Disposable absorbent core, disposable absorbent assembly containing the disposable absorbent core, and method for manufacturing the same.

Abstract

A disposable absorbent article is disclosed having an outer shell and a removable disposable absorbent core insert supported on an interior surface of the outer shell. The core insert is attached to and removable from the inner surface of the outer shell, and the inner surface of the outer shell further includes a retention structure for receiving the absorbent core insert, the core insert being attachable to and removable from the retention structure.

Description

Background Art

[0001] The present disclosure generally relates to disposable absorbent articles or garments, their components, and methods of manufacturing them. More particularly, it relates to the absorbent core of a disposable absorbent article, and further to combinations of the disposable absorbent core and chassis or outer shell of a disposable absorbent article, and methods of manufacturing them.

[0002] Aspects of the present disclosure are particularly suitable for or related to disposable absorbent articles such as baby diapers, training pants for children and infants, and adult incontinence diapers and pants. Certain embodiments provide elastic composite webs, elastic composites or elastic complexes, or elastic distribution patterns within these products to improve the fit and comfort of the product, its support and sealing functions, improve the cost and manufacturability of the product, and / or enhance the aesthetic quality of the product.

[0003] The disposable absorbent articles contemplated by the present invention include training pants, pull-on diapers, disposable underwear, and adult incontinence garments. With respect to training pants, these garments are used by infants to facilitate the transition from the use of diapers to the wearing of regular underwear pants (i.e., during toilet training). Training pants and other disposable pull-on pants have closed sides, so that the user or caregiver pulls the garment up and over the user's legs to put it on and pulls the garment down and off around the user's legs to take it off. These articles and garments are collectively referred to herein as "absorbent pants" or "pant products".

[0004] Elastic components can be incorporated into various parts of absorbent clothing. For example, elastic components can be positioned longitudinally along the diaper, typically on the outside of the absorbent core, to seal around the user's buttocks, legs, or both. In addition, some elastic components (e.g., in the form of elongated elastic yarn or twisted yarn) can be positioned transversely across the entire waist region (including the lateral waist region) of the absorbent clothing. The resulting elasticity allows the clothing to stretch when put on or worn. Furthermore, the elasticity allows the clothing to conform closely to the user's waist and legs while adapting to variations in waist and leg size.

[0005] When elastic components are incorporated into part or a region of absorbent garments, that part or region typically becomes a distinct functional element of the garment. These elastic elements include side panels or selvages, waistbands, and fastening tabs. Partly due to this multi-element structure, elastic composites may require a dedicated sub-manufacturing process that needs to be coordinated within a larger garment manufacturing process. Alternatively, elastic composites can be manufactured individually or simply in a separate sub-process away from the main garment manufacturing system. In either case, the source of the elastic composite can be provided as an input to the garment manufacturing process.

[0006] U.S. Patent Nos. 7,462,172 and 7,361,246 and U.S. Patent Application Publication No. 2012 / 0071852 provide background information on the types of elastic composites related to the present invention (and the manufacture of such composites). These patent publications are therefore incorporated herein by reference and form part of this disclosure, and the incorporated subject matter provides background information and / or exemplary composites and processes suitable for use in or with the composites, systems, and methods of the present invention. Thus, the incorporated subject matter does not serve to limit the scope of the present invention. While these prior patent publications describe the manufacture of elastic composites and their incorporation into absorbent articles, it should be noted that in one embodiment, the present invention is directed more specifically to provide advanced systems and methods for manufacturing stretchable absorbent articles and / or elastic composite webs. More specifically, the object of the present invention is to provide methods and systems by which elastic composites and their formation are smoothly integrated into a method for manufacturing articles and into the stretchable article itself.

[0007] The products considered in this application are disposable consumer goods intended to be purchased in bulk and packaged. Furthermore, disposable absorbent products are single-use products. Once used, the item is discarded and replaced with a new one. Due to the nature of the product and the conditions under which it is used, users can act quickly and utilize the packaging of disposable absorbent articles. Thus, there is a desire to extend the lifespan of the product and minimize the number and cost of items that must be purchased, and perhaps sometimes, a product design objective. More generally, there is a desire to minimize the cost to consumers in maintaining an easy supply of disposable absorbent articles. This disclosure relates to a product design aimed at minimizing such costs while achieving certain performance objectives. [Overview of the project]

[0008] Disposable absorbent articles are disclosed, comprising an outer shell and a removable, disposable absorbent core insert supported on the inner surface of the outer shell. The core insert is attached to and removable from the inner surface of the outer shell. The inner surface of the outer shell further includes a retaining structure for receiving the absorbent core insert. The core insert is attachable to and removable from the retaining structure.

[0009] In another respect, a disposable absorbent core insert for attachment to the outer shell of a disposable absorbent article is disclosed. The disposable absorbent core insert includes a top material layer, a bottom material layer, and an absorbent core material layer positioned between the top material layer and the bottom material layer. A fastener is further included for attaching the core insert to a reusable outer shell of a disposable absorbent article so that the core insert is removable from the outer shell of the disposable absorbent article.

[0010] In another view, a disposable absorbent assembly is disclosed, having an outer shell and a disposable absorbent core insert that is removablely engaged with the outer shell. The core insert includes an absorbent core material section having an absorbent composition. Also disclosed is a method for manufacturing a disposable absorbent assembly, the method comprising preparing a reusable outer shell and a disposable core insert, and removablely engaging the core insert into the outer shell, thereby assembling a disposable absorbent article for use, wherein the core insert provides a removable absorbent core for the absorbent article.

[0011] The above provides a broader overview of the features and technical advantages of this disclosure so that the following detailed description may be better understood. Additional features and advantages that form the subject matter of the claims of this application are described below. Those skilled in the art should understand that the disclosed concepts and particular embodiments may be used as a basis for modifying or designing other structures to accomplish the same objectives of this disclosure. Those skilled in the art should also understand that such equivalent structures will not depart from the spirit and scope of the invention as set out in the appended claims. Novel features that are considered to be features of the product, system, and method, with respect to both organization and operation methods, will be better understood from the following description, which is considered in relation to the appended drawings, along with further objectives and advantages. However, it should be expressly understood that each of the features is provided for illustrative and explanatory purposes only and is not intended to define the limitations of this disclosure.

[0012] To provide a more detailed understanding of the features and advantages of the present invention, the present invention, which has been outlined above, will be described in more detail with reference to embodiments illustrated in the accompanying drawings, which form part of the specification. However, since the drawings only illustrate various representative embodiments of the present invention, they should not be considered to limit the scope of the invention, and other effective embodiments may also be included. [Brief explanation of the drawing]

[0013] [Figure 1A] This is a simplified isometric view of a disposable absorbent article. [Figure 1B] This is a cross-sectional view of an elastic composite material or an elastic composite web. [Figure 2A-2B] Figure 2A is a simplified side view of a manufacturing system or apparatus for elastic composite materials or elastic composite webs. Figure 2B is a plan view of the system shown in Figure 2A. [Figure 2C] Figures 2A and 2B show graphs of example periodic functions that generate a double elastic distribution pattern in an elastic composite web, reflecting the directional lateral motion induced by the elastic guide. [Figure 3] This is a simplified diagram of an elastic composite web. [Figure 4] Figure 1 is a simplified diagram of the web-based process for manufacturing disposable absorbent articles. [Figure 5] This is a simplified diagram of an elastic core structure that can be achieved by the system and method. [Figure 6] Figure 1 is a simplified diagram of the manufacturing system for disposable absorbent articles. [Figure 7] This is a simplified diagram of an elastic composite web used in a web-based process for manufacturing disposable absorbent articles. [Figure 7A] This is a simplified isometric view of a disposable absorbent article according to another embodiment. [Figure 8] Here is a simplified diagram of yet another elastic composite web. [Figure 9] Here is a simplified diagram of yet another elastic composite web. [Figure 10] This is a schematic diagram of a manufacturing system for disposable absorbent articles. [Figure 10A] This is a cross-sectional view of an elastic composite web. [Figure 10B] This is a cross-sectional view of another elastic composite web. [Figure 11A] This is a simplified diagram of an elastic composite according to yet another embodiment. [Figure 11B] This is a simplified diagram of an elastic composite according to yet another embodiment. [Figure 12] This is a simplified perspective view of a disposable absorbent assembly, including a removable disposable absorbent core and a reusable outer shell. [Figure 13] This is a simplified vertical cross-section of the outer shell of a disposable absorbent article. [Figure 14] Figure 13 is a simplified vertical cross-sectional view of a disposable absorbent core insert formed to be received within the outer shell. [Figure 15] Figure 14 is a simplified vertical cross-sectional view of a disposable absorbent article in which a disposable absorbent core insert is received and mounted within an outer shell formed to correspond to that in Figure 13. [Figure 16]Schematic plan view of a removed disposable absorbent core insert with an elastomer oriented in a linear direction added thereto. [Figure 17] Schematic plan view of a removed disposable absorbent core insert with an elastomer oriented in a linear direction added thereto. [Figure 18] Schematic plan view of a removed disposable absorbent core insert with an elastomer oriented in a linear direction added thereto. [Figure 19] Schematic plan view of a removed disposable absorbent core insert with a curved elastomer added thereto. [Figure 20] Schematic plan view of a removed disposable absorbent core insert with a curved elastomer added thereto. [Figure 21] Schematic plan view of a removed disposable absorbent core insert with a curved elastomer added thereto. [Figure 22A] Schematic plan view of a removed disposable absorbent core insert with elastomers arranged circularly added thereto. [Figure 22B] Schematic plan view of a removed disposable absorbent core insert with elastomers arranged circularly added thereto. [Figure 22C] Schematic plan view of a removed disposable absorbent core insert with elastomers arranged circularly added thereto. [Figure 23A] Schematic plan view of a removed disposable absorbent core insert with a pair of circularly arranged elastomers disposed around an absorbent core layer. [Figure 23B] Perspective view of the removed disposable absorbent core insert of FIG. 23A. [Figure 23C] Longitudinal cross-sectional view of a removed disposable absorbent core insert (intentionally excluding the leg cuffs). [Figure 23D] Longitudinal cross-sectional view of the disposable absorbent core insert of FIG. 23C (intentionally excluding the leg cuffs) having a stiffening structure oriented along the longitudinal direction or the machine center line. [Figure 23E]This is a longitudinal cross-sectional view of a disposable absorbent core insert (with the leg cuffs intentionally removed) having a pair of spaced-apart stiffening structures oriented longitudinally or in the machine direction. [Figure 24] Figure 22C is a perspective view of the removed disposable absorbent core insert. [Figure 25] This is a front view of a disposable absorbent article that accepts a disposable absorbent core insert. [Figure 26A] This is a plan view of a disposable absorbent article incorporating a flat, open, and removable disposable absorbent core insert. [Figure 26B] This is a plan view of another disposable absorbent article incorporating a flat, open, and removable disposable absorbent core insert. [Figure 27A] This is a plan view of yet another disposable absorbent article incorporating a flat, open, and removable disposable absorbent core insert. [Figure 27B] This is a plan view of yet another disposable absorbent article incorporating a flat, open, and removable disposable absorbent core insert. [Figure 28A] This disclosure is a lateral cross-sectional elevation view of a core insert having a formed bundle or plug that is received by a corresponding outer shell retainer or receptacle. [Figure 28B] This disclosure is a lateral cross-sectional elevation view of a core insert having a formed bundle or plug that is received by a corresponding outer shell retainer or receptacle. [Figure 29A] Figure 28 is a cross-sectional view of a disposable absorbent article oriented longitudinally along line AA-AA. [Figure 29B] Figure 28 is a cross-sectional view of a disposable absorbent article oriented longitudinally along line AA-AA. [Figure 30A] This is a simplified plan view of another disposable absorbent article comprising an outer shell having a folded edge region, and a disposable absorbent core insert removably held within the outer shell. [Figure 30B] Figure 28 is a cross-sectional view of a disposable absorbent article oriented longitudinally along line AA-AA. [Figure 31A] This is a simplified plan view of a disposable absorbent article comprising a bendable edge region with a snap fastener, and a disposable absorbent core insert detachably held within the bendable edge region. [Figure 31B] This is a simplified plan view of a disposable absorbent article comprising a bendable edge region with a snap fastener, and a disposable absorbent core insert detachably held within the bendable edge region. [Figure 31C] This is a simplified plan view of a disposable absorbent article comprising a bendable edge region with a snap fastener, and a disposable absorbent core insert detachably held within the bendable edge region. [Figure 31D] This is a simplified plan view of a disposable absorbent article comprising a bendable edge region with a snap fastener, and a disposable absorbent core insert detachably held within the bendable edge region. [Figure 32A] This is a simplified plan view of another variation of the folded edge region, and a disposable absorbent article comprising a disposable absorbent core insert detachably held within another variation of the folded edge region. [Figure 32B] This is a simplified plan view of another variation of the folded edge region, and a disposable absorbent article comprising a disposable absorbent core insert detachably held within another variation of the folded edge region. [Figure 33A] This is a plan view of a disposable core insert showing the location of hook patches or areas on the back sheet of the core insert. [Figure 33B] This is a plan view of a disposable core insert showing the location of hook patches or areas on the back sheet of the core insert. [Figure 33C] This is a plan view of a disposable core insert showing the location of hook patches or areas on the back sheet of the core insert. [Figure 34A]This is a detailed cross-sectional view of the resilient fastening or mounting means area for the outer shell and core insert combination in a nearly fully extended state. [Figure 34B] This is a detailed cross-sectional view of the elasticized region in the loosened state shown in Figure 34A. [Figure 35] Figure 35 shows fastening strips arranged at intervals and oriented toward the machine. [Figure 35A] Figure 35A is a transverse cross-sectional view of a disposable absorbent article. [Figure 36] Figures 36 and 36A show alternative embodiments that utilize different arrangements of fasteners to form alternative channel configurations. [Figure 36A] Figures 36 and 36A show alternative embodiments that utilize different arrangements of fasteners to form alternative channel configurations. [Figure 37] Figures 37 and 37A show an alternative embodiment that uses a stiffening section to facilitate the V-shaped bend. [Figure 37A] Figures 37 and 37A show an alternative embodiment that uses a stiffening section to facilitate the V-shaped bend. [Figure 38A] This is a simplified front view of a disposable absorbent article equipped with a retainer clip according to the present disclosure. [Figure 38B] This is a simplified front view of a disposable absorbent article equipped with a retainer clip according to the present disclosure. [Figure 38C] This is a simplified front view of a disposable absorbent article equipped with a retainer clip according to the present disclosure. [Figure 39A] This is a simplified detailed cross-sectional elevation view of a core insert that is removably engaged with a retainer clip provided on the outer shell, as disclosed herein. [Figure 39B] This is a simplified detailed cross-sectional elevation view of a core insert that is removably engaged with a retainer clip provided on the outer shell, as disclosed herein. [Figure 39C]This is a simplified detailed cross-sectional elevation view of a core insert that is removably engaged with a retainer clip provided on the outer shell, as disclosed herein. [Figure 39D] This is a simplified detailed cross-sectional elevation view of a core insert that is removably engaged with a retainer clip provided on the outer shell, as disclosed herein. [Modes for carrying out the invention]

[0014] The present invention will be described in more detail with reference to the accompanying drawings illustrating various exemplary embodiments. However, while the present invention can be embodied in numerous different forms, it should not be construed as being limited by the exemplary embodiments described herein. Rather, these embodiments are presented to ensure that this disclosure is thorough and complete, and to convey the scope of the invention and the best and preferred modes for carrying it out to those skilled in the art. For example, most of the exemplary descriptions presented herein relate to training pants for infants and children. However, the described embodiments of the present invention are equally applicable to the design and manufacture of infant diapers, adult incontinence products, and other similar products.

[0015] In one respect, this disclosure is directed towards disposable absorbent core insights. This disclosure is further directed towards combinations of disposable absorbent core inserts and reusable outer shells into which the core inserts are engaged or inserted. This disclosure is also directed towards disposable absorbent articles or clothing comprising disposable absorbent core inserts and reusable outer shells. In various or other applications, disposable absorbent articles or clothing may take the form of diapers, training pants, adult incontinence products, feminine hygiene products, and other similar disposable absorbent products.

[0016] Figures 1–11 provide a description of prior art systems and methods that serve as background for a detailed description of the subject matter products and methods introduced herein. Figures 12–40B provide simplified diagrams of absorbent products and their components that are the subject matter of the novel disclosure. The method techniques and product designs shown in Figures 1–11 and described in the accompanying description can be employed in the design and manufacture of core inserts and disposable absorbent products according to the disclosure. For example, the method of establishing an elastic distribution between material layers and manufacturing an elasticized body shown in one or more of Figures 1–11 can be employed in part or in whole in the design and manufacture of new products.

[0017] Disposable absorbent articles with a reusable outer shell and a disposable absorbent core insert. Now, referring to Figure 12, a particularly advantageous combination of a disposable absorbent core insert 1910 and a reusable side shell 1912 is shown. In a preferred embodiment, one or both of the core insert 1910 and the outer shell 1912 start as an elastic composite material elasticized by the above technique. In a certain application example, the outer shell provides a central body or chassis of an absorbent article, or alternatively, provides the remainder or finished part of a complete disposable absorbent article. In either case, the combination of the disposable core insert and the outer shell, or the disposable core insert and other components of a disposable absorbent article, can be referred to as a disposable absorbent article assembly 1908. As illustrated, the core insert 1910 is engageable with the outer shell 1912 to form a disposable absorbent garment or article such as a diaper 1908 (Figure 12), or training pants / adult incontinence product 1906 (Figure 25), or at least a central body or chassis. The core insert 1910 is held within the crotch area of ​​the semi-enveloping garment 1906 by the crotch area of ​​the semi-enveloping garment 1906. The absorbent core insert according to this disclosure is disposable and is discarded after each use. However, the outer shell 1912 is only semi-disposable and can be used with up to 20 to 30 core insert replacements.

[0018] As used in this application with respect to the engagement of a core insert and an outer shell, the term “removable” means, or refers to, that the core insert and / or outer shell are configured and / or provided with such configuration that the core insert can be easily and repeatedly attached to a predetermined location on the inner surface of the outer shell (i.e., a “landing”) to provide an absorbent core for a disposable absorbent article (in a groin or target area). The term “removable” further means that the attachment is temporary and not permanent, that the core insert can be removed without destroying or removing any components, and that the outer shell (and the landing) can be reused to receive another “removable” core insert.

[0019] Background System and Method Figures 1–11 are particularly directed toward the design and method for disposable absorbent training pants, and their aspects can be adapted for use in conjunction with embodiments of the present disclosure. The present disclosure and embodiments are applicable not only to disposable absorbent training pants, but also to adult diaper pants and incontinence products, infant diapers, and other disposable absorbent wearable articles and clothing, as well as their components and related manufacturing methods. Some of the resilient chassis product design embodiments shown in Figures 1–11 can be adapted and applied to the designs of absorbent core inserts and outer shells shown in Figure 12 and further described in the present disclosure. See, for example, Figures 26, 27, and 38.

[0020] Figure 1A shows a disposable absorbent training pant 101. The vertical absorbent pant 101 is formed of a stretchable composite 136, in which a first portion or front half is rotated around a line of symmetry and joined to a substantially identical second portion or back half. These two halves are joined by a pair of sealing side seams 130. Each side seam 130 consists of a first portion or bottom of the side edge 106 and a second portion or top of the same side edge 106 to which it is joined (details described later). The resulting absorbent pant 101 has a front vertical waist edge 102, a rear vertical waist edge 103, and a pair of sealing side seams or seals 130 provided on the sides of the absorbent pant 101, respectively. For the sake of simplicity in describing the present invention, the pant body 136 may be described as having an upper waist region 124 and a lower waist, leg, and crotch region (lower region 126). The absorbent pants structure 101 also includes a fluid distribution / storage structure or absorbent core 105 around the crotch area 134 inside the pants 101. In one aspect of the present invention, the absorbent pants structure 101 is directly constructed by forming two side seals 130. This absorbent pants structure 101 includes a waist opening 132 formed by joining two waist edges 103 to complete a continuously enclosing waist edge. The pants structure 101 further includes two leg openings 104 formed by joining halves together (details to be described later).

[0021] The trouser structure 101 also includes side seams 130. The side seams 130 can be provided by permanent bonding seals or reattachable seals. Permanent side seals can be achieved using, for example, adhesive bonding, thermal bonding, ultrasonic bonding, or any suitable bonding mechanism. Reattachable side seals can be achieved using adhesive, hook and loop material, or other reattachable mechanisms.

[0022] To enhance the comfort, fit, and fluid-holding capacity of the absorbent article, and to minimize fluid leakage through the waist and leg openings 132 and 104, the disposable absorbent article 101 is provided with strategically placed elastomer material 120. In preferred embodiments, these elastomer materials consist of elastic twisted or knitted yarns such as natural rubber, latex twisted yarn, or synthetic elastomers such as Lycra or spandex knitted yarn. Other suitable elastomer materials include, but are not limited to, stretchable elastomer films, elastomer ribbons, elastomer nonwovens, and elastomer adhesives. For the purposes of this specification, the description of elastomer materials is limited to the use of elastomer twisted or knitted yarns that can be referred to as elastic twisted yarns or elastic bodies. However, it will be apparent that these elastomer materials are readily replaceable with many other types of elastomer materials.

[0023] The absorbent pants 101 in Figure 1 incorporate multiple distributions of elastic yarn 120 in the upper waist region 124 and the lower waist, leg, and crotch regions (lower region 126). These distributions of elastic yarn impart strategically positioned and advantageously configured elasticity to the composite 136. After sealing of the side edges 106, this feature is directly and easily transferred to the resulting absorbent pants 101, ultimately to the pants 101 worn by the user. Thus, the pants 101 can be referred to as a stretchable disposable absorbent article 101. More specifically, each elastic distribution of the absorbent pants 101 forms a substantially annular region or area of ​​elasticity. In the upper waist region 124, the set or distribution 110 of elastic yarn 120 is positioned approximately around the waist opening 132, directly below the joined waist edges 102, 103, encircling the user's waist. Preferably, the elastic yarns 120 are spaced apart from each other and arranged substantially parallel to the waist edges 102, 103. Thus, the absorbent pants 101 are provided with a particularly advantageous elastic annular region that comfortably wraps around the user's entire waist and effectively seals the waist opening 132. In the lower region 126, multiple distributions of elastic yarns 120 extend substantially around the entire circumference of the leg openings 104 and the crotch region 134. One set or distribution 111 of elastic yarns 120 surrounds the leg openings 104, forming an elastic annular region or area around it. A third annular region or area of ​​the elastic body is located substantially in the center of the crotch region 134.

[0024] The elastic annular regions around the waist and leg openings are advantageously positioned over substantially the entire perimeter of the area to be sealed (i.e., the openings that may occur between the waist and the waist edge 102 and the waist edge 103, and the openings that may occur between the thigh and the circular side edge of the article 101). Furthermore, the strength and direction of the elastic force are maintained substantially uniformly around the openings. A more effective and reliable seal is achieved at all potential leak points around the target openings. Thanks to the uniformity of elasticity around the waist or thigh, uneven fit that could lead to a seal failure is prevented. In particular, the elastic distributions 110, 111 of composite 136 extend over substantially the entire area from one side edge to the other side edge (described later), and after the formation of the pants structure 101, extend substantially continuously (without ends) around the article 101. However, it should be understood that the elastic bodies of the annular regions do not necessarily need to be in contact or overlapping. The end of the elastic body only needs to be brought close to the opposing end so as to provide substantially uniform elasticity around the object to be sealed or the edge, much like the actual elastic ring around it.

[0025] It should be noted that the elastic twisted yarn 120 around the leg opening 104 can overlap with the crotch area 134. Furthermore, it should be noted that the elastic twisted yarn 120 in the upper area 124 and the lower area 126 are not necessarily mutually exclusive, and the elastic twisted yarn in one area may overlap and intersect with the elastic twisted yarn in another area.

[0026] Disposable absorbent articles 101 having one or more elastic annular regions can be manufactured using a single, integrated elastic composite 136 (or a simple elastic composite 136 before fabricating the pants structure 101). Figure 1B is a cross-sectional view of an exemplary elastic composite 136, particularly for the absorbent pants 101 of Figure 1B. In particular, this figure shows multiple distributions of elastic yarns 120 within the elastic composite 136 used in the absorbent pants 101 according to the present invention. The elastic composite 136 has a first edge or lower edge 102 and a second edge or upper edge 103 (which ultimately form the waist edges 102, 103 in the pants structure 101). The composite 136 also has an outer fluid-impermeable back sheet layer 107, an optional intermediate layer 108, a fluid distribution / storage structure or core 105, and a fluid-permeable surface sheet 109. The fluid-impermeable back sheet layer 107 can be selected from a wide range of materials, including hydrophobic and fluid-impermeable nonwoven materials, permeable and impermeable polyethylene membranes, or laminates of these materials. An optional intermediate sheet layer 108 may also include hydrophobic and fluid-impermeable nonwoven materials, permeable and impermeable polyethylene membranes, and laminates of the above materials or other suitable materials. As shown in Figure 1B, the two sheet layers 107, 108 help to hold the elastic distributions 110, 111 in place, although in some embodiments, the elastic distributions are attached only to the surface of the back sheet layer 107. The fluid distribution / storage structure or absorbent core 105 can consist of nonwoven materials, opening membranes, fibers, cellulose cotton pulp, superabsorbent polymer particles or fibers, or any other material available for distributing and absorbing fluids and solids flowing within the object when used. Furthermore, the fluid-permeable surface sheet 109 may comprise a hydrophilic fluid-permeable nonwoven web or opening material.

[0027] In the case of the absorbent pants 101 of Figure 1, the exemplary elastic composite material 136 shows a first distribution 110 of elastic yarns 120 oriented along the first edge 102 and the second edge 103, respectively. In this embodiment, a group of six spaced-apart yarns 120 are bundled together almost together along the edges 102 and 103, but three individual yarns 120 are positioned inside these yarns 120. The spacing between the three individual yarns 120 is wider than the spacing between the first six yarns 120. This spacing between the yarns 102 and 103 corresponds to the spacing of the yarns 120 in the upper region 124 of the disposable absorbent article 101 in Figure 1A, concentrating the elasticity near the edges 102 and 103. The elastic composite material 136 also features two other distributions 111 of elastic yarns 120. The two distributions 111, each consisting of five twisted yarns 120, are located inward from the two outer distributions 110, as shown in Figure 1B. Furthermore, as will be described later, these two distributions 111 correspond to the elastic distributions 11 around the leg opening 104 and within the crotch area 134 of the disposable absorbent article 101.

[0028] Simplified diagrams in Figures 2A and 2B illustrate a system 150 and method for manufacturing a web 240 of elastic composite material 136. More specifically, the system 150 and method are used to incorporate the desired elastic distributions 110, 111 described above into the elastic composite material 136 and composite web 240 (ultimately, absorbent article 101) according to the present invention. The illustrated method provides the first sub-step in manufacturing the elastic composite material 136 and disposable absorbent article 101 of Figure 1. Figure 4 shows the remaining subsequent steps of the method. Both Figures 3 and 4 show an integral elastic composite web 240 particularly suitable for manufacturing disposable absorbent article 101. As described later, the composite web 240 can include and be presented a continuous mechanically oriented distribution of four elastic twists following a particular advantageous pattern. At least two distributions are described by periodic functions characterized by valleys and peaks. The other two distributions are preferably maintained along a direct path.

[0029] Referring to Figures 2A and 2B, the system 250 and method transport, add, and manipulate an elastic composite web 240 in a substantially linear process in the machine direction. For illustrative purposes, the web 240 is assumed to have a first edge or lower edge 202, a second edge or upper edge 203 spaced from the first edge 202 substantially parallel to the direction transverse to the machine, a machine-crossing width formed between the two edges 202, 203, and a longitudinal centerline YY. For part of the description, the machine-crossing direction that traverses the web 240 and the elements supporting the web 240 of the present invention may be referred to as the transverse direction, and the machine direction may be described as corresponding to the longitudinal direction. Preferably, the elastic composite web 240 is advanced at a uniform speed in the longitudinal or machine direction.

[0030] In a preferred embodiment, the method first requires the separate and continuous transport of each of the six elements of the elastic composite material 136 to a joining mechanism such as a nip roller 218 (see, for example, Figure 2A). These elements include a first material sheet 212, a second material sheet 213, a first set 210a of pre-tensioned elastic yarn along the upper edge 203, and a second set 210b of pre-tensioned elastic yarn along the lower edge 202. The first and second sets 210a and 210b of elastic yarn are arranged parallel to each other, but specifically spaced apart from each other according to a predetermined arrangement. In this particular embodiment, the first and second sets 210a and 211b are mirror images of each other. The two individual sets 211a and 211b of pre-tensioned elastic yarn are transported along the machine direction laterally inside the first and second sets 210a and 210b of pre-tensioned elastic yarn. As best shown in Figure 2A, both the first and second sets 210, 211 of the elastic bodies are preferably introduced and conveyed to the nip roller 218 along the horizontal plane of the web 140. The two inner sets 211a, 211b of the elastic bodies are introduced to the same web surface. On the other hand, the two material webs 212, 213 are preferably started from approximately above and below the web surface (hence also referred to as the upper and lower material webs or sheets).

[0031] The elastic twisted yarn can be received under tension by any suitable supply tensioning device (not shown) located upstream of this process. The initial lateral position of the elastic twisted yarn and the spacing between adjacent elastic twisted yarns are initially fixed by elastic guides 215. These fixed elastic guides 215 are mounted on two rods 219 as shown in Figures 2A and 2B. The elastic guides 215 typically include rollers, eyelets, or any other means for conveying and guiding the pre-tensioned elastic twisted yarn. A second set of elastic guides 216a, 216b are mounted on a movable rod 221 downstream of the fixed rods 219. These two movable elastic guides 216a, 216b each engage with one of the two inner sets 211a, 211b of the elastic twisted yarn. Preferably, the movable rod 221 and the movable guides 216a, 216b are located above and below the web surface, respectively. Therefore, the first set of elastic bodies 211a is introduced along the web surface, but after introduction, it is directed slightly above the web surface for a short distance. Similarly, the other set 211b is directed slightly below the web surface after introduction. This adjustment is made before the two sets of elastic bodies 211a and 211b are engaged by the conveying means 217 and advanced to the nip roller 218.

[0032] It should be noted that the special elements of the illustrated system 250 can be replaced with other suitable means or elements. For example, in another system, a fixed guide or eyelet can be mounted on a fixed frame. Furthermore, the movable guide can be mounted on or associated with a mechanical arm, cam system, and other suitable mechanisms.

[0033] The sets of elastic yarns 210a and 210b are distributed substantially parallel to the nip roller 218. These elastic yarns are similar to the distribution of elastic yarns 110 present in the upper waist region 124 of the absorbent article 101 in Figure 1, and are distributed parallel to the upper and lower edges 202 and 203 of the composite web 240. In the case of the absorbent pants 101 in Figure 1, the configurations of the sets of elastic yarns 210a and 210b must be identical. However, it is possible to provide alternative article designs in which the configurations are not identical and one set contains yarns with greater elastic force than the other set. In other designs, the spacing and density of the elastic bodies may differ, achieving special functions or aesthetic attributes. While such designs may deviate from the preferred arrangement of the annular elastic region, as mentioned above, the alternative designs described above are not a complete departure, and it is expected that some aspects of the preferred designs (according to the present invention) will be retained.

[0034] The movable elastic guides 216a and 216b are configured to move in a direction perpendicular to the machine direction of the web 240, changing and directing the placement of the elastic twist sets 211a and 211b to the nip roller 218 and adjusting the lateral spacing of the elastic twists. Thus, the inner sets 211a and 211b of the two elastic bodies can be referred to as variable (as opposed to "fixed") sets of elastic bodies. By positioning the two variable sets 211a and 211b of elastic bodies spaced apart in the machine direction (as described above), the two sets 211a and 211b can move laterally without interfering with each other. In this embodiment, for example, the two sets 211a and 211b of elastic bodies intersect laterally, so that the lower set of elastic bodies reaches the nip roller 218 as the upper set and the other set becomes the lower set.

[0035] Preferably, the elastic guides 216a and 216b are mounted on a reciprocating mechanism and so as to reciprocate continuously in a lateral direction (perpendicular to or transverse to the machine direction of the process). The guides 216a and 216b are supported on the same continuous belt and can always follow and move together with the belt. In other embodiments, the guides 216a and 216b can be driven independently of each other, in particular if the pattern of the elastic distribution does not depend on the other. Suitable drive mechanisms may include cam-based mechanisms, servo-driven mechanisms, or hydraulic mechanisms. Preferably, the motion of the elastic guides 216a and 216b is described by a periodic function in which the relative displacement of the elastic body (or elastic guide) is a function of time (or web length) and discrete increments (P, period). This displacement function represents the periodic shape or pattern of the distributed elastic body.

[0036] The graph in Figure 2C shows an exemplary periodic function reflecting the lateral displacement (D) of the movable guides 216a and 216b over a period (P) (proportional to the width of the elastic composite 136 relative to the machine speed). Two separate functions f1 and f2 represent the relative lateral motion of the guides required to generate a double elastic distribution pattern on the web. As shown in the graph, the two elastic guides inevitably cross twice per period. The multiple crossings translate to generate a series of elastic annular regions on the composite web, or at least two annular regions, or elastic composite 136, per period (P).

[0037] Furthermore, the upper sheet 212 and the lower sheet 213 are oriented toward the web surface by the conveying means 217, and then oriented toward the nip roller 218. Thus, the two sheets 212, 213 and the four sets of elastic material 210, 211 arrive at the nip roller 218 almost together. The upper sheet 212 and the lower sheet 213 play a role in gripping, capturing, and holding the elastic twists in place after passing through the nip roller 218. The resulting web 240 of the elastic material and material web is fixed using any suitable bonding means, including adhesive, ultrasonic, or thermal bonding (not shown). In the case of adhesive bonding, the adhesive can be added to the upper sheet 212 and the lower sheet 213, or directly to the upper and lower sheets that meet and bond at any point before the elastic twists, with the sets of elastic twists 210, 211 and the nip roller 218.

[0038] Figure 3 shows a continuation of the system 250 and method for manufacturing the disposable absorbent article 101 shown in Figures 2A and 2B. The system 250 and method in Figures 2A and 2B include an upper sheet 212 and a lower sheet (not shown), but outputs an elastic composite web 240 with the upper sheet 212 and elastic yarn distributions E10, E11 along the direction of the machine across the web 240. The two variable distributions E11 of elastic yarn positioned in the middle are directed by the periodic lateral motion (and periodic function) of the elastic guides 216a, 216b in Figure 2, resulting in a sinusoidal pattern in this example. The pattern can also be described as a series of annular elastic regions O1 or regions formed by the peaks and troughs of the two variable distributions E11 of the elastic body. Other linear and non-sinusoidal patterns can also be produced in this process, but a sinusoidal pattern is adopted for illustrative purposes. One set 211a of the elastic material is distributed in a first sinusoidal pattern E11 and overlaps with a second set 211b of the elastic material distributed in a second sinusoidal pattern E11. In this example, the first and second sinusoidal patterns are mirror images of each other. The two distributions E11 form a region Ix where one set overlaps and intersects with the other. The degree of overlap of the elastic twist patterns can be measured and will hereafter be referred to as the variable "X". The wavelength of the sinusoidal pattern can also be measured and will hereafter be referred to as the variable "Y". Both variables "X" and "Y" are process parameters that can be adjusted by changing various process parameters such as machine speed, reciprocating speed, and reciprocating depth.

[0039] Figure 4 shows a process or conversion step that further modifies the elastic composite web 240 of Figures 2 and 3 and converts it into the disposable absorbent article 101 of Figure 1A. As shown in Figure 4, the sub-process can be described as receiving the output from the system 250 of Figures 2A and 2B and the sub-process (elastic composite web 240) by proceeding downstream from left to right. The fluid distribution / storage structure or core 105 is added to the center of one of the overlapping regions Ox of two sets 211a, 211b of sinusoidal elastic twists. The elongated core 205 is added and positioned horizontally along the length of the core 205 and attached to the web 240 in a direction across the machine. In this embodiment, the core 205 is located between the upper and lower distributions E11 of the elastic body. Simultaneously with or immediately after the addition of the core 205, a material sheet 209 (not shown) is added onto the core 205 and web 240. This material sheet becomes the surface sheet in the disposable absorbent article 101. Additional features such as independent retractable leg cuffs, fixing tapes, and disposable tapes can be added to the structure at this stage.

[0040] In the next step or stage of this process, preferably, a circular hole 204 can be punched or cut out of the web 240. In this embodiment, the hole 204 is made in the center of the inside of the elastic annular region O1 but not in the overlapping region Ox. As shown in Figure 4, the hole 204 is longitudinally aligned with the intersection Ix of the elastic twist and the wavelength distance "Y" of the sinusoidal pattern. Cutting out the hole 204 provides a leg opening 104 in the disposable absorbent article 101. Therefore, an important requirement of the disposable absorbent article 101 is that the wavelength "Y" of the sinusoidal pattern is equal to the width of the finished product 101.

[0041] The next step in the manufacturing process involves cutting or dividing the continuous composite web 240 along cutting lines 431 across the entire width of the machine. This end cutting can be achieved by a number of mechanisms known to those skilled in the art, including punching or water spray cutting processes. The location of the end cutting is determined with respect to the wavelength "Y" of the sinusoidal pattern. In particular, the cutting lines 431 bisect each hole 204 and every other elastic annular region O1. The cutting lines 431 are also spaced apart on both sides of the core 205.

[0042] After separation, individual double elastic composite materials 136 are formed. At this point, the elastic composite material 136 has a longitudinal centerline that bisects the elongated core 105. Furthermore, the composite material 136 has two side edges 106a and 106b along the initial cutting line. The side edges 106a and 106b consist of linear portions at the top and bottom. A nonlinear cutout is positioned between the two portions and is intended to form a leg opening. The elastic composite material 136 extends from each of the side edges 106a and 106b and is cut by the cutting line, featuring half elastic annular regions that complete an annular elastic region at the center. The elastic composite material 136 also has a core 105 located in the center of the central elastic annular region.

[0043] Finally, the elastic composite material 136 is folded along the folding line 425 corresponding to the longitudinal axis YY of the web 140. The elastic composite material 136 in this embodiment is symmetrical about this axis YY. Therefore, when folded, each feature and part of the lower half matches and covers the exact same features or parts of the upper half. The result is the disposable absorbent article 101 in Figure 4 (and Figure 1A). In the flat and folded state, the article 101 shows a quarter of each leg hole 104 and a quarter of each semi-annular region on the side edges 106a, 106b. To complete the absorbent pant structure, the matched side edges 106a, 106b are sealed (seal 130), while the matched upper edge 102 and lower edge 103 and a quarter of the leg holes are not sealed. The specific manufacturing process of this embodiment employs a high "X" value.

[0044] The process described with reference to Figures 2-4 is an example of the manufacturing process for the absorbent article of the present invention. The steps described do not necessarily have to be completed in the order described. The steps may be completed in a different order, or some steps may be completed simultaneously, which may be preferable in some cases.

[0045] Referring to another example and schematic in Figure 6, another system 650 and method for manufacturing disposable absorbent articles utilizes several different steps and sequences. A first material sheet 612 is transported separately by conventional means. A pre-tensioned elastic body 610 (for the upper waist region) is applied to the sheet 612, preferably near the side edge, as described above. The resulting elastic composite material 640 is then transported by a transport means 617. Two sets of elastic bodies 611a, 611b are also moved using elastic guides 616a, 616b and transported towards the transport means 617. As described above, the elastic guides 616a, 616b vary the lateral position of the sets of elastic bodies 211a, 211b to induce a preferred pattern according to a periodic function. Thus, the elastic composite web 640 can be reinforced with a preferred elastic distribution by matching the two sets of variable elastic bodies 611a, 611b with a nip roller 618. These preferred distributions include a series of annular regions, similar to the embodiments described above.

[0046] Furthermore, another bonding web 609 is added to the elastic composite web 640 by a second nip roller 618. This subsequent addition also includes the incorporation of a sheet material web to which the core material is already intermittently attached, as shown in Figure 6. The resulting output of the second nip roller 618 is an elastic composite web 640 having two material sheets, two sets of variable elastic bodies, and two sets of pre-tensioned elastic bodies parallel to each other, similar to the system and process outputs in Figures 2A and 2B.

[0047] Figures 7–9 illustrate another embodiment of the elastic composite web and distribution that can be realized and / or utilized in the present invention, where similar reference numerals refer to similar elements. Referring first to Figure 7, the elastic composite web 740 includes an upper sheet or back sheet material sheet (not shown) 712 and a lower material sheet (not shown) directly beneath the upper sheet 712 and a plurality of distributions of elastic yarns. Distributions of elastic yarns 710a, 710b are provided along the upper edge 702 and lower edge 703 of the web 740, respectively. These distributions ultimately constitute an elastic annular region around the waist opening. Between these two distributions are two variable elastic distributions 711a, 711b (for the lower waist, crotch, and leg regions). As shown in Figure 3, these variablely positioned elastic yarns are distributed by the periodic lateral motion of the elastic guide in Figure 2, preferably inducing a sinusoidal pattern. A first set of elastic material 711a is distributed in a first sinusoidal pattern and overlaps with the other set of elastic material 711b, which is distributed in a second sinusoidal pattern. In this exemplary embodiment, the first and second sinusoidal patterns are mirror images of each other. In this embodiment, the degree of overlap "X" of the two elastic patterns is much smaller than the degree of overlap described in the embodiments related to Figures 3 and 4. An absorbent article made with this type of elastic distribution resulting from this is shown in Figure 7, characterized by having more elastic material in the crotch area and less elastic material in the mid-waist area.

[0048] Figure 8 shows another elastic composite web 840 with an overlap degree, i.e., an "X" value, of nearly zero. Figure 8A shows an absorbent article 801 using this elastic distribution pattern and the elastic composite 836 separated from the web 840. Article 801 does not feature a crotch region 834 that stretches as widely as in the absorbent article 701 of Figure 7.

[0049] Figure 9 shows yet another embodiment of the elastic composite web 940. This other composite web 940 employs another variable distribution 911a, 911b of elasticity. Specifically, in this embodiment, the variable sets 911a, 911b of elasticity are distributed in a pattern in which the two sets do not overlap. In this example, the value of "X" is negative. This pattern does not provide a series of perfectly annular elastic regions, but the value of "X" is kept small enough to approach a perfect annular region, i.e., a substantially annular elastic region. An example of an absorbent article 901 utilizing such an elastic distribution and substantially annular elastic region is shown in Figure 9A. Due to being substantially annular, the elasticity around the waist opening and leg openings occupies 85% to 95% of the perfect circle, so the elasticity around the openings is substantially continuous and nearly perfect.

[0050] Figures 11A and 11B show yet another elastic composite and disposable absorbent. The elastic composite is similar to those presented in Figures 8 and 8A. The value of the overlapping region size "X" is zero, and the two distributions 1111a and 1111b coincide but do not completely intersect. Instead, the two elastic distributions 1111a and 1111b form a broad, somewhat elongated elastic concentration at the center of the composite 1136. In the resulting disposable absorbent article, this feature transforms into a perfectly circular elastic concentration in the crotch region 1134. Figures 11A and 11B also show the sizes of the exemplary elastic composite of the present invention. Furthermore, the figures also show preferred locations for specific elements of the elastic composite 1136. For example, the core 1105 of this embodiment is centrally located on the aforementioned elastic concentration but is cut to a width close to the length of the aforementioned elastic concentration.

[0051] Figures 11A and 11B further illustrate two steps in an alternative method for manufacturing disposable absorbent articles. Figure 11A represents a potentially integral elastic composite 1136 newly separated from the elastic composite web according to the present invention. Unlike the finished elastic composite described above, the elastic composite 1136 does not have holes or portions from which it is cut (for leg openings to be formed later). Instead, the elastic composite 1136 is folded in a frame on a complete rectangle around the longitudinal axis YY. The folded elastic composite 1136 features a quarter portion of a leg opening 1104 that can be cut or punched out. The side edges 1106 can then be sealed to form the leg opening of the absorbent training pants according to the present invention.

[0052] Elastic distribution gap According to yet another aspect of the present invention, a manufacturing system and method for stretch-absorbing articles includes an improved step of adding a plurality of elastic distributions to a moving web. As described above, a preferred step is to add a continuous elastic distribution substantially in the mechanical direction. This step includes adding and providing at least two periodic or curved distributions (substantially in the mechanical direction) of elastic bodies on the moving web by varying the lateral position of the elastic bodies as the elastic distribution progresses in the mechanical direction. In addition to this step, a continuous elastic distribution can be added to provide a substantially mechanically oriented elastic distribution in each elastic composite having intermittent gaps (in the elastic bodies). That is, a continuous substantially mechanically oriented distribution of elastic bodies is added, but the elastic threads on the finished composite web and the final product are effectively separated due to the intermittent gaps.

[0053] The location of the gaps on the web is predetermined to correspond to the desired gaps or absence of elasticity in the final trouser product. Depending on the application, the gaps may be made wide enough to effectively eliminate elasticity in the target area, or in other applications, the gaps may be minimized to maintain the continuity of the annular elasticity region of the final absorbent article. In one exemplary step, the elastic distribution gaps are located on the web at a position corresponding to the side edge of the trouser product, where a side seal or seam is formed. In yet another embodiment, the elastic distribution gaps are positioned to coincide with the core location near the central or crotch area of ​​the absorbent article. In this embodiment, it would be desirable to separate the core from the elasticity to provide a relatively stable and unbiased core structure, or to position additional elements on the core surface so as not to interfere with them.

[0054] Stretchable or contoured core structure In the system described with respect to the processes shown in Figures 2 and 6, and Figures 3, 4, and 5, the core is intermittently delivered to a pre-cut moving web and oriented substantially perpendicular to the longitudinal direction of movement of the moving web. As specifically shown in Figures 4 and 5, the pre-cut core is delivered between the longitudinal edges of the web and along the web extending longitudinally between each side edge (or dividing line) of the expansion composite material. Thus, the core is attached in accordance with the final position and orientation of the finished disposable absorbent article.

[0055] In many of the embodiments described herein, the process of the present invention is employed to add an elastic distribution over the entire width of each absorbent article, including a core. The engagement or interaction between the elastic body and the core can impart to the core elasticity that is essential or desirable for the design of the absorbent article. The resulting stretchable core may have aesthetic and functional features due to the stretchable region. The advantages of stretchable core structures are illustrated, for example, in U.S. Patent Application No. 2011 / 0130736, particularly in Figures 6–9 of the said publication (this application is assigned to an assignee common to the assignee of the present application, and includes one or more of the inventors of the present application as inventors). One of these figures is reproduced herein as Figure 5, showing a stretchable core structure 1801 (contracted state) achievable by the system and process of the present invention. The core structure includes a plurality of elastic distributions 1810 added laterally in the mechanical direction, traversing the core 1812 approximately in the center of the moving web. This prior patent application publication and, in particular, Figures 6-9 and the accompanying descriptions thereof are incorporated herein by reference for background purposes and constitute part of this disclosure. A common element of the stretchable core designs in these references is an elastic body 1811 that is oriented and added to or near the core 1812, traversing the longitudinal direction of the core 1812. The system and process facilitates the provision of the stretchable core by adding the elastic body to the center of the web moving in the mechanical direction and intermittently positioning the core on the web substrate in its final position and orientation. Furthermore, the system and process described herein allows for deformation of the elastic pattern added to the core, e.g., multiple different distributions or sets of elastic bodies, spacing between elastic bodies, linear and / or curved distribution patterns such as sinusoidal or other shapes.

[0056] Furthermore, this system and process allows for the cutting or formation of gaps in the elastic distribution on the moving web and the finished disposable absorbent article. In one embodiment, other curved or periodic designs can be employed to distribute elastic material around or near the outer circumference of the core, encouraging a pocket or cup shape in the core. The two elastic distributions overlap to create an annular elastic region around the core, which conveniently acts as a kind of O-ring seal. Such an expandable O-ring can be designed to align with the user's buttocks to enhance absorption and retention. The elastic distributions shown in Figures 3-4 and 7-7A are two structures suitable for providing such an annular elastic region and O-ring seal around the core area.

[0057] Several other variations of the process can be employed to engage the elastic distribution with the core. As mentioned above, it may not be possible to directly add the elastic body to the core. For example, the elastic body can be added to the backing sheet and placed between the backing sheet and a second sheet or nonwoven sheet. The resulting composite is then bonded to the core. In this composite, specifically in the backing sheet that directly engages with and connects to the core, the elastic body within the backing sheet composite acts on the core to form the desired expansion and / or contour shape. In another exemplary variation, after adding the elastic body to the backing sheet, the core can be directly added on top of the elastic body (e.g., without an intermediate sheet). In any case, the elastic body, the sheet material, and the core are transported together to the forming roller, and just before reaching the forming roller, adhesive is applied to the material sheet and the elastic body.

[0058] In the core designs of Figures 6 and 7 of the cited U.S. Patent Application Publication No. 2011 / 0130736, the elastic body is added laterally to the center of a rectangular core, or, in certain embodiments, to both or one of two overlapping cores. The stretchability of the absorbent core structure generates a constricted central region in the stretchable core after tension is released in the elastic body, providing aesthetic and functional advantages to the absorbent article, as shown in the cited example. In another embodiment, the spacing or pitch between consecutive elastic bodies can be designed to generate more concave constricted central regions. This can be achieved, for example, by concentrating the elastic bodies more towards the center and making them sparser away from the center (see, for example, Figures 7C–7D of the cited example). Strategically placing elastic bodies between layered cores and other materials can provide the contoured core structure of Figure 8 (of the cited example) and the corrugated structure of Figure 9 (of the cited example).

[0059] Elastic composite web forming machine Figure 10 is a physical schematic diagram of system 1050, more specifically, the elastic composite web forming or joining machine 1000 of the system. The area (or region) within the dashed frame shows a set of system machine elements that output a desired web 1021 of web elements and separate elastic composites in one embodiment of system 1050 of the present invention. System 1050 of the present invention can be described as comprising a plurality of feed lines that converge in a predetermined manner to the joining machine 1000 to produce a predetermined moving web substrate 1021. The input feed lines are controlled to orient the elements of the product in the required quantity, speed, orientation, and lateral position for the web substrate product. Some input feed lines can be associated with “cutting and positioning” units that intermittently add individual units of material to the moving web. Furthermore, the input feed lines are controlled to converge in a desired sequence and at required speeds and engage with other input feed lines.

[0060] In the system 1050 of Figure 10, each element of the web substrate is preferably applied to the machine 1000 linearly or in series in the machine direction. Thus, all feed lines and output lines can approach the machine 1000 from the right, left, or above, but within a lateral window that does not exceed the axial length of the forming roller 1001 (in micro applications, not substantially wider than the width of the web substrate 1021a). The physical features of the system 1050 improve the controllability and flexibility of the process, including the ability to modify the properties of the finished absorbent article. The system of the present invention, and more specifically the machine 1000, occupies a small footprint. Furthermore, the machine 1000 packages itself as a modular, built-in unit.

[0061] As shown in the cross-sectional view of Figure 10A, the web substrate product 1021a is output by the machine 1000. When output from the machine 1000, the moving web substrate 1021a comprises a base surface sheet layer TS, an AD (acquisition and distribution) layer above the surface sheet TS, and a series of individual elongated cores C above the AD layer AD. On this, an intermediate nonwoven layer NW, a back sheet layer BS, and various elastic distributions E sandwiched between them are provided. The directional arrows in Figure 10 indicate the direction in which the composite web 1021a is folded. As shown, the web 1021a is folded so that the surface sheet layer TS rotates toward itself and is ultimately located inside the folded web. In the finished absorbent article when worn, the surface sheet TS is positioned adjacent to the wearer's body.

[0062] After emerging from machine 1000, the web substrate 1021a can be folded, sealed, and cut to produce disposable absorbent articles. These subsequent steps are considered post-joining steps performed after the delivery or output of the web 1021a. The folding step is performed at a folding station 1022 equipped with angled bars positioned directly in front of rollers 1001, 1002. The folding station 1022 directs the web 1021 into a series of rotations that invert and fold the substrate 1021a. Once folded, leg holes are punched, the side seams are sealed together, and then the web substrate is cut along the seams (producing individual pant products). These steps are described above with reference to, for example, Figures 4 and 5. Additional pre-packaging steps may also be employed after the sealing and cutting steps. In another embodiment, the leg cutout cutting and punching steps may be provided before the folding station 1022, immediately after the delivery of the web substrate output 1021a.

[0063] Furthermore, the post-joining step can be modified to provide a diaper product that is entirely different from the pants product. In such a modification, the side seam sealing step can be omitted. In this regard, the output of the web material only requires a splitting step to produce a separate diaper product. In another modification of the system, process, and product obtained from the system and process of the present invention, the web material output by the joining machine can be folded in the reverse direction to produce an improved pants product or diaper. Such products may require modifications to the input supply line to the joining machine, as detailed below.

[0064] Referring to Figures 10 and 10A, several stages of the joining process are shown as a sequence for joining various elements of the web substrate 1021a. The main elements of the machine are the main or forming roller 1001 and its corresponding sub-roller 1002. As shown in Figure 10, the input source 1011 of the backing sheet material is engaged by the forming roller 1001 and the distribution of the stiff elastic body 1012 and the distribution of the curved elastic body 1001, 1003 (as described above in more detail with reference to Figures 2A and 2B). The moving elastic web to be applied to the backing sheet is then engaged from above by the input source 1014 of the intermediate nonwoven. This engagement sandwiches the elastic body and intermediate nonwoven within the backing sheet. In another embodiment, a cutter roller can be added and engaged with the forming roller to selectively cut one or more elastic distributions sandwiched between the backing sheet and the intermediate nonwoven.

[0065] The resulting stretch web then engages with spaced and laterally oriented core input sources 1016. As described above, the cores are spaced to correspond to the center position of the final pants product and are aligned with the longitudinal centerline of the moving web and the forming roller 1001. The cores are preferably pre-cut into elongated rectangular shapes with respect to the longitudinal or mechanical direction and delivered. A cutting roller machine 1027 is located upstream of rollers 1001 and 1002 to receive a continuous supply of sheet core material from the supply roll 1029. Preferably, a second input source 1016 for a second core or ADL layer is oriented onto the resulting stretch composite (together with the core). In this example, a surface sheet input source 1017 engages with the elastic composite (together with the core) to provide a surface sheet layer on the core material. The resulting product is a moving web base material 1021 of stretchable absorbent composite that can be further processed to produce pants or diaper products.

[0066] In this system configuration, the web substrate 1021a is delivered with the back sheet BS facing upwards and the front sheet TS facing downwards. The continuous web 1021a is preferably sent to the folding station 1022, where the web 1021a is effectively inverted and folded. From there, the side seams of the web 1021a are sealed and separated to create individual elastic composites.

[0067] Reversal elastic composite material Another disposable absorbent article is generated in the system and process by changing the input supply line to the joining machine 1000. Another mobile web substrate 1021b of such a stretch composite is shown in a cross-sectional view in Figure 10B. The mobile web 1021b output by the joining machine 1021 provides a top layer, which is a surface sheet layer TS, and multiple elastic distributions E sandwiched between the surface sheet layer TS and the intermediate nonwoven layer NW. The core C, ADL layer AD, and back sheet layer BS make up the remainder of the elastic composite. Referring to Figure 10, such a composite web 1021b can be realized, for example, by switching the surface sheet feed 1017 with a back sheet supply source, possibly as needed, for the ADL and core input supply sources. Finally, the resulting web substrate is folded in the reverse direction (see arrow with folding direction) so that the elastic distributions E are inside the core C. By bringing the elastic body closer to the user, the surface sheet TS is brought closer to the wearer's body so that the stretch composite 1021b can more easily support and accommodate the contours of the wearer's body. The improved engagement of the surface sheet TS around the wearer not only enhances the fit, but also allows the surface sheet TS to be positioned more effectively to prevent leakage. In another embodiment, the process of the present invention can be employed to create stretch pockets around the surface sheet / intermediate nonwoven subcomposite or core by adding a sinusoidal or other curved elastic distribution around the core. The introduction of such upwardly biased pockets also facilitates the use of one or more central holes for space utilization between the core and the surface sheet / intermediate nonwoven.

[0068] Disposable absorbent articles with a reusable outer shell and a disposable absorbent core insert. Disposable absorbable core inserts Figures 16–23 show preferred variations of disposable absorbent core inserts suitable for engaging with an outer shell according to this disclosure (the same elements are shown using the same reference numerals). Figure 25 shows that according to this disclosure any one of the core inserts 1910 is incorporated together with the outer shell. These preferred core inserts 1910 provide a desired shape and are elasticized to improve engagement and retention by the outer shell. First, referring to Figures 16–18, a basic disposable absorbent core insert 1910 preferably includes a backing sheet 2014, a permeable surface sheet 2018 (shown in Figure 16, but cropped in Figures 17 and 18 to show the core layer 2016 and backing sheet 2014), and an absorbent core layer or core section 2016 positioned between the backing sheet 2014 and the permeable surface sheet 2018. The material layers 2014, 2018 are of nonwoven sheet origin in most applications. Optionally, the core insert 190 may include an ADL layer, a tissue layer, or a nonwoven sublayer.

[0069] Typical surface sheet or top layer materials suitable for core inserts include water-permeable nonwoven sheets made from polypropylene or polyethylene fibers, or spunbond materials. Surface sheet materials may also be provided by perforated nonwovens or perforated films. Suitable back sheet or bottom layer materials for core inserts include water-impermeable sheets such as polyethylene films or composites of polyethylene films and nonwoven materials. Suitable back sheet materials are also very hydrophobic nonwoven materials that have high resistance (water head test) to water flow through the material.

[0070] The support of the absorbent core layer 2016 can be provided by cellulose bristles and superabsorbent polymer (SAP), airlaid, or cellulose-free core. More detailed examples of suitable absorbent core structures or compositions can be found in the following patent publications, namely U.S. Patent No. 6,794,557, U.S. Patent No. 8,148,598, U.S. Patent Application Publication 2012 / 0175056, U.S. Patent Application Publication 2014 / 0180230, U.S. Patent Application Publication 2014 / 0276508, U.S. Patent Application Publication 2014 / 0303582, and U.S. Patent Application Publication 2015 / 0045756. Each of these publications, by clearly indicating its source, constitutes part of this application and forms part of this disclosure. Furthermore, the composition of the absorbent core layer is preferably further formulated and configured to achieve desired stiffness in a target region, such as the central region, in order to achieve and promote the desired shape as described in more detail above. Furthermore, the absorbent core layer is preferably supplemented by a stiffening structure or stiffening material positioned adjacent to the target region (described in detail below). For example, the stiffening material is preferably provided by airlaid cellulose or a high-basis-weight nonwoven fabric, and its shape i may be circular or rectangular, or it may be added as a strip. In many applications, the stiffening material is positioned centrally and provides increased longitudinal stiffness.

[0071] The core composition may also be formulated to provide areas that function as stiffening regions. For example, some regions may comprise more absorbent particles (SAP) or absorbent materials of higher density. Alternatively, such regions of absorbent composition may be supplemented with other particles, fibers, or other material layers to increase the density, thickness, or stiffness of the target region. In some embodiments, a hot-melt adhesive may be provided or increased in the target region.

[0072] Suitable materials for providing stiffening sections in core inserts include high-basis-weight nonwoven fabrics, airlaid cellulose materials, and wet-process cellulose materials. Stiffening sections or stiffening materials can also be formed by compressing regions of absorbent material. In another embodiment, the core insert may have different compression zones that produce different degrees of stiffening (for example, as employed in soft-hair superabsorbent polymer cores). Stiffening sections provided by high-basis-weight regions of the core may be formed by adding a more superabsorbent polymer, a more nonwoven fabric, or a more hot-melt adhesive in the region of interest.

[0073] The stiffeners can be used in any portion of the core insert to promote a flat appearance in a certain region or to promote bending in a region along a (bend line) between two stiffeners. In some embodiments, the stiffeners are preferably located in a central target region to resist bending along the core centerline or center point. Alternatively, the two stiffeners may be located on either side of the core centerline (typically the lateral centerline) to promote bending along a desired region or bend line that coincides with the gap between the two stiffeners (see, for example, Figures 23, 37A, and further description below).

[0074] The core layer may also consist of pockets or aggregates of superabsorbent particles, as is known in the art. The shape and dimensions of these pockets, or their components, may vary in different regions to achieve certain stiffness and bending properties. The pocket pattern, determined by the bending pattern, may be designed to achieve specific stiffness. Furthermore, the bonding method (e.g., point bonding, solid bonding, etc.) may vary (see, for example, U.S. Patent Application Publication No. 2014 / 0180230 and U.S. Patent No. 8,148,598).

[0075] The disposable core insert 1910 preferably has a rectangular (Figures 16 and 17) or hourglass (Figure 18) shape, influenced by the presence of multiple elastic yarns between the surface sheet 2014 and the back sheet 2018, and the incorporation of a stiffening structure or material. Preferably, one to three elastic yarns are arranged around the core layer or core section, adjacent to the core layer or core section, or adjacent to the side of the core section. The elastic yarns 2020 are arranged generally along the long side of the absorbent core layer 2016, or generally parallel to the long side of the absorbent core layer 2016. The elastic yarns 2020 are preferably arranged linearly or in a straight line (parallel to the side of the core, as shown in Figures 16-18) so as to form a rising gather or cuff only on the side of the core. The elastic yarns 2020 gather and lift the material (i.e., the nonwoven surface sheet and back sheet) around the side and edge of the core insert. The result is a rise cuff on the sides and, in some designs, at the end of the core insert 1910. See, for example, Figure 23. More preferably, the elastic twisted yarn 2020 is shaped by adding strands to a curved shape so that the front and rear cuffs of the core insert curve inward, as shown in Figures 19–21. In other designs, the elastic twisted yarn 2020 is often further curved to substantially or completely surround the absorbent core layer 2016, so that the rise cuff surrounds the absorbent core layer 2016, as shown in Figures 22A–22C and Figure 23. By completely surrounding the absorbent core layer, the leg gathers provide a continuous leak barrier along the sides, front, and rear of the absorbent core layer, helping to conserve multiple uses of the outer shell.

[0076] Figures 16–18 show an absorbent core insert 1910 characterizing a combination of elastic yarn 2020 and a specifically shaped absorbent core layer. Figure 16 shows a surface sheet 2018 partially cut out to reveal the bottom back sheet 2014, core layer 2016, and elastic yarn 2020. Figures 17 and 18 show a top sheet 2018 fully cut out to reveal all the components of the core insert below. (See also Figures 13–15 for cross-sectional views showing the relative arrangement of the basic components of the core insert 1910.) In the shown application examples, the elastic yarn 2020 is arranged linearly, starting from and spaced along the long side of the core layer. Figures 19–21 show an absorbent core insert using curved elastic yarn 2020. In some of these application examples, the elastic twist 2020 is preferably in contact with or engaged with the absorbent core layer 2016 (either on the side of the backing sheet or the side of the fronting sheet). Figures 22A–22C provide another variation of an absorbent core insert in which curved elastic twists on both sides of the core layer 2016 come together. In the configurations shown in Figures 22A and 22B, the elastic twist 2020 substantially surrounds the core layer 2016 and intersects or meets at or near the apex and bottom edges of the absorbent core layer 2016 (the edge regions of the core insert) so as to surround the core layer 2016. Such elastic twists are typically oriented substantially longitudinally on the moving web (of the absorbent core composite), attached, and periodically changed (laterally) while attached to achieve the desired pattern and curvature. The elastic twists are preferably added to the moving web, including the backing sheet, before or after the core layer is attached to the web. In Figure 22C, the elastic twists 2020 intersect or meet at central positions on both sides of the core layer 2016 (away from the apex or basal edge regions). These elastic twists are typically added transversely to the longitudinal length of the core insert on the moving web.

[0077] In the application examples shown in Figures 22A-22C, the portion of the elastic twisted yarn 2-20 is in contact with the core layer 2016, or is preferably added directly above or below the core layer. As will be explained in more detail below, the extent and location of engagement between the elastic body and the core layer ultimately affects the shape and bias of the core insert, as well as its retention within the outer shell.

[0078] In alternative applications, the elastic twisted yarn may be positioned at a further outward spacing from the periphery of the core layer. The absorbent core insert 1910 in Figure 23A is such an application and is also a variation of the elastic form in Figure 22C. The elastic twisted yarn 2020 is positioned at a spacing away from the periphery of the core layer 2016, surrounding the core layer 2016. As shown in the perspective view in Figure 23B, the tension of the elastic twisted yarn 2020 forms leg gathers on both sides of the core layer 2016, and further lifts the back sheet and / or front sheet material of the core insert 1910 above the core layer 2016, forming a rising barrier 2024 around the core layer 2016. The upper and lower edge regions of the core layer are characterized by dam-like structures 2026 formed by the gathered material (e.g., gathered front and back sheet material). The elastic body 2020 also biases the end region inward, further contributing to the formation of cup or bucket-shaped core sections and core inserts.

[0079] Preferably, the elastic body (e.g., elastic yarn or filament) within the core insert is sandwiched between two sheet layers (a surface sheet and a back sheet) and is connected to both layers along the side and / or end edges. Thus, the elastic body acts to shrink to the smallest possible length. Referring to Figure 23A, the shorter length of the elastic body is achieved during shrinkage when the end or side edge moves out of the plane of the absorbent core layer or section, crossing over the core and forming a smaller loop of the elastic body (see Figures 23B, 28A-28B).

[0080] Figure 24 is a perspective view of the stretchable absorbent core insert 1910 utilizing the elastic form shown in Figure 22C. As shown in Figure 24, the portion of the elastic body 2020 is positioned below the core layer 2016 and adjacent to the back sheet 2014 (or base layer), while the portion along the sides is positioned at a distance away from the core layer 2016. The lateral portion rises above the core layer 2016 and also lifts the material of the surface sheet 2018 and the back sheet 2014. The edge portions of the core layer 2016 are lifted, biasing the edge regions of the core insert 1910 inward so that they move closer together. This results in a cup-shaped absorbent core insert with a circular lifted perimeter formed by the lateral leg gathers 2022 and the lifted edge regions. The circular rising cuff 2024 provides a continuous leak barrier around the core layer 2016.

[0081] As suggested above, the stiffening structure is preferably incorporated to achieve the desired shape of the core layer and the overall shape of the core insert. The stiffening portion is preferably added to or positioned near the center of the core section 2016 in Figures 23 and 24, for example, to provide resistance to the biasing action of the elastic body and to facilitate bending and shaping around the core layer. Furthermore, the stiffening portion can also facilitate the formation of a projection used to attach the core insert 1910 to the outer shell 1912, as will be described in more detail below (and also shown in and described in relation to Figure 23E).

[0082] Figures 23C–23E provide section elevations of exemplary resilient disposable core inserts 1910, highlighting the curved and end-biased contours of the core insert 1910 (the lateral edges of the leg cuffs are intentionally omitted). The core insert 1910 typically includes a nonwoven top layer 2018, a nonwoven bottom layer 2014, and an absorbent material layer or section 2016 sandwiched between the nonwoven top layer 2018 and the nonwoven bottom layer 2014. In Figure 23D, the core insert 1910 includes a single stiffening section S of a material that is stiffer and harder than the nonwoven and absorbent material layers. The area of ​​the stiffening section S is relatively flat compared to Figure 23C, but the resilient core insert maintains a curved contour and lifted end region (dam barrier, DB). In Figure 23E, the core insert 1910 includes a pair of spaced-apart stiffening sections S. The arrangement and juxtaposition of the stiffening sections S create relatively weak regions that become fold lines or fold regions F. In this embodiment, the two stiffening sections also help to shape the central protruding section P (or the protruding section which is configured as a portion that protrudes outward from the rest of the section).

[0083] Figures 28A and 28B are exemplary lateral cross-sectional views of a core insert according to this disclosure, such as the core insert of Figure 23A (the same elements are indicated by the same reference numerals). Both figures show loops of elastic bodies (E) positioned around the absorbent material layer of the core insert to form a perimeter lift leg cuff (LC) including a dam barrier (DB) in the end region. Figure 28B shows another use of stiffeners (S) positioned at intervals in the lateral or cross-mechanical direction to help form a pair of bends (F). The bends (F) help form bundles or plugs (projections) P that can be inserted into retainer clips of the outer shell. The bundles or plugs are then removably attached to or held in the retainer clips, thereby removably attaching the core insert to the outer core.

[0084] The curved elastic body shown in Figure 23 is preferably added using the methods and techniques previously described with respect to Figures 1-11. In this method, the elastic body feeding system is moved laterally (relative to the longitudinal or mechanical direction of the web) to establish an elastic distribution that periodically approaches or intersects the web, forming a series of annular regions. For example, the elastic body is preferably added to establish a sinusoidal pattern. In these applications, the range of lateral displacement must be sufficient to open the core section. The regions where the elastic body intersects are periodically positioned between the core section addition locations.

[0085] The curved elastic bodies shown in Figures 21, 22, and 23 are also preferably added using the methods and techniques previously described with respect to Figures 1-11. However, the elastic bodies are preferably added in a cross-machine direction, opposite to the previously described machine direction. Alternatively, some components, or the entire composite forming the web to be processed, may be oriented 180° from the previously shown orientation to add the required distribution of elastic twists in the machine direction.

[0086] Outer shell Figure 25 shows how the core insert 1910 can be easily attached to or removed from the outer shell. The illustrated combination is a semi-closed training pant 1906. The core insert 1910 is received within the shell 1912 of the garment 1906, but can be easily removed from the shell 1912 of the garment 1906 by separating the core insert 1910 from the shell and removing the core insert 1910 through the waist opening 1990 of the garment.

[0087] Figures 26–30 show variations of an outer shell 1912 suitable for receiving and holding a disposable absorbent core insert 1910 according to the present disclosure. The outer shell is designed to be reused with a number of absorbent core inserts (at least 10–30). Therefore, the outer shell is made from a material that is more durable than the inserts. Suitable materials include high-basic-weight polypropylene or polyethylene materials (>20 gsm), or natural materials such as cotton, or jersey fabric. In one embodiment, the outer shell is made from at least two layers of synthetic nonwoven fabric and a number of elastic yarns placed between the two layers. Preferably, the elastic yarns are distributed to provide elasticity around the waist and leg openings. Such elastic yarns are better established between the two layers as described above with respect to Figures 1–18. Alternatively, the core shell can be shaped by folding and adding darts.

[0088] The outer shell is preferably made from a washable material such as cotton jersey fabric. In such embodiments, the outer shell is preferably garment-like and may include elastic twists, folds, seams, and darts to produce a suitable shape and good fit.

[0089] The outer shell 1912 of the disposable absorbent assembly in Figure 26 features a multi-elastic distribution including a pair of elastic bodies 2636 spanning each lumbar region and a pair of elastic bodies 2638 around each leg (as described above in this application). The core insert 1910 is located in the groin region between the lumbar region and the pair of elastic bodies 2638 around the leg regions. In this embodiment, only two to three widely spaced elastic bodies of the lumbar elastic bodies lie beneath the core insert 1910. The majority of the core insert 1910 sits on the region of the outer shell 1912 that lacks elastic bodies. However, the core insert 1910 includes an elastic body 2620 that transverses laterally (i.e., laterally with respect to the longitudinal length of the outer shell 1912 and the core insert 1910) and surrounds most of the core layer 2616. These surrounding elastic bodies 2620 help to promote the cup or bucket shape of the core insert 1910 described above with respect to Figure 24.

[0090] In the disposable absorbent assembly 1908 of Figures 27A and 27B, the outer shell features a lumbar elastic body 2736 and a number of alternating elastic distributions, including a pair of elastic distributions 2740 that traverse the central portion of the outer shell 1912. The elastic bodies 2740 intersect to form a small elasticized annular region 2742 that ultimately occupies the center of the groin area. The core insert 1910 is centered on this annular region 2742. This centered elasticized annular region 2742 also facilitates the shaping of the outer shell 1912 to accept and hold the specially shaped core insert.

[0091] An elastic body arranged in an annular shape on the outer shell (chassis) forms a loop around the central region of the outer shell material. When the elastic loop makes contact, an excess portion of material is created within the loop that bulges or protrudes outward to form a cup shape or bag (receptacle), and within the receptacle a removable male corresponding portion on the core insert, i.e., a removable insert plug, can be received. A preferred design would have a larger “annular loop region” (see the elastic form in Figure 7). The dimensions of the loop match the dimensions of the insert plug so that the insert fits snugly into the cup created by the contraction of the annular loop elastic body. The elastic loop, and the receptacle formed within the elastic loop, form part of the retaining structure, or retainer, or receiver of the outer shell for removable engagement with the core insert (as described in detail below).

[0092] Easily removable core insert An important feature of the absorbent core insert-outer shell combination is the means for attaching the disposable core insert to or within the outer shell. Such attachment means can borrow from prior art, such as hook and loop systems or adhesive solutions. For example, three to five hook fasteners, which can engage with loop fasteners on the outer shell, may be arranged on the outer surface of the backing sheet of the insert. Alternatively, the hook fasteners may be arranged on the inner surface of the outer shell and configured to engage with aligned loop fasteners on the disposable core insert. In one embodiment, the loop fasteners are provided by a nonwoven material that completely covers either the outer surface of the backing sheet of the core insert or the inner surface of the outer shell. On these areas, elastic twisted yarn may be provided to gather the nonwoven material and produce an improved loop fastener (by increasing the surface area of ​​the loop material). In particular, the elastic twisted yarn also advantageously imparts stretchability and elastic properties to the same area. Alternatively, the core insert may be attached to the outer shell using snap buttons (poppers). These fasteners are positioned at the four corners of the absorbent core insert and are best aligned with the receiving fasteners on the outer shell.

[0093] In another embodiment, other means may be used to easily engage and attach the absorbent core insert within or to the outer shell. In some applications, a hook-and-loop fastening system may be used as a supplementary means for further stabilizing the absorbent core insert within the outer shell. For example, the hook-and-loop system may be located in the center or in the edge region between the absorbent core insert and the outer shell, while other means may be used in other regions.

[0094] In one embodiment, a small soft clip is attached to the inside or outside of the outer shell. Referring to Figure 13, a clip 2850 on the outside of the outer shell 1912 forms a recess or receptacle 2852 near the center of the outer shell. The clip may be formed from a soft silicone material or a dental gel-type material. As suggested above, the elastic body incorporated within the outer shell may be positioned to improve or facilitate the shape or concentration of the receptacle 2852. Figure 14 shows a core insert 1912 with a projection 2854 having an elongated shape that matches the shape of the receptacle 2852. Typically, the desired shape of the absorbent core insert 1910 is achieved by the strategic arrangement of elastic twists. For example, the elastic body may be arranged in a sinusoidal pattern or along the machine direction in the absorbent core insert to form a U-shape in the center of the insert body.

[0095] As shown in Figure 15, the projection 2854 formed on the absorbent core insert readily fits into the receptacle 2852 in the central region of the outer shell and matches the shape of the receptacle 2852. The corresponding shape of the outer shell is similarly generated by establishing a specific elastic form on the outer shell.

[0096] In another embodiment, the absorbent core insert may be shaped differently (e.g., locally) to easily match, engage with, or conform to the shape of the corresponding outer shell, or components or areas of the outer shell. Furthermore, such mounting means may be supplemented by a hook-and-loop system, mounting flaps, and / or fasteners for receiving and holding the core insert within the outer shell. In any such design or combination of designs, consideration must be given to providing a smooth and comfortable surface for contact with the wearer. The core insert also preferably should be easily attached to and removed from the surface of the outer shell (to facilitate handling and consistent placement and to minimize spillage during core insert replacement).

[0097] Alternatively, the outer shell may be bent and elasticized to form flaps at both end regions, as shown in Figures 29–32. The flaps receive and hold the leading and trailing edges of the absorbent core insert, thereby securing the core insert within the outer shell. Figures 29A and 29B show one variation of a flap 2960 formed by bending one or both end edges of the material layer of the outer shell 1912 inward. The flap receives and holds the ends of the core insert in place. In this example, a snap fastener 2962 is used to hold the ends of the flap 2960 while maintaining a gap for receiving the core insert. To remove and discard the core insert, the ends of the core insert can be easily detached from under the flap and / or the fastener can be released. Adhesives or other mounting means such as a hook-and-loop system may also be considered for use. The flap may also be equipped with an elastic body that stiffens and / or biases inward to hold the core insert. In particular, flaps can also provide a dam or barrier that helps contain leakage from the core insert.

[0098] In the embodiments shown in Figures 30A and 30B, the flap 3060 is generated from excess material of the surface sheet or top material layer of the outer shell. The flap is elasticized by a plurality of elastic bodies located at the bend and is biased inward (towards the core insert 1910). In the illustrated embodiments, the flap 3060 has sufficient bias or tension to hold the edge region of the core insert 1910. No additional mounting means are incorporated into the flap 3060 and the outer shell 1912.

[0099] Figures 31-32 show flaps incorporating snap fasteners (using the same reference numerals to show the same elements). In Figures 31A-31D, snap fasteners 3612 are used, but one or more of the fasteners are positioned more inward toward the center of the flap to provide a more reliable grip on the core insert. In the embodiments shown by Figures 32A-32B, the ends or periphery 3270 of the flap are welded or joined to secure the folded shape.

[0100] In addition to the above, clips, or some other matching of the product shape and elasticity, may help to keep the insert centered in the product. Thus, it is clear that, while also considering cost and manufacturing, a combination of mounting means can be used to achieve the desired stability of the core insert within the outer shell, and / or easy acceptance.

[0101] In various embodiments, means for removably attaching an absorbent core insert to an outer shell can be achieved by a hook-and-loop system. Any hook or loop portion of any individual hook-and-loop pair can be provided on the outer shell or on the back sheet of the absorbent core insert. Figures 33A–33C each show preferred locations of hook patches on the core insert 1910. However, it is clear that the illustrated hook patches can be attached on corresponding locations on the outer shell. Furthermore, it is clear that any such pair of loop portions can be provided on the outer shell or on the surface of the nonwoven layer of the absorbent core insert. In the latter case, the hook region on the outer shell only needs to be provided once (for each core insert), thereby reducing material costs. Figures 34A and 34B show the effective use of an elastic body 3420 in the absorbent core insert or outer shell to improve the performance of the nonwoven layer 3414 as a source of loop elements. The hook attachment portion 3480 (for example, a patch on the back sheet of the core insert) is shown above the region of the elastic composite material of two nonwoven layers 3414, 3418 and elastic twisted yarn 3420 positioned between the two nonwoven layers 3414, 3418. If the elastic composite material were in the region of the core layer, only one nonwoven layer would be shown. Figure 34A shows a nearby region fully stretched. The hook element 3482 of the hook attachment portion 3480 is shown disengaged from the nonwoven layer 3414. When the elastic region is loosened, the gathers of the nonwoven material protrude, providing or highlighting fibers or filaments that function as loop elements. In this state, the nonwoven fabric engages more easily and more sufficiently with the hook element 3482.

[0102] Hook elements or hook fasteners can also be formed on a desired nonwoven surface by an ultrasonic bonding method (ultrasonic bonding forming hooks; see, for example, U.S. Patent No. 8,784,722, “Method and Apparatus for Manufacturing Hook Fasteners,” for a description of a suitable method). By this method, the hooks can be formed directly on the substrate, preferably on the PE backing sheet. The hooks can be positioned in any form at any suitable location for positioning the core insert-outer shell.

[0103] Hook fasteners can also be used to add stiffness to specific areas (of the core insert) due to their inherent rigidity. Hook fasteners also impart stiffness by the joining member and by immobilizing the affected component. For example, if necessary, the fastening area of ​​the target band can have added stiffness. Conversely, bending can be facilitated by appropriately positioning the fasteners. For example, in the crotch area, if a V-shaped bend is advantageous, its shape can be facilitated by positioning two hook fastener strips on either side of the longitudinal centerline. The composite can then bend more easily along the mechanical direction (MD) centerline. In addition, bending can be improved if the outer shell is elasticized (for example, as provided in the chassis configurations shown earlier in Figures 1-11).

[0104] In another embodiment, a secondary disposable nonwoven layer may be provided on the shell and beneath the core insert. Such an additional nonwoven layer may be made of a low basis weight meltblown nonwoven fabric. This additional sublayer is not only intended to be separated from the core insert but is also removable from the inner surface of the outer shell for disposal. To make it removable (and disposable), the additional sublayer is fitted with a peelable pressure-sensitive adhesive that is applied to the inner surface of the outer shell or to part or all of the implantation area on the outer shell. Alternatively, the additional sublayer may be fitted with an adhesive or other adhesive means for removable attachment to the inner surface of the outer shell. Thus, multiple sublayers may be used with one outer shell, and multiple core inserts may be used with one sublayer. Positioned beneath the core insert, this additional disposable sublayer helps to capture and / or absorb waste spills or contaminants that might otherwise reach the outer shell. This minimizes cleaning and contamination of the outer shell, thereby extending or promoting its further use. In another embodiment, the disposable absorbent article comprises a number of removable layers.

[0105] Referring to Figure 35, in another embodiment, a plurality of spaced fastening strips 3505 (oriented in the mechanical direction) are provided on the inner surface of the outer shell 3505 (of the implantation region 3507) that are removablely engageable with a core insert 3513 (shown only by dashed lines in Figure 35). Figure 35A provides a transverse (CD-direction) cross-sectional view of a disposable absorbent article having an outer shell 3505 and a removable core insert 3513 (the core insert 3513 is shown in a simplified form) supported on the inner surface of the outer shell 3505. The fastening strips 3515 are spaced apart and thus secure the core insert surround 3513 at regular intervals as shown in Figure 35A. Such arrangement of the fastening strips facilitates the formation of numerous corrugations 3517 within or beneath the core insert enclosure 3513, which also creates corresponding void spaces between the core enclosure 3515 and the outer shell 3505, and between the fastening strips 3511. In another embodiment, corrugation is enhanced and aided by the resilience of the outer shell 3505 on the chassis (and sometimes on the core insert). In the embodiment of Figure 35, a transverse resilience 3519 is provided. Extending longitudinally, the void space provides a channel 3517 that contributes to improved air exchange between the absorbent article and the external environment, acting as a channel 3517. This provides not only comfort but also potentially lower relative humidity, thereby promoting skin health. Such configuration also extends the lifespan of the outer shell and facilitates an increase in the number of core inserts used with the outer shell.

[0106] In another embodiment, the fastening strip extends toward and near the longitudinal edge of the core insert, ensuring the channel extends to the same edge. In this way, communication between the channel and the outside air is improved. In yet another embodiment, the void space or channel extends laterally or transversely.

[0107] Figures 36 and 36A illustrate alternative embodiments that utilize different arrangements of fasteners to form an alternative channel shape, with the same elements indicated by the same reference numerals. In other words, Figure 36 employs a different arrangement of removable fastening points between the core insert and the outer shell to form a channel. In other words, different types of fasteners can be used insofar as the arrangement of fasteners provides an arrangement of spaced fastening points to produce the desired gap space 3617 (forming the channel 3611). In Figure 36, the elongated strip is replaced by discrete fastener pads. Each fastener pad 3611 provides a large portion of the fastening point, thereby creating a concentrated recess (when viewed from above). As a result, the pillow-like structure improves the comfort and feel of the insert.

[0108] The use of transverse elastic bodies (within the outer shell chassis) in the configurations of Figures 35 and 36 provides a more prominent channel with a relatively larger volume. By concentrating the elastic bodies in the center and extending the channel longitudinally, a favorable gradient of channel volume is formed (larger in the elasticized band and smaller elsewhere). The function and benefits of air gaps still exist because the outer shell is air permeable and air exchange is improved. Secondly, since disposable absorbent articles are typically wetter in the groin area, the arrangement of elastic bodies and more prominent channels in the central area is optimal.

[0109] The aforementioned void spaces or channels can also be provided by an absorbent core insert composed of the above-mentioned pockets, or by aggregates of superabsorbent particles. The pocket pattern forms void spaces and channels between the pockets, thereby also providing the above-mentioned pillow-like structure. Suitable bonding patterns are found in WO2015 / 002934A2 and WO2014 / 145312A2, respectively, which are now assigned to the assignee of this application (both of which, by indicating the source, are considered part of this disclosure for all purposes). A preferred bonding pattern is provided in Figures 15A–15D of WO2014 / 145312A2. It should be noted that the bonding pattern or configuration is formed on both sides of the core insert. Thus, the side of the outer shell facing the implantation portion will be configured in this manner.

[0110] As described above, the air gap between the outer shell and the absorbent core insert facilitates air exchange between the moist interior and exterior environment of the diaper, thereby reducing the overall relative humidity inside the diaper. This condition leads to drier skin and better skin health.

[0111] Figures 37 and 37A illustrate an alternative embodiment using a stiffener to facilitate the V-shaped bend, where the same elements are indicated by the same reference numerals. In this embodiment, a hook fastener 3711 is used as both a fastener and a stiffener. Made of a more rigid material, the hook fastener serves a dual role as both a stiffener and a fastener, forming the V-shaped bend when worn. See Figure 37A.

[0112] Figure 38 shows embodiments (A, B, C) of the disposable absorbent article according to the present disclosure as worn by a user. Embodiment AC shows the arrangement of a core insert-outer shell retainer 3810 in the form of a clip-and-plug combination at different placement locations. The clip is preferably made of soft plastic. Embodiment AC also shows an exemplary elastic form for an outer shell chassis suitable for use with the insert. One or more retainers may be used. Preferably, the retainer is positioned along the centerline of the outer shell-core insert. Furthermore, the retainer clip (on the outer shell) is preferably mounted on the outside or inside of the outer shell. The retainer clip may also be permanently fixed or removable.

[0113] Figures 39A-39B illustrate details of an alternative core insert-outer shell retainer 3902 for use with disposable absorbent articles according to this disclosure. As shown in Figure 39A, for example, a bundle of protruding core inserts 3902 (protrusions or plugs) is gathered within the narrow jaws of a clip 3912 to hold the core insert 3910. In Figure 39B, the retainer or clip 3912 is mounted on the inside of the outer shell 3913. Reinforcements may be used to assist in the mating of the insert bundle or plug 3914 into the retainer clip 3912. In Figure 39C, two reinforcements 3930 are provided on the tip or apex of the bundle or plug. In this arrangement, the reinforcements 3930 assist in the actual insertion and retention of the core insert (plug) into the retainer clip. In Figure 39D, the stiffening portion 3930 is provided on the portion of the core insert that remains outside the retainer clip when the core insert is removably engaged with the outer shell. The stiffening portion does not form part of the core insert bundle or plug. However, the stiffening portion adds shape and functions to orient the bent portion that constitutes the bundle or plug, as shown in Figure 39D.

[0114] As described above, the disposable absorbent articles of this disclosure provide means for removably engaging a core insert by fastening it to an outer shell so that a new insert can be subsequently fastened to the same outer shell for further use. While engaged, the core insert is held within the outer shell for use using the same removable engaging means. Preferably, the fastening means includes a retaining structure or retainer on the outer shell for engaging, receiving, and holding the core insert. Furthermore, the fastening means preferably includes a receptive or insertable device or structure on the core insert for being received and removably held within or by the retaining structure. However, the fastening structures on the outer shell and the core insert may each be switched. Although preferred arrangements are described, any combination of fastening structures described in this application, including combinations of fasteners and fastening systems such as receptacles (or recesses) and protrusions (or plugs), hooks and loops, may be switched.

[0115] Although the present invention and its advantages have been described in detail, it should be understood that various modifications, substitutions, and alternatives can be made without departing from the spirit and scope of the invention as set forth in the appended claims. Furthermore, the scope of this application is not intended to be limited to specific embodiments of the processes, machines, manufactures, combinations of matters, means, methods, and steps described herein. As will be readily apparent to those skilled in the art from the disclosure of this application, existing or subsequently developed processes, machines, manufactures, combinations of matters, means, methods, or steps that perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein can be utilized in accordance with the present invention. Accordingly, the appended claims are intended to include, within their spirit, such processes, machines, manufactures, combinations of matters, means, methods, or steps.

Claims

1. A disposable absorbent assembly, wherein the disposable absorbent assembly is Outer shell and The outer shell comprises a disposable absorbent core insert that is removably engaged with the outer shell, the core insert comprising an absorbent core material section having an absorbent composition, A fastener spaced apart between the core insert and the outer shell, the fastener removably engages the core insert with the inner surface of the outer shell, and further includes an arrangement of spaced fasteners to form a gap space between the fastener, the core insert, and the outer shell, the gap space providing an air channel. A disposable absorbent assembly in which the air channels extend longitudinally, and a transversely elastic body is positioned in the center of the outer shell to provide a channel with a larger volume so that a gradient is formed in the channel volume of the air channels.

2. The aforementioned core insert is The top material layer, A base material layer and, The absorbent core material section includes an absorbent core material layer disposed between the top material layer and the base material layer, The disposable absorbent assembly according to claim 1, wherein the arrangement of fasteners arranged at the aforementioned intervals includes fasteners for attaching the core insert to the inner surface of the outer shell such that the core insert is removable from the inner surface of the outer shell.

3. The disposable absorbent assembly according to claim 1, wherein the fastener between the core insert and the outer shell forms the air channel.

4. The air channel is elongated in the longitudinal direction, as described in claim 1 of the disposable absorbent assembly.

5. The disposable absorbent assembly according to claim 4, wherein the air channel extends toward the longitudinal edge of the core insert.

6. The aforementioned fastener is, The disposable absorbent assembly according to claim 5, comprising a plurality of fastening strips provided on the inner surface of the outer shell and engaged with the core insert.

7. The disposable absorbent assembly according to claim 1, wherein the core insert includes pockets of superabsorbent particles, the pockets providing a pocket pattern that forms the void spaces and air channels between the pockets.

8. The disposable absorbent assembly according to claim 5, wherein the fasteners are a plurality of fastening strips, a plurality of corrugations are in the core insert, and the void space is between the core insert and the outer shell, and also between the fastening strips.

9. The disposable absorbent assembly according to claim 5, wherein the fasteners are a plurality of fastening strips, a plurality of corrugations are located beneath the core insert, and the void space is located between the core insert and the outer shell, and also between the fastening strips.

10. The disposable absorbent assembly according to claim 6, wherein the fastening strip extends toward the longitudinal edge of the core insert.

11. The disposable absorbent assembly according to claim 1, wherein the fasteners arranged at the aforementioned intervals include discrete fastener pads.

12. The disposable absorbent assembly according to claim 1, wherein the air channel extends outward from a central region beneath the disposable absorbent core insert.

13. The disposable absorbent assembly according to claim 1, wherein the fastener is a fastening strip.

14. The disposable absorbent assembly according to claim 1, wherein the outer shell includes a transversely elastic body.

15. The disposable assembly according to claim 14, wherein the outer shell is made of at least two layers of synthetic nonwoven fabric.

16. The disposable assembly according to claim 15, wherein the transverse elastic body is disposed between two layers of the synthetic nonwoven fabric.

17. The disposable absorbent assembly according to claim 1, wherein the outer shell is made of a nonwoven fabric.

18. The disposable absorbent assembly according to claim 17, wherein the nonwoven fabric is a polypropylene nonwoven fabric.

19. The disposable absorbent assembly according to claim 17, wherein the nonwoven fabric is polyethylene nonwoven fabric.

20. The disposable absorbent assembly according to claim 1, wherein the fastener includes a hook and a loop fastener.

21. The disposable absorbent assembly according to claim 1, wherein the fastener includes a clip on the outer shell and a projection on the core insert.

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