Disposable pant-type article having contoured leg edges and method for producing a disposable pant-type article - Patents.com

Abstract

The disposable pant-type article 1 has a front body panel 3 and a back body panel 4 joined at side seams, a crotch region 6, a waist opening 10, and first and second leg edges 11, 12 defining leg openings 13, 14. The front leg edge sections 11f, 12f have medial points Pif1, Pif2 disposed on the front leg edge sections at a distance from the side seams 20, 21 greater than from the lateral points Pof1, Pof2, the medial points Pif1, Pif2 on the front leg edge sections being closer to the front waist edge 31 than the lateral points Pof1, Pof2 on the front leg edge sections 11f, 12f. The crotch leg edge sections have midpoints Pci1, Pci2 disposed between the front crotch edge 34 and the back crotch edge 44, the midpoints being closer to the longitudinal centerline Lc than the front end points Pcf1, Pcf2 of the crotch leg edge sections where the leg edges intersect with the front crotch edge.

Description

[Technical field]

[0001] The present disclosure relates to a disposable pant-type article having a front body panel and a rear body panel, the body panels being elastically stretchable in a transverse direction of the article, the front body panel having a front panel waist edge, a front panel crotch edge opposite the front panel waist edge, and first and second front panel side edges, and the back body panel having a back panel waist edge, a back panel crotch edge opposite the back panel waist edge, and first and second back panel side edges. The article has a crotch region comprised of a crotch region web, the crotch region being disposed between the front panel crotch edge and the back panel crotch edge. The side edges of the front and back body panels are joined at side seams to form a waist opening and first and second leg openings, the first leg opening having a first leg edge, and the second leg opening having a second leg edge. [Background technology]

[0002] In the art of disposable pant-type articles, and in particular disposable pant-type articles intended for use by adult users, these articles should meet high demands on fit, comfort and have a tailored underwear-like appearance, while at the same time meeting equally high demands on absorbency and leak prevention. Disposable absorbent articles are articles that are intended to be discarded after a single use and not to be washed or otherwise restored for repeated use.

[0003] Pant-type articles of this kind are relatively complex products with multiple components that are combined to form the absorbent article, including a nonwoven component, a barrier component, an elastic component, and an absorbent core that may usually be provided in the form of an absorbent assembly that includes a barrier layer and a liquid-permeable topsheet that together surround the absorbent core.

[0004] It is common to enhance body conformance and leakage safety by arranging pre-tensioned elastic elements along all or selected portions of the waist and leg openings of pant-type articles.

[0005] It is also proposed in Patent Document 1 to improve the body shape conformity of a pant-type article by providing the article with shaped leg edges. However, although the pant-type article in Patent Document 1 is well suited to some categories of users, body shapes and body sizes vary greatly among users, and there is still a need for a pant-type article that fits well to the body and can meet the needs of a wider range of users. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] European Patent Publication No. 1 603 502 [Patent Document 2] International Publication No. 2017 / 044013 Brochure [Patent Document 3] International Publication No. 2017 / 044014 Brochure Summary of the Invention [Problem to be solved by the invention]

[0007] However, there continues to be a continuing need for pant-type articles that fit snugly, thereby providing good comfort and leakage safety. [Means for solving the problem]

[0008] A disposable pant-type article with good functionality, fit and comfort can be obtained by the features of claim 1. The disposable pant-type article described herein can be produced according to the method of claim 15. Variations of the present disclosure are described in the dependent claims.

[0009] Disclosed herein is a disposable pant-type article, the article having a longitudinal direction and a transverse direction, a longitudinal centerline extending in the longitudinal direction, the article comprising: - a transversely elastically stretchable front body panel, the front body panel having a front waist edge, a front crotch edge opposite the front waist edge, and first and second longitudinal side edges; - a transversely elastically stretchable back body panel, the back body panel having a back waist edge, a back crotch edge opposite the rear waist edge, and first and second longitudinal side edges; - a crotch region disposed between the front panel crotch edge and the back panel crotch edge, the crotch region adjacent the front body panel along the front body panel crotch edge and adjacent the back body panel along the back body panel crotch region.

[0010] A first longitudinal side edge of the front body panel is joined to a first longitudinal side edge of the back body panel at a first side seam and a second longitudinal side edge of the front body panel is joined to a second longitudinal side edge of the back body panel at a second side seam. The article has a waist opening and first and second leg openings. The first leg opening is bordered by a first leg edge and the second leg opening is bordered by a second leg edge, each of the first and second leg edges being defined by a front leg edge section, a crotch leg edge section, and a back leg edge section.

[0011] The front body panel includes a front panel web that is elastically stretchable in the transverse direction, and a front leg edge section of each of the first and second leg edges is disposed within the front panel web.

[0012] The rear body panel includes a rear panel web that is elastically stretchable in the transverse direction, and a rear leg edge section of each of the first and second leg edges is disposed within the elastically stretchable back panel web.

[0013] The crotch region includes a crotch region web, and a crotch leg edge section of each of the first and second leg edges is disposed within the crotch region web from the front crotch edge of the front body panel to the rear crotch edge of the back body panel.

[0014] Each front leg edge section has an inner point located on the front leg edge section at a greater distance from a corresponding side seam than from a longitudinally extending centerline, and an outer point defining an end point of the front leg edge section and located at the corresponding side seam, the distance between the inner point of the front leg edge section and the front waist edge being the minimum distance between the front leg edge section and the front waist edge and being less than the distance between the outer point of the front leg edge section and the front waist edge.

[0015] Each crotch leg edge section has a midpoint located between the front crotch edge and the rear crotch edge that is closer to the longitudinal centerline than a front end point of the crotch leg edge section where the leg edge intersects the front crotch edge.

[0016] The distance between the front end point of the crotch leg edge section and the front waist edge may be greater than the distance between an outer point of the front leg edge section and the front waist edge, such that the front end point of the crotch leg edge section is positioned lower than the outer point of the front leg edge section.

[0017] A midpoint on each crotch leg edge section may be closer to the longitudinal centerline than a rear end point of the crotch leg edge section where the leg edge intersects with the rear crotch edge. Thus, the crotch region may have a smaller width at the midpoint on the crotch leg edge section than the front panel crotch edge and the rear panel crotch edge, which gives the crotch region an hourglass shape.

[0018] The distance between the outer point of each front leg edge section and the front waist edge may constitute the maximum distance between the front leg edge section and the front waist edge in the portion of the front leg edge section defined between the inner point of the front leg edge section and the side seam.

[0019] The first leg edge and the second leg edge may be mirror images of each other about a longitudinally extending centerline.

[0020] It has been found that the leg edge configuration has a higher cut near the longitudinal centerline than at the side seams, resulting in a more modest, underwear-like pant-type article that takes full advantage of the elasticity of the elastic front panel web for improved body conformance and comfort.

[0021] The distance between each inner point of each front leg edge section and the longitudinally extending centerline may be 30 to 50% of the distance between the longitudinally extending centerline and the corresponding side seam, measured in a transverse direction of the pant-type article perpendicular to the longitudinally extending centerline.

[0022] During the production of pant-type articles as disclosed herein, elastic materials, such as elastic elements, films, and web materials, are attached to non-elastic non-stretch materials, and the elastic materials are in a tensile elongated state. In the final pant-type article, the elastic materials are relaxed and gather the non-stretch materials. The non-stretch materials in pant-type articles as disclosed herein limit the stretchability of the stretchable parts of the pant-type articles, such as the elastic front and back panels, leg elastics, and waist elastics. All distances and lengths disclosed herein are measured with the pant-type article in a flattened, generally two-dimensional state, with all elastics in the article stretched to the maximum extent permitted by the non-stretch components in the article, and with all non-stretch components in the article in an ungathered state.

[0023] The distances between the points of the front and rear leg edge sections and the corresponding side seams are measured along the corresponding leg edges. The outer point of the front leg edge section is the outer endpoint of the front leg edge section and is located just inside the side seam with no distance between the outer point and the side seam.

[0024] The distances between the inner and outer points of the front leg edge sections and the corresponding waist edges are measured in the longitudinal direction. In embodiments where one or both waist edges are non-linear, such as a wavy waist edge, the distances are measured in the longitudinal direction y relative to a line extending transversely parallel to and near the front waist edge.

[0025] The distance between the longitudinal centerline and the midpoint on each crotch leg edge section and each of the front and back end points is measured in the transverse direction.

[0026] The distance between the inner point on each front leg edge section and the front waist edge may be 5 to 40 millimeters less, such as 10 to 30 millimeters less, or 15 to 20 millimeters less, than the distance between the outer point on each front leg edge section and the front waist edge. Thus, the inner point on each front leg edge section may be located at least 5 millimeters and at most 40 millimeters closer to the front waist edge than the outer point, such as at least 10 millimeters and at most 30 millimeters, or at least 15 millimeters and at most 20 millimeters.

[0027] The inner point of each front leg edge section may be located up to 20 millimeters closer to the front waist edge than the outer point.

[0028] It has been found that in pant-type absorbent articles having an absorbent core, particularly good body conformance and fit of the article, such as a "hipster" type article, can be achieved when the inner point on the front crotch leg edge section is located at or close to the side edge of the absorbent core.

[0029] The distance between the midpoint on each crotch leg edge section and the longitudinal centerline may be 2 to 30 millimeters less, such as 5 to 20 millimeters or 7 to 15 millimeters, than the distance between the front end point and the longitudinal centerline.

[0030] The distance between the midpoint on each crotch leg edge section and the longitudinal centerline may be 5 to 60 millimeters less than the distance between the rear endpoint and the longitudinal centerline, such as 10 to 50 millimeters, or 12 to 40 millimeters, or 15 to 30 millimeters less than the distance between the rear endpoint and the longitudinal centerline.

[0031] The crotch region includes a crotch panel that is attached by a first side edge of the crotch panel along the front panel crotch edge and by a second side edge of the crotch panel to the back panel along the back panel crotch edge, and the attachment between the crotch panel and the front and back panels may be as overlap seams extending along the front panel crotch edge and the back panel crotch edge.

[0032] Alternatively, or in addition, the crotch region may include a portion of a web material, such as an inner or outer cover web material of a pant-type article, that extends longitudinally continuously from the front panel waist edge to the back panel waist edge and fills the gap between the front panel crotch edge and the back panel crotch edge. The portion of the continuous cover web material that is applied to the crotch region constitutes the crotch region web.

[0033] In either case, the longitudinal extension in the crotch region is defined as the longitudinal distance between the front panel crotch edge of the front elastically stretchable body panel and the back panel crotch edge of the back elastically stretchable body panel. It may be preferred that the crotch region web extends across the entire surface of the crotch region.

[0034] The crotch area web applied to the crotch area, either as part of the contiguous cover material or as the crotch panel material, may be a non-elastic material, such as a non-stretchable nonwoven web.

[0035] Each rear leg edge section of a disposable pant-type article as disclosed herein may have a convexly curved hip portion.

[0036] Each rear leg edge section may have a transition point where the convex curvature of the buttocks portion of the rear leg edge section changes to a straight hip portion of the rear leg edge section or a hip portion having a concave curvature, the transition point being located a distance from the corresponding side seam, such as a distance of 30 millimeters to 100 millimeters from the corresponding side seam.

[0037] The shape of the leg edges of a pant-type article as disclosed herein may be described as the first leg edge and the second leg edge each having a shape that corresponds to half of the contour of the heart-shaped region.

[0038] The pant-type article as disclosed herein may further comprise an absorbent core, which may be part of an absorbent assembly, which comprises an absorbent core, a liquid-permeable topsheet, and a liquid-impermeable backsheet, and the absorbent core is sealed between the liquid-permeable topsheet and the liquid-impermeable backsheet.

[0039] The absorbent assembly has side edges extending in a longitudinal direction of the pant-type article and end edges extending in a transverse direction of the pant-type article. The absorbent assembly may further include leg elastic elements applied along the side edges of the absorbent assembly.

[0040] A midpoint on each crotch leg edge section may be positioned on a side edge of the absorbent assembly, where the distance between the crotch leg edge section and the longitudinal centerline is less than the distance between the front end point and the longitudinal centerline, and optionally less than the distance between the rear end point of the crotch leg edge section and the longitudinal centerline.

[0041] A pre-tensioned first crotch elastic member can be arranged to extend longitudinally along a first leg edge between the front and rear crotch edges, and a pre-tensioned second crotch elastic member can be arranged to extend longitudinally along a second leg edge between the front and rear crotch edges.

[0042] A midpoint on each crotch leg edge section, where the distance between the crotch leg edge section and the longitudinal centerline is less than the distance between the front end point and the longitudinal centerline and optionally less than the distance between the rear end point of the crotch leg edge section and the longitudinal centerline, may be disposed on a side edge of the corresponding crotch elastic member.

[0043] In the disposable pant-type article disclosed in this specification, the crotch elastic members each have a front end portion of the front panel crotch edge and a rear end portion of the back panel crotch edge, and the front end portion of each of the first and second crotch elastic members may overlap and be attached to the front body panel, and / or the rear end portion of each of the first and second crotch elastic members may overlap and be attached to the back body panel.

[0044] The crotch elastic may be a flat strip of crotch elastic and may include or consist of an elastic film.

[0045] The crotch elastic member may have a width in the transverse direction of the article within the range of 15 mm to 50 mm, such as 20 mm to 40 mm, or 25 mm to 35 mm, and a length in the longitudinal direction of the article within the range of 150 mm to 350 mm, such as 170 mm to 320 mm, or 200 mm to 310 mm. The dimensions of the crotch elastic member are measured with the side seams of the pant-type article laid flat and the side seams broken or cut open.

[0046] Each of the first crotch elastic member and the second crotch elastic member may have a width at the front and rear end portions of the crotch elastic member that is wider than the width at an intermediate portion of the crotch elastic member that is disposed between the front and rear end portions of the crotch elastic member.

[0047] The width of the front end portion may be equal to the width of the rear end portion. The ratio of the width of the end portions to the smallest width of the middle portion may be from 1:0.5 to 1:0.9.

[0048] The concave curved portion of the crotch elastic member may have a radius of curvature of 200 to 700 mm.

[0049] The pretensioning of the crotch elastic member may be preferably achieved by attaching the crotch elastic member to the pant-type article in a stretched state. The crotch elastic member may be applied and attached to the pant-type article with the end portions of the crotch elastic member in a non-tensioned state. The non-tensioned end portions of the crotch elastic member may each have a length of 5% to 8% of the total length of the crotch elastic member, including the length of the end portions and the intermediate portion in tension between the end portions.

[0050] The absorbent assembly, if present, may be stretched and applied over the attached crotch elastic member. In this manner, the absorbent assembly will overlay the crotch elastic member on the inner surface of the pant-type article, the inner surface being the surface intended to face the wearer when the pant-type article is worn. The inner surface of the absorbent assembly is formed by the liquid-permeable topsheet and may optionally include reinforced elastic elements and / or barrier cuffs extending along the side edges of the absorbent assembly.

[0051] The topsheet and optional barrier cuffs of the absorbent assembly may preferably be formed from a fibrous web material, such as a nonwoven material, to impart a woven character to the inner surface of the absorbent assembly. The barrier cuffs may be elastic barrier cuffs.

[0052] A first reinforcing elastic feature may be disposed on the elastically stretchable back body panel web along some or all of the rear leg edge section of the first leg edge, and a second reinforcing elastic feature may be disposed on the elastically stretchable back body panel web along some or all of the rear leg edge section of the second leg edge. The reinforcing elastic feature is a secondary elastic element applied in addition to the elastic material in the elastic body panel.

[0053] The first reinforcing elastic feature may extend along a first portion of the rear leg edge section of the first leg edge in a direction away from the longitudinal centerline of the pant-type article toward the first side seam. The first reinforcing elastic feature may have an end point on the rear leg edge section of the first leg edge, and a second portion of the rear leg edge section of the first leg edge is free of the first reinforcing elastic feature. The second portion of the rear leg edge section of the first rear leg edge may have a length as measured along the first leg edge from the end point of the first reinforcing elastic feature to the first side seam that is 25% to 75% of the total length of the rear leg edge section of the first leg edge.

[0054] The second reinforcing elastic feature may extend along a first portion of the rear leg edge section of the second leg edge in a direction away from the longitudinal centerline of the pant-type article toward the second side seam. The second reinforcing elastic feature may have an end point on the rear leg edge section of the second leg edge, and a second portion of the rear leg edge section of the second leg edge is free of the second reinforcing elastic feature. The second portion of the rear leg edge section of the second leg edge may have a length as measured along the second leg edge from the end point of the second reinforcing elastic feature to the second side seam that is 25% to 75% of the total length of the rear leg edge section of the second leg edge.

[0055] The first and second reinforcing elastic features of the pant-type article disclosed herein may be formed from an elastic member that is continuously applied between the side edges of the pant-type article and then cut to provide elasticity only along the portion of the rear leg edge section where the reinforcing elastic is desired. The continuous elastic member may be cut at a location corresponding to the longitudinal centerline of the pant-type article and allowed to snap back at an attachment area configured at the intersection between the rear leg edge section and the crotch leg edge section to avoid elastic contraction in the crotch region of the article.

[0056] The first and second reinforcing elastic features may include a plurality of individual elastic elements, such as from 2 to 15 individual elastic elements, from 3 to 12 individual elastic elements, or from 4 to 10 individual elastic elements.

[0057] The plurality of discrete elastic elements may be elastic cords, stretchable threads, or rubber bands applied in spaced relation along the rear leg edge sections of the first and second leg edges.

[0058] The reinforced elastic member may be covered with a nonwoven covering web.

[0059] The reinforced elastic feature may intersect with and be attached to the first and second crotch elastic members. The first and second crotch elastic members may already be attached to the crotch region prior to attaching the reinforced elastic feature, or the reinforced elastic feature may already be attached to the crotch region prior to attaching the crotch elastic members. As defined herein, the rear end portion of the first crotch elastic member and the rear end portion of the second crotch elastic member may overlap and be attached to the elastic back body panel. The reinforced elastic feature may then rest on and be attached to the rear end portion of the first crotch elastic member and the rear end portion of the second crotch elastic member. Thus, the rear end portion of the crotch elastic member may act as an anchor area for the reinforced elastic feature at the inner end of the reinforced elastic feature.

[0060] It may be advantageous for the reinforced elastic features to be attached to the non-tensioned end portion of the crotch elastic member, as in this manner a more secure attachment between the reinforced elastic features and the crotch elastic member may be provided.

[0061] In a disposable pant-type article as disclosed herein, the elastically stretchable front panel web and / or the elastically stretchable back panel web may include or consist of an elastic laminate, the elastic laminate including first and second layers of fibrous material and an intermediate elastic layer disposed between the first and second layers of fibrous material.

[0062] The intermediate elastic layer comprises or consists of a layer of elastic film.

[0063] It may be preferred that all sections of the first leg edge and second leg edge are cut in an elastic web material, such as an elastic film, elastic nonwoven, or elastic foam material, with the primary direction of cut being the direction of stretchability of the elastic material, i.e., the front and rear leg edge sections are cut primarily in the transverse direction and the crotch leg edge section is cut primarily in the longitudinal direction and extends at least partially within the longitudinally pre-tensioned crotch elastic member.

[0064] A portion of each leg cut extending into the crotch region web may be cut through the crotch region web, through the corresponding crotch elastic member, if present, and through a peripheral edge portion of the absorbent assembly, the peripheral edge portion of the absorbent assembly being formed by one or both of the liquid impermeable backsheet and the liquid permeable topsheet of the absorbent assembly, the peripheral edge portion of the absorbent assembly being configured outwardly from the peripheral edge of the absorbent core of the absorbent assembly. In an absorbent assembly as disclosed herein, the topsheet and the backsheet both extend beyond the perimeter of the absorbent core and may be joined to one another at an edge seal that extends along the perimeter of the absorbent core outwardly from the peripheral edge of the absorbent core.

[0065] The leg cuts formed through the peripheral edge portions of the absorbent assembly and optionally through the crotch elastic member have midpoints on the crotch leg edge sections located on the side edges of the absorbent assembly and optionally also on the side edges of the crotch elastic member, where the distance between the crotch leg edge section and the longitudinal centerline is less than the distance between the front end points and the longitudinal centerline, and optionally less than the distance between the rear end points of the crotch leg edge section and the longitudinal centerline.

[0066] Each crotch elastic member has a concave edge resulting from a leg cut made along a concave line through the layers of material in the crotch region. As referred to herein, the concave edge may be a continuously curved concave edge or an edge including two or more straight segments and optionally one or more curved segments. As referred to herein, the concave edge may include a V-shape and a U-shape, as well as any other shape, to provide a pant-type absorbent article having a crotch region that is narrower in the longitudinal middle portion of the crotch region than in the end portions of the crotch region. The concave edge of the crotch elastic member formed by simultaneously cutting through multiple layers of material in the crotch region, including one or more layers from the peripheral edge portions of the absorbent assembly, coincides with the concave edge of the liquid-permeable topsheet and / or the concave edge of the liquid-impermeable backsheet of the absorbent assembly.

[0067] Thus, the liquid impermeable backsheet and / or the liquid permeable topsheet of the absorbent assembly may be adjacent to the first and second crotch elastic members along at least a portion of the concave crotch leg edge section that extends within the crotch elastic member, such as, for example, a portion of each concave crotch leg edge section that is positioned within an intermediate portion of the corresponding crotch elastic member.

[0068] A pant-type absorbent article having a concave crotch leg edge section in which the leg edge shape of the crotch elastic member is formed by cutting the crotch elastic member together with the crotch region web and preferably one or more additional web materials, such as the topsheet and / or backsheet of the absorbent assembly, provides a pant-type absorbent article with cuff-shaped, wrinkle-free elastic leg edges that comfortably conform to the shape of the wearer's crotch.

[0069] In a disposable pant-type article as disclosed herein, the elastically stretchable front body panel web may extend transversely between the first and second front panel side edges and form part of or constitute a continuous front panel web extending longitudinally from the front waist edge to the front crotch edge, and / or the elastically stretchable back body panel may extend transversely across the width of the rear portion between the first and second back panel side edges and form part of or constitute a continuous back panel web extending longitudinally from the rear waist edge to the rear crotch edge.

[0070] Also disclosed herein is a continuous method for producing a disposable pant-type article, such as the disposable pant-type article disclosed herein, the method comprising: - advancing a continuous, elastically stretchable, front panel web in a machine direction, the front panel web being tensioned in the machine direction and having a front waist edge and an opposed front crotch edge; - advancing a continuous, elastically stretchable back panel web in a machine direction, the back panel web being tensioned in the machine direction and having a rear waist edge and an opposed rear crotch edge, the back panel web being spaced from the front panel web in a cross-machine direction perpendicular to the machine direction, such that there is a gap in the cross-machine direction between the crotch edge of the front panel web and the crotch edge of the back panel web; - advancing a non-elastic continuous crotch web in a machine direction, the crotch web having a first side edge and an opposing second side edge; - attaching a crotch web to the tensioned front panel web and the tensioned back panel web, thereby bridging a gap between the front crotch edge of the front panel web and the rear crotch edge of the back panel web and forming a continuous chassis web of interconnected precursor articles, the precursor articles being connected at parting lines extending in a cross machine direction between the precursor articles; - forming leg cuts in the chassis web, each leg cut having a closed loop configuration, forming a first leg edge of the preceding precursor article and a second leg edge of the subsequent precursor article, the first leg edge of the preceding precursor article having a front leg edge section cut in the front panel web, a crotch leg edge section cut in the crotch web from the front crotch edge of the front panel web to the rear crotch edge of the rear panel web, and a rear leg edge section cut in the rear panel web, and the second leg edge of the subsequent precursor article having a front leg edge section cut in the front panel web, a crotch leg edge section cut in the crotch web, and a rear leg edge section cut in the rear panel web; each front leg edge section has an inner point located on the front leg edge section at a distance from a corresponding side seam that is greater than its distance from a longitudinally extending centerline, and an outer point located on the front leg edge section at the corresponding side seam, the distance between the inner point of the front leg edge section and the front waist edge being the smallest distance between the front leg edge section and the front waist edge and less than the distance between the outer point of the front leg edge section and the front waist edge; each crotch leg edge section has a point disposed between the front crotch edge and the rear crotch edge, and a distance between the first leg edge and the second leg edge is less than an end point of the crotch leg edge section where the leg edge intersects with the front crotch edge; - folding the chassis web along a crease extending in the machine direction to align a waist edge of the front panel web with a waist edge of the back panel web; - forming first and second side seams in each precursor article, the side seams being formed in a cross machine direction from the aligned waist edges of the front and back panel webs to the leg cuts; - cutting individual pant-type articles from the chassis web; Includes.

[0071] The elastically stretchable front panel web and / or the elastically stretchable back panel web comprise or consist of an elastic laminate, which comprises at least a first layer of a non-stretchable fibrous material, such as a nonwoven web, and an elastic layer.

[0072] The elastic laminate includes a second layer of fibrous material, and the elastic layer may be an intermediate elastic layer disposed between the first and second layers of fibrous material.

[0073] The elastic layer in the laminates disclosed herein may comprise or consist of a layer of elastic film.

[0074] The elastic layer in the laminates disclosed herein may comprise or consist of a layer of elastic nonwoven material.

[0075] Either or both of the front and back panel webs may comprise or consist of a three-layer laminate web including two outer nonwoven layers and an intermediate elastic layer between the outer nonwoven layers. The three-layer nonwoven-film-nonwoven laminate provides an elastic panel with a smooth, soft, skin-friendly, textile-like surface. The laminate may be produced by known methods or combinations of methods such as stretch bonding, methods involving incremental stretching, and the like.

[0076] A three-layer elastic panel web may be formed by stretch bonding a first surface of an elastic layer, such as an elastic film, elastic nonwoven, or by stretch bonding a plurality of parallel elastic elements, such as cords or filaments, to a first nonwoven layer and then bonding a second nonwoven layer to a second surface of the elastic layer, or by bonding a second nonwoven layer to cover the plurality of parallel elastic cords on the first nonwoven layer. Stretch bonding means that the elastic layer or elastic elements are stretched in the machine direction MD, such as 50-600%, to retain the elastic properties of the elastic film layer in the composite base web.

[0077] In the methods as disclosed herein, when using a laminate elastic panel web that includes one or more non-elastic layers, such as elastic layers or elements and one or more non-elastic nonwoven layers bonded together by stretch bonding, the web is held in tension throughout the process until the final step of cutting the individual pant-type articles from the chassis web, which generally means that the web is stretched in the machine direction to the maximum extent permitted by the one or more non-elastic layers.

[0078] The crotch web as disclosed herein may be any suitable non-elastic web material, such as a non-elastic nonwoven web, a non-elastic polymeric film, or a non-elastic laminate. Laminates including one or more nonwoven webs and laminates including one or more nonwoven webs and polymeric films may also be contemplated. The crotch web may be a crotch panel web having a first side edge and an opposing second side edge, the first side edge of the crotch panel web being attached to the front crotch edge of the tensioned front panel web at a front seam, and the second side edge of the crotch panel web being attached to the rear crotch edge of the tensioned rear panel web at a rear seam, thereby bridging the gap between the front crotch edge of the front panel web and the rear crotch edge of the rear panel web. Alternatively, the crotch web may be an outer or inner cover web that extends in the cross machine direction over the entire distance or over at least 75% of the distance between the front waist edge and the rear waist edge.

[0079] The method as disclosed herein comprises: - providing a pair of crotch elastic members, the pair comprising a first prefabricated crotch elastic member and a second prefabricated crotch elastic member; - stretching each crotch elastic member in a longitudinal direction of the crotch elastic member to align the longitudinal direction of the crotch elastic member with the cross-machine direction; - attaching each stretched crotch elastic member to a crotch panel web while maintaining the crotch elastic members stretched and aligned in the cross-machine direction, and attaching such that a first crotch elastic member is spaced from a second crotch elastic member in the machine direction by a crotch spacing and such that a pair of crotch elastic members of a preceding precursor article is spaced from a pair of crotch elastic members of a succeeding precursor article by an article spacing in the machine direction, the article spacing being dependent on the pitch length of the precursor articles in the chassis web of the interconnected precursor articles.

[0080] In the method disclosed herein, the crotch elastic member may be a strip-shaped crotch elastic member. The strip-shaped crotch elastic member may be a strip of inherently elastic material such as an elastic film or elastic nonwoven material, or may be a prefabricated elastic member comprising one or more layers of a nonelastic web to which one or more elastic elements are attached under tension. Such elastic elements may be a plurality of elastic cords, stretchable threads, or rubber bands applied parallel to each other along the length of the crotch elastic member corresponding to the cross machine direction of the method of the present invention, and spaced apart along the width of the crotch elastic member corresponding to the machine direction of the method of the present invention. Laminates of elastic films and one or more nonelastic nonwoven webs are also contemplated for the crotch elastic member as disclosed herein.

[0081] In the methods as disclosed herein, it may be preferred that the crotch elastic member comprises or consists of an elastic film.

[0082] The stretched crotch elastic member may have a width as measured in the machine direction within the range of 15 mm to 50 mm, such as 20 mm to 40 mm, or 25 mm to 35 mm, and a length as measured in the cross machine direction within the range of 150 mm to 350 mm, such as 170 mm to 320 mm, or 200 mm to 310 mm.

[0083] Methods as disclosed herein may include overlapping a first end portion of each of the first and second crotch elastic members of the pair of crotch elastic members with the tensioned front panel web and attaching the overlapped first end portion of each of the first and second crotch elastic members to the tensioned front panel web, and / or overlapping a second end portion of each of the first and second crotch elastic members of the pair of crotch elastic members with the tensioned back panel web and attaching the overlapped second end portion of each of the first and second crotch elastic members to the tensioned back panel web.

[0084] When the stretched crotch elastic members are stretched against the chassis web, the end portions of the crotch elastic members can be held by movable clamps in the stretching device. The clamped end portions are not stretched and are applied and attached to the chassis web in an untensioned state. The two untensioned end portions of each crotch elastic member can have a combined stretch in the cross-machine direction (i.e., along the length of the crotch elastic members) of 10% to 15% of the total stretch of the stretched crotch elastic members in the cross-machine direction.

[0085] In a method including applying a tensioned crotch elastic member as disclosed herein, the front section of the leg edge may be formed by cutting primarily in the direction of tension of the front panel web, and the crotch section of the leg edge is formed by cutting primarily in the direction of tension of the first and second crotch elastic members.

[0086] The methods disclosed herein may further include applying and attaching a prefabricated absorbent assembly between the first and second leg edges of each precursor article, the absorbent assembly including an absorbent core, the absorbent core being disposed between a liquid impermeable backsheet and a liquid permeable topsheet.

[0087] The absorbent assembly has side edges extending in a longitudinal direction of the absorbent assembly corresponding to the cross machine direction of the method, and end edges extending in a cross direction of the absorbent assembly corresponding to the cross machine direction of the method. The absorbent assembly may further include leg elastic elements applied along the side edges of the absorbent assembly.

[0088] The absorbent assembly may be stretched and applied over the attached crotch elastic member. In this manner, the absorbent assembly will overlay the crotch elastic member on the inner surface of the pant-type article produced, the inner surface being the surface intended to face the wearer when the pant-type article is worn. The inner surface of the absorbent assembly is formed by a liquid-permeable topsheet and may optionally include barrier cuffs extending along the side edges of the absorbent assembly.

[0089] It may be preferred that the topsheet and optional barrier cuffs of the absorbent assembly are formed from a fibrous web material, such as a nonwoven material, to impart woven characteristics to the inner surface of the absorbent assembly.

[0090] The absorbent core of a pant-type article as disclosed herein is not necessarily part of a prefabricated absorbent assembly that includes a topsheet and a backsheet.

[0091] Methods as disclosed herein may also include attaching waist elastic members along a front waist edge of the front panel web and / or attaching waist elastic members along a back waist edge of the back panel web, where the one or more waist elastic members are attached before or after the crotch panel web is attached to the front and back panel webs. The one or more waist elastic members may be attached to the waist edges of one or both of the front and back panel webs before the front and back panel webs are attached to the crotch panel web.

[0092] The waist elastic members may be attached to the front and back panel webs according to a method as disclosed in U.S. Pat. No. 5,999,623 or U.S. Pat. No. 5,999,636, which involves attaching a continuous waistband component to a base web at a defined waistband attachment area and cutting the base web and the attached waistband component along a cut through the attachment area in the machine direction, thereby producing a first panel web including a first panel portion to which a first portion of the waistband component is attached, and a second panel web including a second panel portion and a second panel portion to which a second portion of the waistband component is attached. After cutting the base web and the elastic waistband component, the two web portions are shifted in the cross machine direction such that the edges of the web portions to which the portions of the waistband component are attached face away from each other instead of towards each other. The two web portions having attached portions of the waistband component may be used in a method of producing a disposable pant-type article as disclosed herein as a front panel web having waist elastic members arranged along a waist edge of the front panel web and a back panel web having waist elastic members arranged along a waist edge of the back panel web.

[0093] Alternatively, waist elastic members may be attached to the waist edges of one or both of the front and back panel webs after the front and back panel webs are attached to the crotch panel web.

[0094] The waistband members are components of the chassis web that are configured to create a distinct waistband in the final pant-type article as disclosed herein. Each waistband member has an outer edge that faces away from the crotch edge of the corresponding panel web and an inner edge that faces toward the crotch edge of the corresponding panel web. The inner edge of the waistband member defines a distinct boundary between the waistband member and the main body portion of the corresponding panel web.

[0095] Depending on how the waistband member is applied to the panel web, as in the application methods disclosed in U.S. Patent Nos. 5,393,349 and 5,433,633, the waistband member may completely overlap the waist edge portions of the panel web, or the waistband member may be attached to the waist edges of the panel web with only a slight overlap, sufficient to create a bond between the waistband member and the panel web.

[0096] Methods as disclosed herein may involve feeding and stretching continuous reinforcing leg elastics in the machine direction prior to forming the leg cuts in the chassis web, and attaching the stretched reinforced leg elastics in a curved configuration along the back panel crotch.

[0097] The continuous reinforcing leg elastic members are stretched in the machine direction and tensioned prior to forming the leg cuts in the chassis web and then attached in a stretched condition along the crotch edge of the panel web so that excess portions of the elastic elements can be trimmed when forming the leg cutouts.

[0098] The continuous leg elastic member may include a plurality of individual elastic elements, such as 2 to 15 elastic elements, 3 to 12 elastic elements, or 4 to 10 elastic elements.

[0099] The multiple individual elastic elements may be elastic cords, stretch threads, or rubber bands spaced apart in the cross machine direction.

[0100] Attaching the continuous reinforced elastic element may include forming one or more attachment areas on the tensioned rear panel web by applying an adhesive to the tensioned rear panel web, and attaching the continuous reinforced elastic element to the tensioned rear panel web at the one or more attachment areas. The adhesive and the adhesive-bearing reinforced elastic member may be covered by a cover web, such as a nonwoven cover web.

[0101] If present, the first and second crotch elastic members may be attached to the chassis web prior to attachment of the reinforced elastic element. In embodiments in which the second end portions of the first and second crotch elastic members are tensioned and then overlap and attached to the panel web, which in turn is attached to the reinforced elastic element, it may be preferred that the reinforced elastic element overlays and is attached to the second end portions of the first and second crotch elastic members.

[0102] It may be advantageous for the reinforcing elastic element to be attached to the non-tensioned end portion of the crotch elastic member, as in this manner a more reliable attachment between the reinforcing elastic element and the crotch elastic member may be provided.

[0103] A portion of each leg cut extending into the crotch panel web may be cut through the crotch panel web, through a corresponding crotch elastic member, and through a peripheral edge portion of the absorbent assembly that is formed by one or both of the liquid impermeable backsheet and the liquid permeable topsheet of the absorbent assembly and that is configured outwardly from a side edge of the absorbent core of the absorbent assembly. In an absorbent assembly as disclosed herein, the topsheet and the backsheet both extend beyond the perimeter of the absorbent core and may be joined to one another at an edge seal that extends along the perimeter of the absorbent core outwardly from the peripheral edge of the absorbent core.

[0104] In the methods disclosed herein, a first leg edge of each precursor article in the chassis web is - a front leg edge section extending into the tensioned front panel web, the main extension direction of the front leg edge section being the machine direction; - a crotch leg edge section extending into the crotch panel web between the front panel crotch edge and the back panel crotch edge, the crotch leg edge section having a primary extension direction in the cross machine direction; a rear leg edge section extending into the tensioned rear panel web, the rear leg edge section having a main extension direction in the machine direction; The second leg edge of each precursor article comprises: - a front leg edge section extending into the tensioned front panel web, the main extension direction of the front leg edge section being the machine direction; - a crotch leg edge section extending into the crotch panel web between the front panel crotch edge and the back panel crotch edge, the crotch leg edge section having a primary extension direction in the cross machine direction; a rear leg edge section extending into the tensioned rear panel web, the main extension direction of the rear leg edge section being the machine direction.

[0105] After applying the reinforced elastic element onto the tensioned rear panel web, the methods disclosed herein may include forming rear leg edge sections of the first and second leg edges while simultaneously cutting off excess portions of the reinforced elastic element, leaving remaining portions of the reinforced elastic element attached along the rear leg edge sections of each of the first and second leg edges between a rear point of each leg edge where the leg edge intersects the rear panel crotch edge and a cut point on the leg edge where the reinforced elastic element is cut off.

[0106] Thus, the portion of each rear leg edge section between the cut point and the parting line between adjacent precursor articles closest to the cut point is free of reinforcing elastic. The portion of each rear leg edge section free of reinforcing elastic elements may have a length, as measured along the corresponding leg edge from the cut point to the nearest parting line, that is 25% to 75% of the total length of the rear leg edge section.

[0107] The pant-type article and method for the production thereof disclosed herein are further described below with reference to the accompanying drawings. [Brief description of the drawings]

[0108] [Figure 1A] FIG. 2 is a plan view of a stretched and unfolded absorbent pant-type article with open side seams, as viewed from the inside of the pant-type article. [Figure 1B] FIG. 1B shows the pant-type article of FIG. 1A without the leg elastic and absorbent assembly. [Figure 1C] FIG. 1B is a detailed view showing a first leg edge of the pant-type article of FIG. 1A. [Diagram 2] FIG. 2 illustrates a heart-shaped leg curve. [Diagram 3] FIG. 1B is an enlarged view showing the central portion of the pant-type article of FIG. 1A. [Figure 4] FIG. 1B shows the pant-type article of FIG. 1A stretched and unfolded with the side seams closed. [Diagram 5] FIG. 5 shows the pant-type article of FIG. 4 in a stretched, unfolded state, as it would appear prior to use. [Figure 6] FIG. 1 is a plan view of a section of a chassis web at an advanced stage in production. [Figure 7] FIG. 1 is a plan view of a section of a chassis web at an advanced stage in production. [Figure 8] FIG. 1 is a plan view of a section of a chassis web at an advanced stage in production. [Figure 9] FIG. 1 is a plan view of a section of a chassis web at an advanced stage in production. [Figure 10] FIG. 1 is a plan view of a section of a chassis web at an advanced stage in production. [Figure 11] FIG. 1 is a plan view of a section of a chassis web at an advanced stage in production. [Figure 12] FIG. 12 shows a detail of FIG. [Figure 13] FIG. 12 is a plan view of a section of the chassis web of FIGS. 6-11 in a final stage of production. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0109] It should be understood that the drawings are schematic and that individual components or features, such as layers of material, are not necessarily drawn to scale. The absorbent pant-type incontinence products for adult users shown in the figures are provided by way of example only. As used herein, "absorbent pant-type article" means a pant-type article that absorbs or is adapted to absorb bodily fluids, such as urine, blood, and loose feces.

[0110] As disclosed herein, pant-type articles that do not have an absorbent core or that have an absorbent core that is not part of an absorbent assembly may also be contemplated. Further, the absorbent pant-type article may be a baby diaper, training pants, feminine hygiene pants, swimwear, disposable pants, etc.

[0111] The pant-type article shown in the figures is a simplified article, and the article may include additional features such as barrier cuffs, disposal means, etc. Also, it should be understood that the waist elastics disclosed herein are optional or other suitable types of waist elastics may be used. The side seams may be reclosable side seams, and the pant-type article may include fastener elements to provide reclosability of the side seams.

[0112] The method for producing pant-type articles disclosed herein is described in the context of disposable pant-type articles that include an absorbent assembly. However, it should be understood that the method is equally applicable to the production of absorbent and non-absorbent pant-type articles that do not include an absorbent assembly. The method disclosed herein is useful for the production of any type of disposable pant-type article, such as adult incontinence products, baby diapers, training pants, swim pants, disposable underwear pants, women's sanitary pants, etc.

[0113] Referring first to Figure 1A, a pant-type article 1 in the form of a pant-type incontinence product for an adult user is shown. The pant-type article 1 is shown in Figure 1A in an unfolded, flat state with all elastic elements in a stretched state. The pant-type article has a longitudinal direction y and a transverse direction x. As stated herein, all measurements of distances and dimensions are taken with the pant-type molded article in a fully stretched, unfolded, non-gathered state as shown in Figures 1A, 1B, 3, and 4.

[0114] The pant-type article 1 is seen from the inside surface, which is the surface that faces the wearer's body when the article is worn, opposite the outer garment-facing surface of the pant-type article 1.

[0115] The pant-type article 1 comprises a front body panel 3, a rear body panel 4, and an absorbent assembly 80 disposed within the crotch region 6 of the pant-type article 1 and extending forwardly beyond the front body panel 3 and rearwardly beyond the rear body panel 4 in the longitudinal direction y. The absorbent assembly 80 fills the gap between the front body panel 3 and the rear body panel 4. The absorbent assembly 80 is a separately produced component that includes an absorbent core 81 enclosed between a liquid permeable topsheet 82 and a liquid impermeable backsheet 83.

[0116] The front body panel 3 has a front panel waist edge 31 extending in the transverse direction x, a pair of front panel side edges 32, 33 extending in the longitudinal direction y, and a front panel crotch edge 34 extending in the transverse direction opposite the front panel waist edge 31. The back body panel 4 has a back panel waist edge 41 extending in the transverse direction x, a pair of back panel side edges 42, 43 extending in the longitudinal direction y, and a back panel crotch edge 44 extending in the transverse direction x opposite the back panel waist edge 41.

[0117] In the pant-type article 1 shown in the figures, the elastically stretchable front body panel 3 is formed from a continuous front body panel extending in a transverse direction x across the width of the pant-type article 1 between first and second front panel side edges 32, 33 and extending longitudinally from the front waist edge 31 to the front crotch edge 34. The elastically stretchable back body panel 4 is formed from a continuous back body panel web extending in a transverse direction x across the width of the pant-type article 1 between first and second back panel side edges 42, 43 and extending in a longitudinal direction y from the rear waist edge 41 to the rear crotch edge 34.

[0118] The crotch region 6 is disposed between the front and back body panels 3 and is adjacent to the front body panel 3 along the front panel crotch edge 34 and adjacent to the back body panel 4 along the back panel crotch edge 44. The extension of the crotch region 6 in the longitudinal direction y is defined as the distance in the longitudinal direction between the front panel crotch edge 34 and the back panel crotch edge 44.

[0119] The first front panel side edge 32 is joined to the first back panel side edge 42 at a first side seam 20, and the second front panel side edge 33 is joined to the second back panel side edge 43 at a second side seam 21, thereby creating a pant-type article 1 having a waist opening 10, a first leg opening 13, and a second leg opening 14, as shown in Figures 4 and 5.

[0120] FIG. 4 shows the pant-type article 1 in a fully stretched and unfolded state with all elastic elements, which have been stretched and unfolded during production, so that the pant-type moulded article 1 appears generally two-dimensional.

[0121] FIG. 5 shows the pant-type article 1 in a state in which all of the elastic elements that were stretched and spread out during production have contracted to a relaxed state, gathering together the web material in the pant-type article 1.

[0122] The side seam of the pant-type article disclosed herein may be a generally band-shaped joint formed by ultrasonic welding or heat welding. In order to have sufficient strength to withstand the forces applied to the pant-type article while the article is being worn and to allow sufficient manufacturing tolerances when separating individual pant-type garments from the precursor web, the side seam generally has a width on the order of 5 to 10 millimeters. It is also known to make side seams with a width of less than 5 millimeters.

[0123] It is generally desirable for a soiled pant-type garment to be easily removable without having to pull the garment down the user's legs, and therefore the side seams are generally made to tear easily by hand to allow a user or caregiver to pull the side seams apart prior to removing the soiled pant-type garment.

[0124] The waist opening 10 is defined by a front panel waist edge 31 and a back panel waist edge 41. The first leg edge 11 defines a first leg opening 13 and the second leg edge 12 defines a second leg opening 14.

[0125] The front body panel 3 includes a front body panel web that is elastically stretchable in at least the transverse direction x and provides the overall elastic stretchability of the front body panel 3. The front leg edge sections 11f, 12f of each of the first and second leg edges 11, 12 are arranged within the elastically stretchable front body panel web 3 as shown in FIG.

[0126] The rear body panel 4 includes a rear body panel web that is elastically stretchable in at least the transverse direction x and provides the overall elastic stretchability of the rear body panel 4. The rear leg edge sections 11r, 12r of each of the first and second leg edges 11, 12 are arranged within the elastically stretchable rear body panel web 4 as shown in FIG.

[0127] The crotch region 6 comprises a crotch region web, preferably a non-elastic web material such as a non-elastic nonwoven. The crotch leg edge sections 11c, 12c of each of the first and second leg edge sections 11, 12 are arranged in the crotch web material.

[0128] The total length of the first leg edge 11 is the combined length of the front leg edge section 11f, the crotch leg edge section 11c, and the rear leg edge section 11r of the first leg edge 11, and the total length of the second leg edge 12 is the combined length of the front leg edge section 12f, the crotch leg edge section 12c, and the rear leg edge section 12r of the second leg edge 12.

[0129] The first leg edge 11 and the second leg edge 12 are mirror symmetrical with respect to a center line Lc extending in the longitudinal direction of the pant-type article 1. The first leg edge 11 and the second leg edge 12 may be described as having a shape corresponding to half the contour of a heart-shaped region, as shown in Figure 2. The heart-shaped contour shown in Figure 2 may be obtained by shifting the positions of the leg edges 11, 12 in the transverse direction x until their ends are joined to create a continuous curve.

[0130] 1A and 1B, each front leg edge section 11f, 12f has an inner point Pif1, Pif2 located on the front leg edge section 11f, 12f at a distance from a corresponding side seam 20, 21 that is greater than from a longitudinally extending centerline Lc, and an outer point Pof1, Pof2 located on the front leg edge section 11f, 12f at the corresponding side seam 20, 21. The distance between the inner point Pif1, Pif2 and the front waist edge 31 is less than the distance between the outer point Pof1, Pof2 and the front waist edge 31.

[0131] Thus, the medial points Pif1, Pif2 are the points on the front leg edge sections 11f, 12f that are closest to the front waist edge 31, or, if the front waist edge 31 is a non-straight line, such as a wavy line, the medial points Pif1, Pif2 are the points on the front leg edge sections 11f, 12f that are closest to a straight line that extends parallel to the front waist edge 31. The distance from the medial points Pif1, Pif2 to the longitudinally extending centre line Lc is less than the distance between each medial point Pif1, Pif2 and the corresponding side seam 20, 21, as measured in the transverse direction x perpendicular to the longitudinally extending centre line Lc. As disclosed herein, the distance between each medial point Pif1, Pif2 on each front leg edge section 11f, 12f and the longitudinal centerline Lc may be 30 to 50% of the total distance between the longitudinal centerline Lc and the corresponding side seam 20, 21, measured in a transverse direction x perpendicular to the longitudinal centerline Lc.

[0132] The distances between the inner points Pif1, Pif2 on the front leg edge sections 11f, 12f and the respective side seams 20, 21 are measured along the leg edge sections 11f, 12f. The outer points Pof1, Pof2 are the end points of the front leg edge sections 11f, 12f, which are located at no distance from the side seams 20, 21.

[0133] The distances between the medial and lateral points Pif1, Pif2, Pof1, Pof2 on the front leg edge sections 11f, 12f and the front waist edge 31 are measured in the longitudinal direction y from the respective points Pif1, Pif2, Pof1, Pof2 on the front leg edge sections 11f, 12f perpendicular to the front waist edge 31, as shown by the arrows in Figure 1B. In embodiments having a non-linear waist edge 31, such as the embodiment shown in Figures 1A and 1B, the distances are measured in the longitudinal direction y from the respective points Pif1, Pif2, Pof1, Pof2 on the front leg edge sections 11f, 12f to a line extending parallel to and along the front waist edge 31.

[0134] As stated herein, the distance between the inner points Pif1, Pif2 of the front leg edge sections 11f, 12f and the front waist edge 31 is the smallest distance between the front leg edge section corresponding to the highest point on the front leg edge section and the front waist edge 31. Each front leg edge section 11f, 12f of the disposable pant-type article disclosed herein has only a single such highest point Pif1, Pif2, the distance between the front leg edge section 11f, 12f and the front waist edge 31 being the smallest distance between the front leg edge section 11f, 12f and the front waist edge 31.

[0135] As described herein, the distance between the outer points Pof1, Pof2 of the front leg edge sections 11f, 12f and the front waist edge 31 within the portion of the front leg edge defined between the inner points Pif1, Pif2 of the front leg edge sections 11f, 12f and the side seams 20, 21 is the greatest distance between the front leg edge sections 11f, 12f and the front waist edge 31 that corresponds to the lowest point on the front leg edge sections 11f, 12f within this portion of the front leg edge sections 11f, 12f. Each front leg edge section 11f, 12f of the disposable pant-type article disclosed in this specification has only a single such lowest point Pof1, Pof2 where the distance between the front leg edge section 11f, 12f and the front waist edge 31 in the portion of the front leg edge section 11f, 12f defined between the inner points Pif1, Pif2 of the front leg edge section 11f, 12f and the side seams 20, 21 is the maximum distance between the front leg edge section 11f, 12f and the front waist edge 31.

[0136] Referring to FIG. 1C showing a detailed view of the first leg edge 11 of the pant-type diaper 1A, the rear leg edge section 11r has a convexly curved buttock portion with a maximum curvature located at an inner point Pir1 on the rear leg edge section 11r.

[0137] The rear leg edge section 11r further has a first transition point Por1 located closer to the first side seam 20 than the inner point Pir1 on the first rear leg edge section 11r. At the first transition point Por1, the convexly curved hip portion of the rear leg edge section changes into a concavely curved hip portion of the rear leg edge section. The first transition point Por1 between the convex hip portion and the concave hip portion is shown in FIG. 1C as being located at a distance from the first side seam 20 that may be 30 millimeters to 80 millimeters from the side seam 20. A corresponding second transition point Por2 is on the second rear leg edge section 12r as shown in FIG. 1A.

[0138] The distances between the medial points Pir1, Pir2 on the rear leg edge sections 11r, 12r and the respective side seams 20, 21, and the distances between the transition points Por1, Por2 and the respective side seams 20, 21 are measured along the leg edge sections 11r, 12r.

[0139] Each crotch leg edge section 11c, 12c has a midpoint Pci1, Pci2 located between the front crotch edge 34 and the rear crotch edge 44, which midpoint Pci1, Pci2 is closer to the longitudinal centerline Lc than the front end points Pcf1, Pcf2 of the crotch leg edge sections 11c, 12c where the leg edges 11, 12 intersect with the front crotch edge 34. The midpoints on the crotch leg edge sections 11c, 12c are also closer to the longitudinal centerline Lc than the rear end points Pcr1, Pcr2 of the crotch leg edge sections 11c, 12c where the leg edges 11, 12 intersect with the rear crotch edge 44. The distance between the front end points Pcf1, Pcf2 of the crotch leg edge sections 11c, 12c and the front waist edge 31 may be greater than the distance between the outer points Pof1, Pof2 of the front leg edge sections 11f, 12f and the front waist edge 31, as shown in the figure, such that the front end points Pcf1, Pcf2 of the crotch leg edge sections 11c, 12c are positioned lower than the outer points Pof1, Pof2 of the front leg edge sections 11f, 12f.

[0140] The distances between points Pci1, Pci2, Pcf1, Pcf2, Pcr1, Pcr2 of the crotch leg edge sections 11c, 12c and the longitudinal centreline Lc are measured in the transverse direction x from points Pci1, Pci2, Pcf1, Pcf2, Pcr1, Pcr2 of the crotch leg edge sections 11c, 12c, respectively, to the longitudinal centreline Lc, as indicated by the arrows in FIG. 1B.

[0141] The rear leg edge section 12r of the second leg edge 12 of the pant-type article 1 of FIG. 1A has a shape corresponding to the rear leg edge section 11r of the first leg edge 11.

[0142] A first crotch elastic member 61 is arranged extending in the longitudinal direction y along the first leg edge 11 between the front panel crotch edge 34 and the back panel crotch edge 44, and a second crotch elastic member 62 is arranged extending in the longitudinal direction y along the second leg edge 12 between the front panel crotch edge 34 and the back panel crotch edge 44. The crotch elastic members 61, 62 are constituted by strips of elastic film which are applied to the pant-type article in a stretched state to form functional leg elastics in the crotch region of the pant-type article 1.

[0143] The crotch leg edge sections 11c, 12c of the first and second leg edges 11, 12 are concavely curved and extend partially into the corresponding crotch elastic members 61, 62.

[0144] The crotch leg edge sections 11c, 12c are cut to be slightly concave in curvature so that the crotch elastic members 61, 62 also have a somewhat modified band shape with concave cut edges along portions of the crotch leg edge sections 11c, 12c, as can be seen in Figure 6. The cuts in the crotch elastic members 61, 62 do not need to be made with a continuous curvature and could have any useful shape.

[0145] It may be preferred that all sections 11f, 12f, 11c, 12c, 11r, 12r of the first leg edge 11 and the second leg edge 12 are cut in a coherent elastic web material, such as an elastic film, elastic nonwoven, or elastic foam material, with the main direction of cut being the direction of stretchability of the elastic material, i.e. the front and rear leg edge sections 11f, 12f, 11r, 12r are cut mainly in the transverse direction x and the crotch leg edge sections 11c, 12c are cut mainly in the longitudinal direction y.

[0146] The crotch elastic members 61, 62 each have a front end portion 61', 62' at the front panel crotch edge 34, a rear end portion 61", 62" at the back panel crotch edge 44, and an intermediate portion 61"', 62"' between the front end portion 61', 62' and the rear end portion 61", 62". The front end portion 61', 62' of each of the first and second crotch elastic members 61, 62 is overlapping and attached to the front body panel 3, and the rear end portion 61", 62" of each of the first and second crotch elastic members 61, 62 is overlapping and attached to the back body panel 4. The end portions 61', 62', 61", 62" of the crotch elastic members 61, 62 may be non-tensioned portions of the crotch elastic members 61, 61. The untensioned end portions 61', 62', 61", 62" of the crotch elastic members 61, 62 may each have a length that is 5% to 8% of the overall length of the crotch elastic member, including the length of the end portions 61', 62', 61", 62" and the pre-tensioned intermediate portions 61"', 62"' disposed between the end portions 61', 62', 61", 62".

[0147] The crotch leg edge sections 11c, 12c are cut into the crotch elastic members 61, 62 with a concave curvature such that the front and rear end portions 61', 62' and 61", 62" of the crotch elastic members 61, 62 have widths of the front and rear end portions 61', 62', 61", 62", of the crotch elastic members 61, 62 that are greater than the widths of the intermediate portions 61"', 62"' of the crotch elastic members.

[0148] In the pant-type article 1 shown in the figures, the width wf of the front end portions 61', 62' is equal to the width wr of the rear end portions 61", 62". A suitable ratio between the widths wf, wr of the end portions and the minimum width wc of the intermediate portion may be from 1:0.5 to 1:0.9.

[0149] The crotch region 6 is formed by a crotch panel 6' which is attached to the front body panel 3 along the front panel crotch edge 34 by a first side edge 65 of the crotch panel 6' and to the back body panel 4 along the back panel crotch edge 44 by a second side edge 66 of the crotch panel 6'. The attachments between the crotch panel and the front and back panels are made as overlap seams.

[0150] Alternatively, or in addition to applying a crotch panel in the crotch region as shown in the figures, the crotch region may include a portion of a web material, such as an inner or outer cover web material of a pant-type article, that extends continuously longitudinally from the front panel waist edge to the back panel waist edge and fills the gap between the front panel crotch edge and the back panel crotch edge. The portion of the continuous cover web material that is applied to the crotch region constitutes the crotch web material.

[0151] A first reinforcing elastic feature 71 is arranged on the elastically stretchable back body panel 4 along the rear leg edge section 11r of the first leg edge 11, and a second reinforcing elastic feature is arranged on the elastically stretchable back body panel 4 along the rear leg edge section 12r of the second leg edge 12. The first reinforcing elastic feature 71 extends along a first portion 11r' of the rear leg edge section 11r of the first leg edge 11 in a direction away from the longitudinal centerline Lc of the pant-type article 1 towards the first side seam 20, has an end point Pe1 on the rear leg edge section 11r of the first leg edge 11, and is absent from the first reinforcing elastic feature 71 in a second portion 11r'' of the rear leg edge section 11r of the first leg edge 11.

[0152] The second portion 11r″ of the rear leg edge section 11r of the first rear leg edge 11 that is free of reinforcing elastic has a length lf1 as measured along the first leg edge 11 from an endpoint Pe of the first reinforcing elastic feature 71 to the first side seam 20 that is 25% to 75% of the total length lt1 of the rear leg edge section 11r of the first leg edge 1.

[0153] The second reinforcing elastic feature 72 extends along a first portion 12r' of the rear leg edge section 12r of the second leg edge 12 in a direction away from the longitudinal centerline Lc of the pant-type article 1 toward the second side seam 21 and has an end point Pe2 on the rear leg edge section 12r of the second leg edge 12, the second portion 12r'' of the rear leg edge section 12r of the second leg edge 12 is free of the second reinforcing elastic feature 72, and the second portion 12r'' of the rear leg edge section 12r of the second rear leg edge 12 has a length lf2 as measured along the second leg edge 12 from the end point Pe2 of the second reinforcing elastic feature 72 to the second side seam 21 that is 25% to 75% of the total length lt2 of the rear leg edge section 12r of the second leg edge 12.

[0154] The first and second reinforcing elastic features 71, 72 are attached to the rear end portions 61", 62" of the crotch elastic members 61, 62, which are preferably non-tensioned portions of the crotch elastic members 61, 62 and act as non-stretchable inner fastening regions for the reinforcing elastic features 71, 72.

[0155] Referring to Figures 1 and 3, the pant-type article 1 further comprises an absorbent assembly 80 including an absorbent core 81, a liquid-permeable topsheet 82, and a liquid-impermeable backsheet 83, wherein the absorbent core 81 is sealed between the liquid-permeable topsheet 82 and the liquid-impermeable backsheet 83.

[0156] The absorbent core 81 shown in the figures has a rectangular design, however, it should be understood that the present disclosure is not limited to rectangular cores and that the absorbent core can have any useful shape, such as an hourglass shape, a T-shape, etc., as known in the art.

[0157] The absorbent assembly 80 is applied to the inner surface of the pant-type article 1, which is the surface intended to face the wearer when the pant-type article 1 is being worn. The absorbent assembly 80 covers the pre-tensioned crotch elastic members 61, 62. The inner surface of the absorbent assembly is formed by a liquid permeable topsheet 82 and may optionally include barrier cuffs (not shown) extending along the side edges of the absorbent assembly 80.

[0158] The portion of each leg edge 11 , 12 that penetrates into the crotch region 6 is formed by a cut through the material of the crotch panel 6 ′, through the corresponding crotch elastic members 61 , 62 , and through the peripheral edge portions 84 , 85 of the absorbent assembly 80 .

[0159] The peripheral edge portions 84 , 85 of the absorbent assembly 80 are formed by edge portions of the liquid permeable topsheet 82 and the liquid impermeable backsheet 83 which extend outwardly in the transverse direction x from peripheral side edges 86 , 87 of the absorbent core 81 of the absorbent assembly 80 .

[0160] As disclosed herein, the topsheet 82 and the backsheet 83 may both extend beyond the perimeter of the absorbent core 81 and be joined to one another at an edge seal that extends along the perimeter of the absorbent core outwardly from the peripheral edge of the absorbent core. In the illustrated embodiment, the topsheet 82 and the backsheet 83 are joined with edge seals only at peripheral edge portions 84, 85 that extend along peripheral side edges 86, 87 of the absorbent core 81. However, such edge seals may be arranged along the entire perimeter of the absorbent core 81, i.e., along the transverse end edges of the absorbent core 81. Additionally, the peripheral edge portions 84, 85 of the absorbent assembly 80 may be formed by only one of the topsheet and the backsheet as described herein.

[0161] The absorbent assembly 80 covers the crotch elastic members 61, 62 on the inner surface of the pant-type article 1 by having peripheral edge portions 84, 85 of the absorbent assembly 80 formed by the topsheet 82 and the backsheet 83 rest on portions of the respective crotch elastic members 61, 62 adjacent to the corresponding crotch leg edge sections 11c, 12c.

[0162] As described herein, the crotch leg edge sections 11c, 12c are formed by cuts having a concave curvature made through the overlapping crotch web material, crotch elastic members 61, 62, and the topsheet 82 and backsheet 83 at peripheral edge portions 84, 85 along each crotch leg edge section 11c, 12c. As shown in Figures 1 and 2, the cuts are made such that a small portion of each of the crotch elastic members 61, 62 is cut out at an intermediate portion 61"', 62"' of the crotch elastic members 61, 62 to provide the intermediate portions 61"', 62"' of the crotch elastic members 61, 62 with concavely curved edges that are coextensive with the simultaneously formed cut edges of the crotch web material, the topsheet 82, and the backsheet 35. In the illustrated embodiment, the crotch web material is the web material that forms the crotch panel 6'. However, in other embodiments, the crotch web material may be formed by a portion of the outer cover web, as described herein.

[0163] The absorbent core 81 as disclosed herein may comprise any conventional material suitable for absorbing discharged bodily waste, such as cellulosic fluff pulp, tissue layers, highly absorbent polymers (superabsorbents), absorbent foam materials including hydrogel foam materials, absorbent nonwoven materials, or the like. The absorbent core may include non-absorbent components, such as reinforcing elements, shaping elements, binders, etc. Various types of liquid receiving and distribution elements may also be included in the core.

[0164] The liquid pervious topsheet 82 may include or consist of a nonwoven material. Other suitable topsheet materials include tow fibers, porous foams, apertured plastic films, and laminates, as well as combinations of such materials. The best topsheet materials are soft, non-irritating to the skin, readily permeable to bodily fluids, and have low rewetability.

[0165] The liquid impermeable backsheet 83 may consist of a thin plastic film, such as a polyethylene or polypropylene film, a nonwoven material coated with a liquid impermeable material, a hydrophobic nonwoven material that resists liquid penetration, or a laminate of a plastic film and a nonwoven. The backsheet material may be breathable to allow vapors to escape from the absorbent while preventing liquids from passing through the backsheet material.

[0166] The topsheet and backsheet may be connected to one another, for example, by adhesive bonding, gluing, or thermal or ultrasonic welding. The topsheet and / or backsheet may further be attached to the absorbent core by any method known in the art, such as adhesives, thermal bonding, welding, needling, etc.

[0167] A pant-type article as disclosed herein may be of the type shown in the figures and have a two-piece chassis with a crotch panel connected to the front panel along the front panel crotch edge and to the back panel along the back panel crotch edge. Alternatively, the pant-type article may comprise a one-piece chassis with an inelastic outer or inner cover web extending the entire distance between the front panel waist edge and the back panel waist edge, the cover web constituting an inelastic layer of each of the front and back panels and constituting a crotch web material in the crotch region of the pant-type article.

[0168] The elastically stretchable front body panel and the elastically stretchable back body panel may comprise or consist of a stretch bonded laminate elastic web material.

[0169] Suitable stretch-bonded laminates may include layers or webs of nonwoven materials, such as spunbond, airlaid, wetlaid, carded, electrospun or meltblown nonwovens, etc. The nonwoven materials may be bonded by any suitable technique, such as needling, hydroentangling, ultrasonic welding, or thermal bonding.

[0170] The fibers of the nonwoven material used herein may be man-made, natural, or a mixture of man-made and natural fibers. Man-made fibers include monocomponent, bicomponent, and multicomponent fibers of polymers such as polyolefins, polyesters, polyacrylates, and regenerated fibers such as viscose and modal fibers. Natural fibers are, for example, cellulosic fibers such as pulp fibers, cotton fibers, flax, and hemp.

[0171] The pant-type article 1 disclosed herein may have an elastic waist feature 90 arranged along the waist opening 10. The elastic waist feature 90 may be formed by one or more elastic elements extending parallel to the front panel waist edge 31 and the back panel waist edge 41. The one or more elastic waist elements may be incorporated into the front body panel 3 and the back body panel 4 or may be applied as a separate waistband attached to the front panel waist edge 31 and the back panel waist edge 41. The pant-type article 1 shown has an elastic waist feature 90 extending around the entire circumference of the waist opening 10. However, the elastic waist feature may be arranged only along a portion of the waist opening, such as only along the back panel waist edge, only along the front panel waist edge, or only along a portion of one or both of the front and back panel waist edges having a length less than the entire length of the corresponding panel waist edge.

[0172] As disclosed herein, the elastic material in the elastic elements arranged along the leg openings 13, 14 and waist opening 10 may be any suitable elastic material such as natural or synthetic rubber, thermoplastic polyurethanes also referred to as spandex (polyurethane-polyurea copolymers) or styrene block copolymers or thermoplastic elastomers such as elastane. The elastic elements may be of the elastane type available under the trade name "LYCRA", although any suitable rubber yarn may be used. The yarn may have a linear mass density, dtex, of about 80 to 1200 dtex.

[0173] The nonwoven web material used in the pant-type article as disclosed herein can include thermoplastic materials.The nonwoven web material is typically incorporated into the joints and seams of the pant-type article, and it is desirable that the nonwoven web can be welded by heat or ultrasonic welding process.Examples of polymers suitable for use in the fibrous nonwoven web as disclosed herein are polyethylene polypropylene, and other polyolefin homopolymers and copolymers, and polyester.Weldable nonwoven webs have a high content of thermoplastic components, preferably at least 50% thermoplastic fibers, more preferably at least 80% thermoplastic fibers.

[0174] The elastic material used in the front and back body panels is preferably a breathable elastic film, such as an apertured elastic film or a microporous elastic film. The elastic film has a density of 20 to 80 g / m 2 , preferably 20 to 60 g / m 2The elastic web may be of any suitable elastic polymer, natural or synthetic. Examples of materials useful for the elastic web are low crystalline polyethylene, metallocene catalyzed low crystalline polyethylene, ethylene-vinyl acetate copolymer (EVA), polyurethane, polyisoprene, butadiene-styrene copolymer, styrene block copolymers such as styrene / isoprene / styrene (SIS), styrene / butadiene / styrene (SBS), or styrene / ethylene-butadiene / styrene block copolymers. Blends of these polymers may also be used, as well as other modified elastomeric or non-elastomeric materials. The total basis weight of the stretch-bonded elastic laminate web is preferably from 40 to 100 g / m 2 , more preferably 90 g / m 2 The following is the result.

[0175] The contouring of the rear leg edge sections as described in connection with the figures, as well as the provision of crotch elastic members, reinforced rear elastic features, and waist elastics, are optional for pant-type absorbent articles as disclosed herein.

[0176] A continuous method for producing the disposable pant-type articles disclosed herein will now be described with reference to FIGS.

[0177] 6 shows a continuous elastic front panel web 101 being advanced in the machine direction MD. The front panel web 101 is advanced in the machine direction MD while being stretched in the machine direction MD such that the front panel web 101 is tensioned in the machine direction MD.

[0178] The front panel web 101 has a front waist edge 102 and an opposing front crotch edge 103 .

[0179] 6 further illustrates a continuous elastic back panel web 108 being advanced in a machine direction MD parallel to the elastic front panel web 101. The back panel web 108 is advanced in the machine direction MD while being stretched in the machine direction MD such that the back panel web 108 is tensioned in the machine direction MD.

[0180] The back panel web 108 has a back waist edge 109 and an opposing back crotch edge 110. The back panel web 108 is spaced from the front panel web 101 in a cross-machine direction CD perpendicular to the machine direction MD such that there is a gap 115 in the cross-machine direction CD between the crotch edge 103 of the front panel web 101 and the crotch edge 110 of the back panel web 108.

[0181] The front waist elastic members 104 are arranged along the front waist edge 102 and the back waist elastic members 111 are arranged along the back waist edge 109. The waist elastic members 104, 111 have already been attached to the front panel web 101 and the back panel web 108 before the production step shown in FIG. 6, for example by methods such as those disclosed in U.S. Pat. No. 5,399,623 or U.S. Pat. No. 5,499,636. The methods in U.S. Pat. No. 5,499,623 and U.S. Pat. No. 5,499,623 start with a base web to which a continuous waistband component is attached, after which the base web is cut into two parts along a cut extending in the machine direction, cutting both the base web and the waistband component along the cut. The bisecting of the base web forms a first panel web to which a first portion of the waistband component is attached, and a second panel web to which a second portion of the waistband component is attached. The two web parts are then offset in the cross machine direction such that the cut edges of the web parts to which these portions of the waistband component are attached are arranged facing away from each other. When the web portions are further processed in the manner disclosed herein, the cut edge of the first panel web forms the front waist edge 102 of the front panel web 101 and the cut edge of the second panel web forms the back waist edge 109 of the back panel web 108, as shown in Figure 6. The divided waistband components form front waist elastic members 104 and back waist elastic members 111 on the respective front panel webs 101 and back panel webs 108.

[0182] The methods of US Pat. Nos. 5,993,336 and 5,993,354 result in a front waist elastic member 104 coinciding with a front waist edge 102 of a front panel web 101 and a rear waist elastic member 111 coinciding with a rear waist edge 109 of a back panel web 108. In the example shown in Figs. 6-13, the front waist edge 102 and the rear waist edge 109 have a coincident sinusoidal configuration. It should be understood that the waist edges need not have an undulating configuration as shown in the figures, and other configurations such as straight edges, zigzag edges, etc. may be used. Furthermore, it should be understood that other methods for attaching the waistband members to the front and rear panel webs may also be used. The front waistband member may alternatively be attached with an edge seam along the front waist edge of the front panel web, and the rear waistband member may be attached with an edge seam along the rear waist edge of the back panel web. In such an embodiment, the waistband members extend in a cross machine direction CD outward from the waist edges of the corresponding panel webs. Another contemplated arrangement of the waistband members is to be attached slightly inwardly from the waist edge of the panel webs. In such an embodiment, each waistband member completely overlaps a corresponding panel web with a small edge portion of the panel web extending outwardly in the cross machine direction CD from the waist edge of the panel web a distance on the order of 2 to 15 mm.

[0183] Waistband members attached to the front and back panel webs by methods other than those disclosed in U.S. Patent Nos. 5,993,333 and 5,993,523 may be attached during any suitable stage of the methods as disclosed herein, or may be attached prior to the stage shown in Figure 6. It should also be understood that waist elastic members as disclosed herein are optional to the methods and disposable pant-type articles as disclosed herein.

[0184] The waist elastic member may comprise or consist of any suitable elastic or stretchable material as known in the art, including elastic yarns, elastic films, elastic nonwovens, and elastic foams. Additionally, the elastic member may be applied in the form of a plurality of elongated elastic elements, as a single band of elastic or stretchable material, e.g., an elastic laminate. In all cases, the elastic member is a component of the chassis web or disposable pant-type article as disclosed herein, and is separate and distinct from other elastic properties of the chassis web of the pant-type article, such as leg elastics or body elastics.

[0185] Then, an inelastic continuous crotch panel web 118 having a first side edge 119 and an opposing second side edge 120 is advanced in the machine direction MD such that the first side edge 119 of the crotch panel web 118 is attached along the crotch edge 103 of the tensioned front panel web 101 with a first overlap seam 121 and the second side edge 120 of the crotch panel web 118 is attached along the crotch edge 110 of the tensioned back panel web 108 with a second overlap seam 122, as shown in FIG. The crotch panel web 118 fills the gap 115 between the front panel web 101 and the back panel web 108 and forms a coherent chassis web 130 of interconnected precursor articles 131a, 131b, 131c separated by parting lines Ld extending in the cross machine direction CD, each precursor article 131a, 131b, 131c having a pitch length Lp in the machine direction MD between the parting lines Ld. The pitch lengths Lp of the precursor articles 131a, 131b, 131c remain the same until the final step of the method disclosed herein, when the individual pant-type articles are separated from the chassis web 130.

[0186] Referring to FIG. 8, a pair of crotch elastic members 141, 142 consisting of a first belt-like crotch elastic member 141 and a second belt-like crotch elastic member 142 is provided.

[0187] Each crotch elastic member 141 , 142 is elongated in a crotch elastic member longitudinal direction Le, such that the longitudinal direction Le of the crotch elastic members 141 , 142 is aligned with the cross machine direction CD of the moving chassis web 130 .

[0188] Each stretched crotch elastic member 141, 142 is then attached to the chassis web 130 aligned in the cross-machine direction CD while the crotch elastic members 141, 142 remain stretched. The pairs of crotch elastic members are attached to the chassis web 130 with the first crotch elastic member 141 spaced apart in the machine direction from the second crotch elastic member 151 by a crotch spacing SC, and are symmetrically positioned on either side of a precursor article centerline Lc extending in the cross-machine direction CD. The pairs of crotch elastic members of the precursor articles 131a, 131b, 131c are spaced apart in the machine direction by an article spacing corresponding to the pitch lengths of the precursor articles 131a, 131b, 131c.

[0189] In the illustrated moving chassis web 130, first end portions 143, 144 of each of the first and second crotch elastic members 141, 142 are overlapped and attached to the tensioned front panel web 101, and second end portions 145, 146 of each of the first and second crotch elastic members 141, 142 are overlapped and attached to the tensioned back panel web 108.

[0190] When stretching the stretched crotch elastic members 141, 142 against the chassis web, the first and second end portions 143, 144, 145, 146 of the crotch elastic members 141, 142 may be held by movable clamps in a stretching device (not shown). The clamped end portions 143, 144, 145, 146 are not subjected to stretching and are applied and attached to the chassis web in an untensioned state.

[0191] The stretched crotch elastic members 141, 142 may have a width w as measured in the machine direction MD ranging from 15 mm to 50 mm and a length l as measured in the cross machine direction ranging from 150 mm to 350 mm.

[0192] In a preferred embodiment of the methods disclosed herein, the elastic member comprises or consists of an elastic film.

[0193] Referring to FIG. 9, a continuous reinforcing leg elastic member 150 is stretched in the machine direction MD and attached in a curved configuration along the crotch edge 110 of the tensioned back panel web 108 in an elongated condition.

[0194] The reinforced leg elastics 150 are attached to one or more attachment areas (not shown) formed on the tensioned rear panel web 108 by applying adhesive continuously or discontinuously to selected portions of the tensioned rear panel web 108 prior to application of the reinforced leg elastics 150. After attachment of the reinforced leg elastics 150, the leg elastics 150 and exposed adhesive may be covered with a nonwoven cover web 151, as shown in FIG.

[0195] The reinforcing leg elastics 150 span over and are attached to the preferably non-tensioned second end portions 145,146 of the first and second crotch elastics 141,142.

[0196] 10, the method may further include mounting an absorbent assembly 160 including an absorbent core 161 against the moving chassis web 130. The absorbent assembly 161 further comprises a liquid impermeable backsheet 162 and a liquid permeable topsheet 163 that together surround the absorbent core 161.

[0197] The absorbent assembly 160 is applied over the precursor article centerline Lc and stretched to cover the attached crotch elastics 141, 142.

[0198] The absorbent core 161 is disposed between the topsheet 163 and the backsheet 162 and absorbs liquids, such as urine or other body fluids, that pass through the topsheet 163 .

[0199] The topsheet 163, backsheet 162, and absorbent core 161 may be made of any materials suitable for their purposes.

[0200] The absorbent core 161 may be a single layer or a multi-layer structure. The absorbent core 161 may include a suitable amount of superabsorbent material. Such superabsorbent materials are well known in the field of absorbent articles and are composed of water-swellable and water-insoluble materials that can absorb large amounts of liquid upon formation of a hydrogel. The absorbent core 161 may include superabsorbent material in the form of fibers or particles of absorbent polymeric material. For example, the superabsorbent material may be a surface cross-linked partially neutralized polyacrylate. The superabsorbent material, for example, superabsorbent fibers or particles, may be mixed with other absorbent materials such as cellulosic fluff pulp or one or more liquid acquisition materials and / or arranged in pockets or layers within the absorbent core 161.

[0201] The absorbent core 161 may further include components to improve the properties of the absorbent core 161, such as integrity and strength. For example, the absorbent core 161 may include one or more binders, such as binder fibers. Resilient fibers, chemically stiffened fibers, and the like may be present in the absorbent core 161 to resist wet collapse of the cellulosic fibers. Such fibers may also be useful to maintain a liquid transport capillary network in the absorbent component so that absorbent fluid is distributed throughout the absorbent component and absorbed by the superabsorbent material even in portions of the absorbent component outside the initial wetness region of the absorbent article.

[0202] The topsheet 163 is the layer that faces the wearer and may include or consist of a fluid-permeable nonwoven, a perforated polymeric film, a mesh or a foam. The topsheet may be made from a thermoplastic material, such as a thermoplastic synthetic fiber, film, or netting. The topsheet 163 may consist of a single layer or have a multi-layer, e.g., laminate construction including two or more layers. The layers may be made of the same material or some or all of the layers may be made of different materials.

[0203] Additionally, the backsheet 162 may be constructed of a liquid impermeable layer such as a polymeric film, e.g., a polyethylene or polypropylene film. The backsheet 162 may be breathable. Materials that may be used for the backsheet 162 include thin flexible liquid impermeable plastic films, or fluid impermeable nonwoven materials, fluid impermeable foams, and fluid impermeable laminates. The backsheet 162 may be formed by a single layer, or may be a multi-layer structure in which at least one layer is fluid impermeable.

[0204] After the absorbent assembly 160 is optionally attached to the chassis web 130, leg cuts 170 are formed in the chassis web 130 between the precursor articles 131a, 131b, 131c, with each leg cut 170 having a closed loop configuration as shown between precursor articles 131b and 131c in Figure 6. The leg cuts form a first leg edge 171 of the preceding precursor article 131c and a second leg edge of the succeeding precursor article 131b.

[0205] As shown in FIG. 11, the first leg edge 171 of each precursor article 131a, 131b, 131c in the chassis web is - a front leg edge section 171f penetrating into the tensioned front panel web 101; - a crotch leg edge section 171c penetrating into the crotch panel web 118 between the front panel crotch edge 103 and the back panel crotch edge 110; and - rear leg edge section 171r penetrating into tensioned rear panel web 108 It consists of:

[0206] The second leg edge 172 of each precursor article 131a, 131b, 131c is - a front leg edge section 172f penetrating into the tensioned front panel web 101; - a crotch leg edge section 172c that penetrates into the crotch panel web 118 between the front panel crotch edge 103 and the back panel crotch edge 110; and - rear leg edge section 172r penetrating into tensioned rear panel web 108 It consists of:

[0207] As shown in Figure 11, the closed-loop leg cuts 170 form cut-out portions 173 having an approximately heart shape inside each leg cut 170. The shape of the leg cuts 170 and the contours of the cut-out portions will be described in more detail with reference to the pant-type article 1 shown in Figures 1A, 1B, 1C and 3-5. The contours of the cut-out portions 173 correspond to the contours of the combined leg edges 11, 12 shown in Figure 2.

[0208] After forming the leg cuts 170, the cut-out portions 173 are removed from the chassis web and are not a further part of the process as disclosed herein.

[0209] The length of each of the crotch leg edge sections 171c, 172c is measured along the corresponding leg edge 171, 172 from a forward point Pf1, Pf2 on the leg edge 171, 172 where the leg edge 171, 172 intersects with the front panel crotch edge 103 to a rearward point Pr1, Pr2 on the leg edge 171, 172 where the leg edge 171, 172 intersects with the back panel crotch edge 110.

[0210] The length of the front leg edge section 171f of the first leg edge 171 is measured along the first leg edge 171 from a forward point Pf1 on the first leg edge 171 where the first leg edge 171 intersects the front panel crotch edge 103 to the parting line Ld behind the first leg edge 171 in the machine direction MD, i.e., to the parting line Ld closest to the forward point Pf1.

[0211] The length of the rear leg edge section 171r of the first leg edge 171 is measured along the first leg edge 171 from a rear point Pr1 on the first leg edge 171 where the first leg edge 171 intersects the back panel crotch edge 108 to the parting line Ld behind the first leg edge 171 in the machine direction MD, i.e., to the parting line Ld closest to the rear point Pr1.

[0212] The length of the front leg edge section 172f of the second leg edge 172 is measured along the second leg edge 172 from a forward point Pf2 on the second leg edge where the second leg edge 172 intersects the front panel crotch edge 103 to the parting line Ld in front of the second leg edge 171 in the machine direction MD, i.e., to the parting line Ld closest to the forward point Pf2.

[0213] The length of the rear leg edge section 172r of the second leg edge 172 is measured along the second leg edge 172 from a rear point Pr2 on the second leg edge 172 where the second leg edge 172 intersects the back panel crotch edge 108 to the parting line Ld in front of the second leg edge 172 in the machine direction MD, i.e., to the parting line Ld closest to the rear point Pr2.

[0214] 12, each front leg edge section 171f, 172f has an inner point Pif1, Pif2 that is located proximal to the crotch leg edge section 171c, 172c of the leg edge 171, 172, which is closer to the front waist edge 102 than an outer point Pof1, Pof2 on the front leg edge section 171f, 172f that is distal from the crotch leg edge section 171c, 172c. The outer points Pof1, Pof2 are located at corresponding parting lines Ld between the precursor articles 131a, 131b, 131c.

[0215] With further reference to FIG. 12, each crotch leg edge section 171c, 172c has an intermediate point Pci1, Pci2 that is located between the front crotch edge 103 and the rear crotch edge 110, and the distance between the first leg edge 171 and the second leg edge 172 is less than a forward point Pf1, Pf2 of the crotch leg edge section 171c, 172c where the leg edges 171, 172 intersect with the front crotch edge 103.

[0216] After forming the leg cuts, the absorbent assembly 160 is centered in the chassis web between the first leg edge 171 and the second leg edge of each precursor article 131a, 131b, 131c.

[0217] As shown in Figure 11, a portion of each crotch leg edge section 171c, 172c is formed by cutting through the crotch panel web 118, through the corresponding crotch elastic member 141, 142, and through the peripheral edge portions 164, 165 of the absorbent assembly 160. The peripheral edge portions 164, 165 of the absorbent assembly 160 are formed by portions of the liquid impervious backsheet 162 and liquid permeable topsheet 163 of the absorbent assembly 160 that extend outwardly in the machine direction MD from corresponding peripheral edges 166, 167 of the absorbent core 161 of the absorbent assembly 160. In the illustrated absorbent assembly 160, both the topsheet 163 and the backsheet 162 extend beyond the peripheral edges 166, 167 of the absorbent core 161 and are joined to one another with edge seals.

[0218] As can be seen in FIG. 6, the crotch leg edge sections 171c, 172c are cut with a slight concave curvature so that the band-like crotch elastic members 141, 142, which initially have a generally rectangular shape, are also given a somewhat modified band-like shape having concave cut edges along at least a portion of the crotch leg edge sections 171c, 172c.

[0219] 11 and 12, when cutting the rear leg edge sections 171r, 172r of the first and second leg edges 171, 172, the excess portion 150s of the reinforcing elastic element 150 is simultaneously cut away along with the cut-out portion 173, leaving the remaining portion 150r of the reinforcing elastic element 150 attached along the rear leg edge sections 171r, 172r of each of the first and second leg edges 171, 172 between the rear points Pr1, Pr2 of each leg edge 171, 172 where the leg edges 171, 172 intersect with the rear panel crotch edge 110 and the cut point Pc on the leg edge where the reinforcing elastic element 150 is cut away. Thereby, the portion of each rear leg edge section 171r, 172r between the cut point Pc and the parting line Ld closest to the cut point Pc is free of reinforcing elastic. The portion of each rear leg edge section 171r, 172r that is free of the reinforcing elastic element 150 may have a length, as measured along the corresponding leg edge 171, 172 from the cut point Pc to the nearest dividing line Ld, that is 25% to 75% of the total length of the rear leg edge section 171r, 172r.

[0220] After forming the leg edges 171, 172 by cutting cut-out portions 173 from the chassis web 130 along cuts 170, the chassis web 130 is folded along fold lines Lv extending in the machine direction MD to align the waist edge 102 of the front panel web 101 with the waist edge 109 of the back panel web 108 as shown in FIG. 13.

[0221] A first side seam 181 and a second side seam 182 are formed in each precursor article 131a, 131b, 131c from the aligned waist edges 102, 109 of the front and back panel webs 101, 108 to the leg cut 170 along the parting line Ld between the precursor articles 131a, 131b, 131c.

[0222] The first side seam 181 of the preceding precursor article 131a and the second side seam 182 of the subsequent precursor article 131b may be formed as a single wide seal extending along the parting line Ld, as shown in Figure 13. When cutting the individual pant-type articles from the chassis web 130 of the precursor articles 131a, 131b, 131c by cutting the chassis web along the parting line Ld, the single wide seal shown in Figure 13 is simultaneously divided into the two side seams 181, 182 of the interconnected precursor articles 131a, 131b.

[0223] Alternatively, the side seams 181, 182 may be formed as separate seals placed on either side of the parting line Ld.

[0224] The side seams may be formed by any method suitable for the purpose, such as by heat welding, ultrasonic welding, or by using an adhesive. In the case of an adhesive side seal, the adhesive is typically applied before the chassis web is folded along the crease Lv. [Explanation of symbols]

[0225] Lc Longitudinal center line lf1 length lf2 length lt1 Total length lt2 total length Pcf1, Pcf2 pre-endpoint PCR1, PCR2 post-endpoint Pe endpoint Pe1 endpoint Pe2 Endpoint Pif1, Pif2 inner points Pof1, Pof2 outer points Pir1 inner point Por1, Por2 transition point wf, wr width 1. Pants-type items 3 Front body panel 4 Back Panel 6 Crotch area 6' Crotch Panel 10 Waist opening 11 First leg edge 11c, 12c Crotch leg edge section 11f, 12f nose landing gear edge section 11r, 12r Rear leg edge section 11r' First part 11r” Second Part 12 Second leg edge 12r' First part 12r” Second Part 13 First leg opening 14 Second leg opening 20 First side seam 21 Second Side Seam 31 Front panel waist edge 32, 33 Front panel side edge 34 Front panel crotch edge 41 Rear panel waist edge 42, 43 Rear panel side edge 44 Rear panel crotch edge 61 First crotch elastic member 61', 62' front end part 61”, 62” rear end part 61”', 62”' middle part 62 Second crotch elastic member 65 First Side Edge 66 Second Side Edge 71 First reinforcement elastic characteristic 80 Absorbable Assembly 81 Absorbent Core 82 Liquid-permeable top sheet 83 Liquid impermeable backsheet 84, 85 Surrounding edge parts 86, 87 Peripheral side edges 90 Elastic waist feature 101 Elastic front panel web 102 Front waist edge 103 Opposing front crotch edges 104 Front waist elastic member 108 Continuous elastic back panel web 109 Rear Waist Edge 110 Opposing rear crotch edges 111 Rear waist elastic member 115 Gap 118 Inelastic continuous crotch panel web 119 First Side Edge 120 Second Side Edge 121 First overlap seam 130 Chassis Web 131a, 131b, 131c Precursor articles 141, 142 Crotch elastic member 143, 144 First end portion 145, 146 second end 150 Continuous reinforcing leg elastic member 150r Remaining 150s surplus parts 151 Nonwoven cover web 160 Absorbable Assembly 161 Absorbent Core 162 Liquid impermeable back sheet 163 Liquid-permeable top sheet 164, 165 Surrounding edge part 166, 167 Peripheral edges 170 Leg Cut 171 First leg edge 171c crotch leg edge section 171f nose landing gear edge section 171r Rear leg edge section 172 Second leg edge 172c crotch leg edge section 172f nose landing gear edge section 172r Rear leg edge section 173 Cutout part 181 First Side Seam 182 Second Side Seam

Claims

1. A disposable pant-type article (1), said article (1) having a longitudinal direction (y) and a transverse direction (x), a longitudinal centerline (Lc) extending in said longitudinal direction (y), said article comprising: a front body panel (3) elastically stretchable in said transverse direction (x), said front body panel (3) having a front waist edge (31), a front panel crotch edge (34) opposite said front waist edge (31), and first and second longitudinal side edges (32, 33); a rear body panel (4) elastically stretchable in said transverse direction (x), said rear body panel (4) having a rear waist edge (41), a rear panel crotch edge (44) opposite said rear waist edge (41), and first and second longitudinal side edges (42, 43); a crotch region (6) located between the front panel crotch edge (34) and the back panel crotch edge (44), the crotch region (6) being adjacent to the front body panel (3) along the front panel crotch edge (34) and adjacent to the back body panel (4) along the back panel crotch edge (44); Equipped with - said first longitudinal side edge (32) of said front body panel (3) is joined to said first longitudinal side edge (42) of said back body panel (4) at a first side seam (20) and said second longitudinal side edge (33) of said front body panel (3) is joined to said second longitudinal side edge (43) of said back body panel (44) at a second side seam (21), said article (1) having a waist opening (10) and first and second leg openings (13, 14), said first leg opening (13) being bordered by a first leg edge (11) and said second leg opening (14) being bordered by a second leg edge (12), each of said first and second leg edges (11, 12) being constituted by a front leg edge section (11f, 12f), a crotch leg edge section (11c, 12c), and a rear leg edge section (11r, 12r); - said front body panel (3) comprises a front panel web which is elastically stretchable in said transverse direction (x), said front leg edge sections (11f, 12f) of each of said first and second leg edges (11, 12) being arranged within said elastically stretchable front panel web; - said rear body panel (4) comprises a rear panel web which is elastically stretchable in said transverse direction (x), said rear leg edge sections (11r, 12r) of each of said first and second leg edges (11, 12) being arranged within said elastically stretchable rear panel web; - said crotch region (6) comprises a crotch region web, said crotch leg edge sections (11c, 12c) of each of said first and second leg edges (11, 12) being arranged within said crotch region web from said front panel crotch edge (34) to said back panel crotch edge (44); Each nose landing gear edge section (11f, 12f) inner points (Pif1, Pif2) located on the front leg edge sections (11f, 12f) at a distance from the corresponding side seam (20, 21) that is greater than its distance from the longitudinally extending centerline (Lc); - outer points (Pof1, Pof2), said outer points (Pof1, Pof2) constituting end points of said front leg edge sections (11f, 12f) located at the corresponding side seams (20, 21); having a distance between the inner point (Pif1, Pif2) of the front leg edge section (11f, 12f) and the front waist edge (31) is the smallest distance between the front leg edge section (11f, 12f) and the front waist edge (31) and is smaller than a distance between the outer point (Pof1, Pof2) of the front leg edge section (11f, 12f) and the front waist edge (31), each of the front leg edge sections (11f, 12f) comprising a single inner point (Pif1, Pif2); a disposable pant-type article (1), wherein each crotch leg edge section (11c, 12c) has an intermediate point (Pci1, Pci2) located between said front panel crotch edge (34) and said back panel crotch edge (44), said intermediate points (Pci1, Pci2) being closer to said longitudinal centre line (Lc) than the front end points (Pcf1, Pcf2) of said crotch leg edge sections (11c, 12c) where said leg edges (11, 12) intersect with said front panel crotch edge (34).

2. 2. The disposable pant-type article (1) according to claim 1, wherein the distance between the outer point (Pof1, Pof2) of each front leg edge section (11f, 12f) and the front waist edge (31) constitutes a maximum distance between the front leg edge section (11f, 12f) and the front waist edge (31) in a portion of the front leg edge section (11f, 12f) defined between the inner point (Pif1, Pif2) of the front leg edge section (11f, 12f) and the side seam (20, 21).

3. 3. The disposable pant-type article (1) according to claim 1 or 2, wherein a distance between each inner point (Pif1, Pif2) on each front leg edge section (11f, 12f) and the longitudinally extending centre line (Lc) is 30 to 50% of a distance between the longitudinally extending centre line (Lc) and a corresponding one of the side seams (20, 21), said distances being measured in the transverse direction (x), perpendicular to the longitudinally extending centre line (Lc).

4. 4. A disposable pant-type article (1) according to claim 1, 2 or 3, wherein the inner points (Pif1, Pif2) on each front leg edge section (11f, 12f) are arranged at a position at least 5 millimeters and at most 40 millimeters closer to the front waist edge (31) than the outer points (Pof1, Pof2).

5. 5. The disposable pant-type article (1) according to claim 4, wherein the inner points (Pif1, Pif2) on each front leg edge section (11f, 12f) are arranged at a position at most 20 millimeters closer to the front waist edge (31) than the outer points (Pof1, Pof2).

6. The disposable pant-type article (1) according to any one of claims 1 to 5, wherein the intermediate points (Pci1, Pci2) on each crotch leg edge section (11c, 12c) are closer to the longitudinal centerline (Lc) than the rear end points (Pcr1, Pcr2) of the crotch leg edge sections (11c, 12c) where the leg edges (11, 12) intersect with the rear panel crotch edge (44).

7. 7. The disposable pant-type article (1) according to any one of claims 1 to 6, wherein the distance between the midpoint (Pci1, Pci2) on each crotch leg edge section (11c, 12c) and the longitudinal centerline (Lc) is 2 to 30 millimeters less than the distance between the front end points (Pcf1, Pcf2) and the longitudinal centerline (Lc).

8. 8. A disposable pant-type article (1) according to claim 6 or 7, wherein the distance between the midpoint (Pci1, Pci2) on each crotch leg edge section (11c, 12c) and the longitudinal centerline (Lc) is 5 to 60 millimeters less than the distance between a rear end point (Pcr1, Pcr2) and the longitudinal centerline (Lc).

9. A disposable pant-type article (1) according to any one of claims 1 to 8, wherein each rear leg edge section (11r, 12r) has a hip portion with a convex curvature.

10. The disposable pant-type article (1) according to claim 9, wherein each rear leg edge section (11r, 12r) has a transition point (Por1, Por2) at which the convex curvature of the buttocks portion of said rear leg edge section (11r, 12r) changes into a straight hip portion or a hip portion having a concave curvature, said transition points (Por1, Por2) being located at a distance of 30 millimeters to 100 millimeters from the corresponding side seam (20, 21).

11. The article (1) further comprises an absorbent assembly (80), the absorbent assembly (80) comprising an absorbent core (81), a liquid permeable topsheet (82), and a liquid impermeable backsheet (83), the absorbent core (81) being sealed between the liquid permeable topsheet (82) and the liquid impermeable backsheet (83); The disposable pant-type article (1) according to any one of claims 1 to 10, wherein the intermediate points (Pci1, Pci2) on each crotch leg edge section (11c, 12c) are arranged on a side edge of the absorbent assembly (80).

12. 12. The disposable pant-type article (1) according to any one of claims 1 to 11, wherein a pre-tensioned first crotch elastic member (61) is arranged to extend in the longitudinal direction (y) along the first leg edge (11) between the front panel crotch edge (34) and the rear panel crotch edge (44), and a pre-tensioned second crotch elastic member (62) is arranged to extend in the longitudinal direction (y) along the second leg edge (12) between the front panel crotch edge (34) and the rear panel crotch edge (44).

13. The disposable pant-type article (1) according to claim 12, wherein the intermediate points (Pci1, Pci2) on each crotch leg edge section (11c, 12c) are arranged on a side edge of the corresponding crotch elastic member (61, 62).

14. The disposable pant-type article (1) according to claim 13, wherein each crotch elastic member (61, 62) has a minimum width at said midpoint (Pci1, Pci2) on said crotch leg edge section (11c, 12c).

15. The disposable pant-type article (1) according to claim 12, 13 or 14, wherein a front end portion (61', 62') of each of the first crotch elastic member (61) and the second crotch elastic member (62) is attached to the front body panel (3) in an overlapping manner, and / or a rear end portion (61", 62") of each of the first crotch elastic member (61) and the second crotch elastic member (62) is attached to the rear body panel (4) in an overlapping manner.

16. 16. The disposable pant-type article (1) according to any one of claims 1 to 15, wherein a first reinforcing elastic feature (71) is arranged on the elastically stretchable rear panel (4) along at least a first portion (11r') of the rear leg edge section (11r) of the first leg edge (11), and a second reinforcing elastic feature (72) is arranged on the elastically stretchable rear panel (4) along at least a first portion (12r') of the rear leg edge section (12r) of the second leg edge (12).

17. The disposable pant-type article (1) according to any one of the preceding claims, wherein the crotch region web is of a non-elastic material.

18. A disposable pant-type article (1) according to any one of claims 1 to 17, wherein the elastically stretchable front panel web and / or the elastically stretchable back panel web comprises or consists of an elastic laminate, the elastic laminate comprising at least a first layer of a non-stretchable fibrous material and an elastic layer.

19. 20. The disposable pant-type article (1) of claim 18, wherein the elastic laminate comprises a second layer of fibrous material, the elastic layer being an intermediate elastic layer disposed between the first and second layers of fibrous material.

20. the elastic layer comprises or consists of a layer of elastic film, or A disposable pant-type article (1) according to claim 18 or 19, wherein said elastic layer comprises or consists of a layer of elastic nonwoven material.

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