the garment-facing surface of the absorbent article 10 and effectively "covers" the backsheet 28, such that no film is present on the garment-facing surface. The outer cover material may include bonding patterns, pores, and / or three-dimensional features. The outer cover material may be a water-entangled nonwoven fabric material.

[0023] Absorbent core 30 The term "absorbent core" refers to a component of an absorbent article 10 that can absorb and contain liquids such as urine received by the absorbent article. Therefore, absorbent cores typically have high absorbency. Absorbent cores typically contain absorbent material enclosed within a core wrap. An absorbent core is shown positioned between a top sheet and a back sheet, with an example outline shown by a dotted line in Figure 2. The chassis of the article is typically composed of these layers extending in the same longitudinal and transverse directions.

[0024] The core wrap may be a single material folded around the absorbent material, or it may include separate top and bottom layers that can be bonded together or otherwise joined. The absorbent material typically comprises superabsorbent particles, optionally mixed with cellulose fibers. As used herein, “absorbent core” does not include any capture and distribution layer or system, top sheet, or back sheet of the absorbent article.

[0025] As illustrated, the external shape of the absorbent core 30 can typically be roughly rectangular, as defined by the longitudinal edge of the core wrap, as well as the transverse front and rear edges. The absorbent material layer may also have a roughly rectangular perimeter, but non-rectangular perimeter cores are also commonly used, in particular, the absorbent material may have a narrower width toward the central region of the core ("hourglass" or "dogbone" shape). In this way, the absorbent material area may have a relatively narrow width in the area of ​​the core intended to be located within the crotch region of the absorbent article. This can, for example, provide better wearing comfort. Other shapes, such as "T" or "Y" shapes, can also be used for the absorbent material layer.

[0026] The absorbent material may be any conventional absorbent material known in the art. For example, the absorbent material may contain a blend of cellulose fibers and superabsorbent particles ("SAP"), typically in a percentage of SAP ranging from about 50% to about 75% by weight of the absorbent material. The absorbent material may also not contain cellulose fibers, as is known in so-called air felt-free cores, where the absorbent material consists of or is essentially SAP. The absorbent material may also be a high internal-phase emulsion foam.

[0027] In this specification, “superabsorbent polymer” or “SAP” refers to an absorbent material, typically a cross-linked polymer material, that can absorb at least 10 times its weight in 0.9% saline solution when measured using a centrifugal retention capacity (CRC) test (EDANA method WSP241.2.R3(12)). SAP can specifically have a CRC value of at least 20 g / g, specifically 20 g / g to g / g. As used herein, “superabsorbent polymer particles” refers to a superabsorbent polymer material in the form of fine particles that are fluid in a dry state.

[0028] Various absorbent core designs containing large amounts of SAP have been proposed in the past; see, for example, U.S. Patent No. 5,599,335 (Goldman), European Patent No. 1,447,066 (Busam), International Publication No. 95 / 11652 (Tanzer), U.S. Patent Application Publication No. 2008 / 0312622(A1) (Hundorf), and International Publication No. 2012 / 052172 (Van Malderen). Specifically, the SAP printing techniques disclosed in U.S. Patent Application Publication No. 2006 / 024433 (Blessing), No. 2008 / 0312617, and No. 2010 / 0051166(A1) (both by Hundorf et al.) may be used. However, this disclosure is not limited to any particular type of absorbent core. The absorbent core may also include one or more adhesives, such as auxiliary adhesives applied between the inner surface of one (or both) of the core wrap layers and the absorbent material to reduce leakage of SAP outside the core wrap. Furthermore, as described in the Hundorf references above, microfiber adhesive nets may be used in air felt-free cores. These adhesives are not shown in the figures for simplification. Other core structures, including high-loft nonwoven fabric substrates such as carded nonwoven layers having a porous structure on which SAP particles are deposited, may also be used in this disclosure.

[0029] Absorbent materials can be deposited as continuous layers within a core wrap. Absorbent materials may also exist discontinuously, for example, as individual pockets or stripes of absorbent material encapsulated within the core wrap and separated from each other by material-free bonding areas. Continuous layers of absorbent material, particularly SAP, can also be obtained by combining two absorbent layers having matching discontinuous application patterns of absorbent material, the resulting layer being substantially continuously distributed across the entire absorbent particulate polymer material area. For example, as taught in U.S. Patent Application Publication 2008 / 312,622(A1) (Hundorf), each layer of absorbent material thus includes a pattern having land areas of absorbent material and material-free bonding areas, where the land areas of absorbent material in the first layer substantially correspond to the material-free bonding areas in the second layer, and vice versa.

[0030] The basis weight (amount deposited per surface unit) of the absorbent material may be varied to create a contour distribution of the absorbent material, particularly in the longitudinal direction to provide greater absorbency toward the center and middle of the core, but also in the transverse direction of the core, or both. The absorbent core may also include one or more longitudinally (or otherwise) extending channel-forming areas 40, which are areas of the absorbent layer that substantially do not contain absorbent material within the absorbent material layer. The upper side of the core wrap may, advantageously, be bonded to the lower side of the core by adhesive, mechanical, or ultrasonic bonding through these material-free areas. Exemplary disclosures of such channels in an air felt-free core can be found in International Publication 2012 / 170778 (Rosati et al.) and U.S. Patent Application Publication 2012 / 0312491 (Jackels). Channels can, of course, also be formed in absorbent cores comprising a mixture of cellulose fibers and SAP particles. These channels can be embodied in any preferred shape, and any preferred number of channels can be provided. In another example, the absorbent core can be embossed to create channel indentations.

[0031] Inner leg cuff 32 / Outer leg cuff 34 For example, referring to Figures 1 and 2, the absorbent article 10 may include one or more pairs of inner leg cuffs 32 and one or more pairs of outer leg cuffs 34. The inner leg cuffs 32 may be positioned laterally inward of the outer leg cuffs 34. Each of the inner leg cuffs 32 may be formed from a piece of material partially bonded to a layer of the chassis of the absorbent article 10 and has an elasticated edge 33 that can stand upward from the wearer-facing side of the absorbent article 10. As is known in the art, the inner leg cuffs (which may also be designed as barrier leg cuffs) provide improved containment of bodily waste near the junction of the wearer's torso and legs. The inner leg cuffs 32 are bounded by a proximal edge 31 directly or indirectly bonded to the top sheet and / or back sheet and a free end edge 33 intended to contact the wearer's skin and form a seal with the skin. The inner leg cuff 32 is present in at least the crotch region 14 and may extend at least partially to the front and rear waist regions 12 and 16 of the absorbent article 10 on both sides of the central longitudinal axis 50. Each inner leg cuff 32 may include one or more elastic bodies (e.g., elastic strands or strips) near or at the free end edge. These elastic strands provide tension to lift the inner leg cuff 32 perpendicular to the wearer-facing side of the article, thus forming a seal around the wearer's thigh. The outer leg cuff 34 may also be present in at least the crotch portion 14 of the article and may further extend to at least the front and rear waist regions 12 and 16 of the article. The outer leg cuff 34 includes a longitudinally extending elastic thread 35, which helps the outer leg cuff 34 form a seal around the wearer's leg, at least in the crotch portion of the article.

[0032] Captured material One or more trapping materials (not shown for readability) are typically located at least partially between the top sheet 26 and the absorbent core 30. The trapping material may be a hydrophilic material that provides considerable absorption of urine or other bodily excretions. These traps help dehydrate the top sheet 26, moving the urine closer to and into the absorbent core 30. The trapping material may include, for example, one or more nonwoven materials, foams, molded films, aperture-processed molded films, cellulose materials, cross-linked cellulose materials, airlaid cellulose nonwoven materials, spunlace materials, or combinations thereof. Typically, the trapping material may have a width and length smaller than the width and length of the top sheet 26 and / or the absorbent core 30. In the context of a women's pad, the trapping material may be a secondary top sheet. The trapping material may have one or more channels (including embossed plates) as described above with respect to the absorbent core 30. The channels of the trapping material may or may not be aligned with the channels of the absorbent core 30. In one embodiment, the first capture material may include a nonwoven fabric material oriented toward the top sheet, and the second capture material may include a crosslinked cellulose material deposited on the first capture material and oriented toward the absorbent core.

[0033] Landing Zone 44 Referring to Figures 1 and 2, the absorbent article 10 may have a landing zone area 44 formed on a portion of the garment-facing surface of the outer cover material. The landing zone area 44 is typically the front waist region 12 of the absorbent article 10 when it is fastened from back to front. In some cases, the landing zone 44 may be, or include, one or more other nonwoven materials attached to a portion of the backsheet 26 within the front waist region 12. Essentially, the landing zone 44 is configured to receive fasteners 45 disposed on fastening tabs 46 extending from the rear selvage 42. A common configuration is, for example, to include multiple loops on the landing zone 44 configured to engage with multiple hooks on the fasteners 45, or vice versa.

[0034] Moisture level indicator / graphic The absorbent articles of this disclosure may include graphics and / or moisture indicators visible from the garment-facing side (not shown for simplification). Graphics may be printed on the landing zone, backsheet, and / or other locations. Moisture indicators are typically applied to the side of the backsheet facing the absorbent core so that they can come into contact with bodily waste within the absorbent core. In some cases, moisture indicators may form part of the graphics. For example, moisture indicators may appear or disappear and may form / remove letters within some graphics. In other examples, moisture indicators may or may not be aligned with the graphics (e.g., the same design, same pattern, same color).

[0035] Posterior ear portion 42 and anterior ear portion 47 The absorbent article 10 has a pair of rear ears 42 located on the rear portion of the article, and typically, in the case of a tape-type diaper, a pair of front ears 47 located on the front portion. In most tape-type diapers, only a pair of front and rear ears may be required. Each of the rear ears 42 may include another fastening tab 46 at its distal edge, having a fastener 45 configured to engage with the material in the landing zone 44. The rear ears 42 or a portion thereof may be elastic or may have an elastic panel. In one embodiment, an elastic film or elastic strand may be placed between a first nonwoven material and a second nonwoven material. The elastic film may or may not be aperture-processed. The rear ears may be molded. The rear ears 42 are typically another component attached to the chassis of the absorbent article on the wearer-facing surface, on the clothing-facing surface, or midway between the two surfaces by an attachment portion 420. The front selvage is typically made from a nonwoven fabric material having a basis weight of 10 gsm to 30 gsm.

[0036] Lumbar gasket element 36 The absorbent article 10 includes a lumbar gasket element 36 disposed in the rear portion 16 of the article between the rear ear portions 42. The lumbar gasket element 36 provides improved fit and accommodation and is typically elastically expandable and contractable to dynamically fit the wearer's waist. The lumbar gasket element 36 may be substantially rectangular with its long sides 72, 74 oriented transversely, but the lumbar gasket element does not necessarily have to be a perfect rectangle. As shown in Figure 3, the lumbar gasket element 36 includes a proximal edge portion 72 extending transversely and a distal edge portion 74 that is longitudinally opposed and extends transversely (proximal and distal as used herein refer to the transverse centerline 48 of the article). The lumbar gasket element 36 may also have a first side edge portion 76 and a second side edge portion 78. Both the side edges 76 and 78 extend longitudinally between the proximal edge 72 and the distal edge 74. The waist gasket element 36 may be constructed in several different configurations, including those described in U.S. Patents No. 4,515,595 and No. 5,151,092.

[0037] It should be understood that the waist gasket element 36 can be located in various places relative to various diaper components. For example, the distal edge 74 of the waist gasket element 36 may be continuous with the rear waist edge 20 of the article, but the waist gasket element 36 may also be positioned longitudinally inward from the waist edge 20 of the absorbent article, as shown in the figure. For example, the longitudinal distance between the distal edge 74 of the waist gasket element of the diaper 10 and the rear edge 20 may be at least 5 mm. Such a distance may help to prevent the waist gasket element 36 from extending onto the rear waist edge 20 of the article if it is mispositioned in the machine direction during production.

[0038] The waist gasket element 36 illustrated in Figures 3 and 4 may be manufactured as described in International Patent Publication Nos. 2020 / 242714, 2021 / 092606, 2020 / 242715, and 2021 / 092607. Without limiting the articles of the present invention, the waist gasket element 36 may be attached to a portion of the chassis formed by the top sheet 26 by at least one adhesive disposed in an adhesive zone 170 and by one or more mechanical connectors 172, 174 disposed in corresponding non-adhesive zones. The adhesive zone 170 may be disposed on adjacent distal edge portions 74 of the waist gasket element 36, as shown in Figure 3, and the mechanical connectors 172, 174 may be disposed on a first side edge portion 76 and a second side edge portion 78, respectively. Such embodiments are disclosed in more detail in the four International Publications (WOs) listed above, which are incorporated herein by reference.

[0039] The waist gasket element 36 may include, or consist of, a laminate of an elastic film bonded between a first nonwoven fabric and a second nonwoven fabric. The first nonwoven fabric, the elastic film, and the second nonwoven fabric may be bonded by any preferred technique such as ultrasonic bonding or adhesive bonding. One or both of the nonwoven fabrics may be, for example, an elastomer nonwoven fabric or an inelastic nonwoven fabric. It should be understood that the first and second nonwoven fabrics may be the same size or have different sizes, and may define the same width and / or length or have different widths and / or lengths. Furthermore, it should be understood that the waist gasket element may have two layers of nonwoven fabric, but the disclosure is not limited thereto. For example, a continuous elastic substrate may be configured as a double laminate having an elastic film bonded to a single nonwoven fabric substrate, such as a double laminate formed of an elastic film and a nonwoven fabric. Furthermore, instead of an elastic film, the waist gasket element may include an elastic strand or other preferred material. The laminate of the film and one or more nonwoven fabrics may be an extruded laminate. It should also be understood that the waist gasket elements may be assembled in various ways, as disclosed in U.S. Patents No. 6,572,595, 6,830,780, 7,087,287, and 7,783,244, all of which are incorporated herein by reference, and in U.S. Patent Publications 2018 / 0042778(A1), 2018 / 0042787(A1), 2018 / 0042779(A1), and 2018 / 0042778(A1).

[0040] Mechanical joints 76 and 78 are shown in Figures 3 and 4 to illustrate the mechanical connection between the lumbar gasket element 36 and the chassis (leg cuff, top sheet, and back sheet). However, in some configurations, the mechanical connection is between the lumbar gasket element 36 and the leg cuff 32, such that the top sheet is not incorporated into the mechanical joints 76 and 78. Furthermore, in some configurations, the lumbar gasket element may be mechanically connected to the top sheet 26 but not to the back sheet 28. Referring to Figures 3 and 4, the mechanical joints 76 and 78 in the illustrated examples are shown to extend from the lumbar gasket element 36 to the back sheet 28, and to intermediate materials between them, such as the leg cuff 32 and the top sheet 26. The first grouping of mechanical joint 76 may be located within a first adhesive-free zone, and the second grouping of mechanical joint 78 may be located within a second adhesive-free zone. The first adhesive-free zone and the second adhesive-free zone may each have a width W1 in the transverse direction. Depending on the configuration, the width W1 may be in the range of about 5 mm to about 30 mm, or in the range of about 10 mm to about 20 mm, or about 15 mm. Each of the first adhesive-free zone and the second adhesive-free zone may extend longitudinally at least from the proximal edge 72 to the distal edge 74 of the waist gasket element 36. The mechanical connectors 76, 78 may extend through a plurality of absorbent article components to connect the waist gasket element 36 (as shown in Figures 3 to 4), but the mechanical connectors may extend only through the waist gasket element 36 and the top sheet 26, or only through the waist gasket element 36 and the leg cuff 32, or only through the waist gasket element 36, the top sheet 26, and the leg cuff 32.

[0041] The central portion of this exemplary waist gasket element 36 is attached to the chassis 26 by adhesive 170. The waist gasket element 36 may define at least one adhesive zone 170 of adhesive on the surface of the waist gasket element 36 that is bonded to the chassis.

[0042] The waist gasket element 36 is elasticized to form wrinkles when no reaction tension is applied, as shown in Figure 1. These wrinkles can be flattened when the absorbent article is stretched flat as shown in Figures 2 to 4. The width of the waist gasket element 36 can be measured under the tension required to stretch the article. Typically, the width Wg of the waist gasket element is in the range of 30 mm to 100 mm under these conditions. In the array according to the present invention (as described below), the width Wg may be greater for the second article than for the first article. The width of the third article may be greater than that of the second article.

[0043] When the fastening member 42 is pulled around the wearer's waist and connects to the landing zone 44 on the anterior waist region to form a closed waist perimeter, a direct line of tension is formed between the fastening members 42. By offsetting the axis of the waist gasket element 36 by a certain distance from the axis of the tab 46, it is beneficial to avoid the waist gasket element 36 aligning with this direct line of tension. Thus, by configuring the absorbent article 10 such that the waist gasket element axis 36 is separated from the tab axis, the waist gasket element 36 can be exposed to a lower force level than the force level to which the fastening members 42 are exposed. As a result, the expandable waist gasket element axis 36 can retain energy that can be used to close the gap when the wearer bends, but without affecting the overall span of the user to which the article can fit.

[0044] Figures 3-4 also show chassis end connectors 62 located on the rear edge 20 of the diaper. The end connectors are mechanical or adhesive connectors that seal the absorbent article, and in particular, the top sheet and back sheet are strongly bonded together by the end connectors 62 to reduce the risk of accidental delamination of the chassis layers. The figures also show tuck-down connectors 64, which are typically thermal or mechanical connectors that attach the inner leg cuff material 32 to the chassis, particularly the top sheet 26 in the rear lumbar region of the article.

[0045] Bio-based absorbent materials suitable for recycling The components of absorbent articles described herein may be at least partially composed of bio-based components, such as those described in U.S. Patent Application Publication 2007 / 0219521(A1). For example, superabsorbent polymer components may be made bio-based by deriving them from bio-based acrylic acid. Bio-based acrylic acid and methods for producing it are further described in U.S. Patent Application Publication 2007 / 0219521, as well as U.S. Patents 8,703,450, 9,630,901, and 9,822,197. Other components, such as nonwoven fabric and film components, may include bio-based polyolefin materials. Bio-based polyolefins are further discussed in U.S. Patent Publications 2011 / 0139657, 2011 / 0139658, 2011 / 0152812, and 2016 / 0206772, and U.S. Patent No. 9,169,366. Exemplary bio-based polyolefins for use in this disclosure include polymers available under the designations SHA7260®, SHE150®, or SGM9450F® (all available from Braskem SA).

[0046] The components of the absorbent article may contain bio-based component values ​​of approximately 10% to approximately 100%, approximately 25% to approximately 100%, approximately % to approximately 100%, approximately 50% to approximately 100%, approximately 75% to approximately 100%, or approximately 90% to approximately 100%, for example, using Method B of ASTM D6866-10.

[0047] The components of the absorbent articles described herein may be recycled for other uses, whether or not they are formed at least partially from recyclable materials. Examples of recyclable absorbent article materials include nonwovens, films, fluff pulp, and superabsorbent polymers. The recycling process may involve using an autoclave to sterilize the absorbent articles, after which the absorbent articles may be shredded and separated into different by-product streams. Exemplary by-product streams may include plastics, superabsorbent polymers, and cellulose fibers such as pulp. These by-product streams may be used in the manufacture of fertilizers, plastic manufacturing articles, paper products, viscose, building materials, absorbent pads for pet or hospital beds, and / or for other uses. Further details relating to absorbent articles that aid in recycling, diaper designs suitable for recycling, and diaper designs that are suitable for recycling and have bio-based components are disclosed in U.S. Patent Application Publication No. 2019 / 0192723.

[0048] package The absorbent articles of this disclosure may be contained within a package that is transported from the manufacturing site to the place of sale and / or to the consumer. The package may include polymer film, corrugated cardboard, paper, and / or any other common packaging material. Graphics and / or markings relating to the characteristics of the absorbent articles (particularly the size of the articles and the corresponding weight range) may be formed, printed, placed, and / or positioned on the outer portion of the package. Each package typically contains multiple absorbent articles. The absorbent articles may be packaged under compression to reduce the package size while still providing a sufficient quantity of absorbent articles per package. Packaging absorbent articles under compression allows caregivers to easily handle and store the packages and also provides manufacturers with reduced distribution costs due to package size.

[0049] Figure 5 illustrates a package 500 containing absorbent articles. The package includes at least one side 510 that displays information about the articles contained within the package, such as the brand of the articles 520, e.g., Pampers®, and optionally a sub-brand 530, e.g., "baby-dry". The size of the articles 540, e.g., size 4, and associated weight range 550 (e.g., 9-14 kg) are also typically indicated on at least the information side 510. Typically, an illustration of the articles 560 may be included, and the number of articles 570 may be included. As is known in the art, tape-type diapers for infants and toddlers have a wide weight range, however this may substantially overlap from one size to the next size up, and in particular, the upper limit of the range widens from one size to the next immediate size.

[0050] array "Array" means a given system of different absorbent articles having different structures (e.g., different dimensions and / or absorbency) and designed to be used in a particular order according to the different needs of potential users. A typical array of absorbent articles according to the present invention may include, in particular, a series of diapers adapted for progressive use as an infant or toddler grows. Multiple absorbent articles of a given specification may be packaged within a package. Thus, an array of articles may be packaged within a corresponding array of packages. Packages may have the same brand and / or sub-brand and / or the same trademark registration and be sold in common sales locations (e.g., lined up close to each other in a given area of ​​a retail store). Thus, an array of articles according to the present invention is typically packaged within a series of packages having similar packaging elements (e.g., type of packaging material, film, paper, main color, design theme, etc.) that communicate to consumers that the different individual packages are part of a larger lineup. The array often has the same brand, e.g., "Huggies," and the same sub-brand, e.g., "Pull-Ups," or, as illustrated in Figure 5, "Pampers" as the main brand and "baby-dry" as the sub-brand. Different products within the array may also have the same brand, "Huggies," and the sub-brand, "Little Movers." Differences between the "Pull-Ups" products in the array and the "Little Movers" products within the array may include product form, application form, different fastening designs, or other structural elements intended to accommodate differences in physiological or psychological development. Furthermore, the packaging is distinctly different, with "Pull-Ups" primarily packaged in blue or pink film bags, while "Little Movers" are primarily packaged in red film bags.

[0051] Array of absorbent articles according to the present invention An array of absorbent articles according to the present invention comprises at least a first article and a second article, the second article being fitted to a wearer having a larger size than the first article. An array of diapers typically comprises three or more articles, e.g., 4 to 16 different articles, particularly 6 to 14 different articles (including intermediate "P" or "Plus" sizes, e.g., 4+, if present). Each individual article in the array is typically characterized by a size indicating its rank or order within the array (typically, numbering is used where smaller numbers correspond to smaller sizes) and an associated recommended weight range (typically, the weight in kilograms of the infant or toddler recommended for that particular size). The manufacturer adapts the dimensions and absorbent material usage for each size according to the indicated recommended user.

[0052] As shown in Figure 3, each rear ear portion 42 has an innermost edge 420 which is the edge closest to the longitudinal centerline 50, having a length 60 when measured in the longitudinal direction. The waist gasket element 36 has a length 70 when measured in the longitudinal direction (if the waist gasket element is not rectangular, the length is measured along the longitudinal axis 50). According to the present invention, it has been found that improved waist accommodation can be obtained when the ratio obtained by dividing the length 60 of the innermost edge of the rear ear portion by the length 70 of the waist gasket element should be in the range of 1.0 to 3.0, particularly 1.5 to 2.5, more specifically 1.8 to 2.2. Therefore, in a first aspect of the present invention, at least two articles of different sizes in the array have dimensions within this range. Preferably, at least three, four, five, six, seven, or eight articles in the array have such a ratio in the range of 1.0 to 3.0, particularly 1.5 to 2.5, more specifically 1.8 to 2.2. At least 50% (or at least 70% or 100%) of the articles in the array having lumbar gasket elements may have a ratio obtained by dividing the length 60 of the innermost edge of the posterior ear by the length 70 of the lumbar cuff element, in the range of 1.0 to 3.0, particularly 1.5 to 2.5, and more specifically 1.8 to 2.2 for each article.

[0053] In another embodiment, the inventors found that the ratio obtained by dividing the length of the innermost edge of the posterior ear portion by the length of the lumbar cuff element cuff can be in the range of 1.0 to 3.0, particularly 1.5 to 2.5, and more specifically 1.8 to 2.2, but for better leak prevention, the length 70 of the lumbar gasket element 36 should also increase with the size of the articles in the array. Not every size in the array requires this increase in length compared to the immediately smaller size, however, in an array of articles, the length of the lumbar gasket element of a second article is at least 2 mm longer than the length of the lumbar gasket element of the first article. This difference in length can be at least 4 mm. For arrays of at least three different articles, or even more (e.g., an array of diapers that extends from newborns to toddlers), a third article may be provided in the array, and the length of the lumbar gasket element of the third article is at least 2 mm longer than the length of the lumbar gasket element of the second article. The difference in length may also be at least 4mm longer.

[0054] In this context, the terms “first” article, “second” article, and “third” article refer to articles of different sizes and increasing sizes, however, the first, second, and third sizes do not necessarily have to be size number 1, size number 2, or size number 3 of a given array. Rather, there may be a first size, a second size, and several intermediate sizes between the second and third sizes. This and different aspects of the present invention are illustrated in the following two example arrays.

[0055] Exemplary Array 1 (all dimensions in mm):

[0056] [Table 1]

[0057] Exemplary Array 1 includes eight basic sizes and three additional plus sizes ("P"), thus forming an array of 11 items with a larger recommended weight range. The P sizes have a higher limit (+1 = +1 kg) relative to their weight range boundaries compared to the basic sizes that expand. Each item has a ratio obtained by dividing the length of the innermost edge of the posterior ear portion by the length of the lumbar cuff element cuff, ranging from 1.0 to 3.0, particularly 1.5 to 2.5, and more specifically 1.8 to 2.2. The items have three different lumbar gasket element lengths (40 mm, 45 mm, 50 mm), which increase with the size of the item. Accordingly, articles of sizes 1 to 3 are each first articles according to the present invention, any of the articles of sizes 3 to 4 are second articles according to the present invention, while any of the articles of sizes 5 to 8 are third articles according to the present invention, with a ratio of 60 / 70 for these third articles being within the claimed scope, and the innermost edge length of the rear ear portion also being 5 mm longer than the innermost edge length of the rear ear portion of the second articles. Alternatively, articles of size 5 and above may have a longer waist gasket element length of 55 mm instead of 50 mm to provide further protection using an acceptable additional material cost.

[0058] Exemplary Array 2 (all dimensions in mm):

[0059] [Table 2]

[0060] Exemplary Array 2 includes eight basic sizes and three additional plus sizes ("P"), thus forming an array of 11 articles with a larger recommended weight range. Each article has a ratio obtained by dividing the length of the innermost edge of the posterior ear portion by the length of the lumbar gasket element cuff, ranging from 1.0 to 3.0, particularly 1.5 to 2.5, with seven of the eight articles having a ratio ranging from 1.8 to 2.2. The articles have three different lumbar gasket element lengths (40mm, 45mm, and 50mm). Each article of size 1 to 2 is a first article according to the present invention (length 70=40mm), while each article of size 3 / P to 4 / P is a second article according to the present invention (length 70=45mm), and each article of size 5 and above is a third article according to the present invention (length 70=50mm). Optionally, articles of size 5 or larger may have a longer waist gasket element length of 55 mm instead of 50 mm to provide further protection at an acceptable additional material cost.

[0061] others The dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​listed. Instead, unless otherwise indicated, each such dimension is intended to mean both the listed value and the functionally equivalent range encompassing that value. For example, a dimension disclosed as "mm" is intended to mean "approximately mm".

Claims

1. An array of personal hygiene articles (10), comprising at least a first article and a second article, wherein the second article is fitted to a wearer having a larger size than the first article. Each article includes a longitudinal centerline (50), a transverse centerline (48), a top sheet (26), a back sheet (28), an absorbent core (30), a chassis optionally including a trapping material, a pair of rear ear portions (42) attached to the chassis and extending transversely outward from the chassis, and a waist gasket element (36) disposed on the wearer-facing side of the article between the rear ear portions (42), Each of the aforementioned posterior ear portions (42) has an innermost edge portion (420) having a length (60), The waist gasket element (36) has a length (70) measured along the longitudinal centerline, An array of personal hygiene articles (10), wherein the ratio of the length (60) of the innermost edge of the posterior ear portion to the length (70) of the lumbar gasket element is in the range of 1.0 to 3.0 for at least the first article and the second article, and the length of the lumbar gasket element of the second article is at least 2 mm longer, preferably at least 4 mm longer, than the length of the lumbar gasket element of the first article.

2. The array of personal hygiene articles according to claim 1, wherein the ratio of the length (60) of the innermost edge of the posterior ear portion to the length (70) of the lumbar gasket element is in the range of 1.5 to 2.5, more preferably 1.8 to 2.2, for at least the first article and the second article.

3. The array includes at least a third article, the third article being fitted to a wearer having a larger size than the second article. The ratio of the length of the innermost edge of the rear ear portion to the length of the waist gasket element of the third article is in the range of 1.0 to 3.0, preferably 1.5 to 2.5, and more preferably 1.8 to 2.

2. The array of personal hygiene articles according to claim 1 or 2, wherein the length of the lumbar gasket element of the third article is at least 2 mm, preferably at least 4 mm, longer than the length of the lumbar gasket element of the second article.

4. The array of personal hygiene articles according to any one of claims 1 to 3, wherein the array comprises 3 to 12 articles of different sizes, and at least 50% of the articles in the array have a lumbar gasket element.

5. An array of personal hygiene articles according to any one of claims 1 to 4, wherein the length of the lumbar gasket element of the first article, the second article, and, if present, the third article, is 30 mm to 60 mm for each of these articles, and the length is measured in the longitudinal direction.

6. The array of personal hygiene articles according to claim 5, wherein the length of the lumbar gasket element of the first article is in the range of 30 mm to 50 mm, and the length of the lumbar gasket element of the second article is in the range of 35 mm to 55 mm, and if present, the length of the lumbar gasket element of the third article is in the range of 40 mm to 60 mm.

7. An array of personal hygiene articles according to any one of claims 1 to 6, wherein the width of the waist gasket element for at least the first article, the second article, and, if present, the third article, is in the range of 30 mm to 100 mm, and the width is measured transversely with the waist gasket element gently stretched to remove any wrinkles.

8. An array of personal hygiene articles according to any one of claims 1 to 7, wherein at least one, two or more, or all of the articles in the array have at least one channel-forming area (40) within the absorbent core.

9. An array of personal hygiene articles according to any one of claims 1 to 8, wherein at least one, two or more, or all of the articles in the array have an absorbent core that is substantially free of cellulose fibers in the absorbent material.

10. An array of personal hygiene articles according to any one of claims 1 to 9, wherein at least a portion of the lumbar gasket element (36) is attached to the chassis with adhesive within an adhesive zone (170), and at least a portion of the lumbar gasket element includes mechanical attachment portions (172, 174) to the chassis, located on a first side edge (76) of the lumbar gasket element (36) and in a first adhesive-free zone adjacent thereto, and on a second side edge (78) of the lumbar gasket element and in a second adhesive-free zone adjacent thereto.

11. The array of personal hygiene articles according to claim 10, wherein the waist gasket element includes a third adhesive-free zone disposed adjacent to and on the proximal edge (72) of the waist gasket element in the central region of the waist gasket element, such that the proximal edge of the waist gasket element in the central region is not attached to the chassis.

12. The array of personal hygiene articles according to claim 10 or 11, wherein the adhesive zone (170) is disposed on and adjacent to the distal edge (74) of the lumbar gasket element.

13. The array of personal hygiene articles according to any one of claims 10 to 12, wherein the first mechanical mounting portion (172) and the second mechanical mounting portion (174) extend through the waist gasket element, the top sheet, and the back sheet.

14. The array of personal hygiene articles according to any one of claims 1 to 13, wherein the array includes separate packages (500) for each of the articles of different sizes (540) within the array.

15. An array of personal hygiene items according to any one of claims 1 to 14, wherein the personal hygiene item is a tape-type diaper (550) for infants and / or toddlers having different recommended weight ranges.

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