Absorbent article with waist relief feature

An absorbent article includes a liquid pervious bodyside liner; a liquid impervious outer cover; and an absorbent core positioned between the bodyside liner and the outer cover. The absorbent article defining a crotch portion connected between a front portion and a back portion; the front portion includes a front waist region, a front waist edge, and a front waist relief area. The front waist relief area is defined in part by a first material cut edge and a second material cut edge wherein the second material cut edge extends beyond the first material cut edge to define a fringe.

BACKGROUND OF THE INVENTION

The umbilical cord of newborn infants is a very sensitive area during the first weeks of life. Doctors recommend minimizing contact with this area during the healing process. As such, some absorbent articles have been provided with a cutout in the front portion of the article to accommodate the umbilical cord area. However, some of the currently available cutouts may have stiff edges that may occasionally rub against the umbilical cord. Thus, there is a need for a waist relief feature having a soft edge to minimize irritation and a need for a method to make said feature.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides an absorbent article having a liquid pervious bodyside liner, a liquid impervious outer cover, and an absorbent core positioned between the bodyside liner and the outer cover. The absorbent article has a crotch portion connected between a front portion and a back portion. The front portion includes a front waist region, a front waist edge, and a front waist relief area. The front waist relief area is defined in part by a first material cut edge and a second material cut edge. The first material cut edge defines a first relief depth of at least 10 mm and the second material cut edge defines a second relief depth wherein the second relief depth is at least 3 mm less than the first relief depth.

In various embodiments, the first material may be the outer cover and the second material may be the liner. In some embodiments, the first material may be the outer cover and the second material may be a waist elastic. In some embodiments, the first material may be the outer cover and the second material may be an outer cover facing material. In some embodiments, the first material may be the outer cover and the second material may be the fastener landing material.

In some embodiments, the front waist relief area defines a width and the second material cut edge extends beyond the first material cut edge by the same amount along substantially the entire width of the front waist relief area. In some embodiments, the first material has a first relief depth of least 20 mm and a first relief width of at least 60 mm. In some embodiments, the second material has a second relief depth of less than 3 mm.

In some embodiments, the second material cut edge extends beyond the first material cut edge to define a fringe and the fringe includes an anchor tab joined thereto.

In some embodiments, the back waist region includes a back waist relief area. The back waist relief area is defined in part by a first material back cut edge and a second material back cut edge wherein the first material back cut edge defines a first back relief depth and the second material back cut edge defines a second back relief depth wherein the second back relief depths is at least 3 mm less than the first back relief depth.

In some embodiments, the front waist relief area defines a width and the second material cut edge extends beyond the first material cut edge by the same amount along substantially the entire width of the front waist relief area and the second material has a second material back relief depth of less than 3 mm in the back waist relief area.

In another aspect, the present invention provides an absorbent article having a liquid pervious bodyside liner, a liquid impervious outer cover, and an absorbent core positioned between the liner and the outer cover. The absorbent article has a crotch portion connected between a front portion and a back portion. The front portion includes a front waist region, a front waist edge, and a front waist relief area. The front waist relief area is defined in part by a first material cut edge and a second material cut edge. The first material cut edge has a first relief depth of at least 20 mm, the second material cut edge has a second relief depth of at least 10 mm, and the second relief depth is at least 3 mm less than the first relief depth. In this aspect, the first material includes the outer cover and the second material includes a front waist elastic joined to the front waist region.

In some embodiments, the front waist relief area defines a width and the second material cut edge extends beyond the first material cut edge to define a fringe wherein the fringe extends beyond the first material cut edge by the same amount along substantially the entire width of the front waist relief area.

In some embodiments, the back portion may include a back waist region, a back waist edge, and a back waist relief area. The back waist relief area is defined in part by a first material back cut edge and a second material back cut edge. The first material back cut edge has a relief depth of at least 10 mm in the back waist relief area. The second material back cut edge has a relief depth of less than 3 mm.

In some embodiments, the front waist relief area defines a width and the second material front cut edge extends beyond the first material front cut edge by the same amount along substantially the entire width of the front waist relief area.

In some embodiments, the second cut edge of the front waist elastic extends beyond the first cut edge of the outercover, outercover facing, and liner.

Another aspect of the present invention provides an absorbent article having a liquid pervious bodyside liner, a liquid impervious outer cover, and an absorbent core positioned between the liner and the outer cover. The absorbent article defines a crotch portion connected between a front portion and a back portion. The front portion includes a front waist region, a front waist edge, and a front waist relief area. The front waist relief area is defined in part by a first material front cut edge and a second material front cut edge. The back waist relief area is defined in part by the first material back cut edge and the second material back cut edge. The first material front cut edge has a first front relief depth of at least 20 mm, the second material front cut edge has a second front relief depth of at least 10 mm and the second front relief depth is at least 3 mm less than the first front relief depth. The first material back cut edge has a first back relief depth of at least 5 mm. The first material is the outer cover and the second material is a waist elastic.

In some embodiments, the second material front cut edge extends beyond the front cut edge of the outercover, outercover facing, and liner at a longitudinal centerline.

In some embodiments, the front waist relief area defines a width and the second material front cut edge extends beyond the first material front cut edge to define a front fringe. The front fringe extends beyond the first material front cut edge by the same amount along substantially the entire width of the front waist relief area.

DETAILED DESCRIPTION OF THE DRAWINGS

The waist relief features of the present invention may be useful for providing relief to the healing umbilical area of newborns and/or increasing comfort in the waist portions and/or increasing retraction in the waist portions of various absorbent articles. The absorbent articles of the present invention will be described in terms of diapers adapted to be worn by babies, particularly newborns, about the lower torso. However, the absorbent articles of the present invention may also be applicable to other articles such as adult incontinent absorbent articles, training pants, feminine care absorbent articles and the like.

FIG. 1representatively illustrates a diaper10of the present invention in an unfastened condition. Portions of the diaper10are cut away to illustrate underlying structures. The surface of the diaper which contacts the wearer is facing the viewer inFIG. 1. The diaper10has a longitudinal direction12and a lateral direction14. In the longitudinal direction12, the diaper10defines a front portion22, a back portion24, and a crotch portion26connecting the front portion22and the back portion24. The diaper10includes a bodyside liner30, an outer cover32and an absorbent core34located between the bodyside liner30and the outer cover32. The front portion22may include, at least partially, one or more front ears23. The back portion24may include, at least partially, one or more back ears25. The front ears23and/or the back ears25may be formed from extensions of the bodyside liner30, the outer cover32, combinations of both the bodyside liner30and the outer cover32, or by the addition of one or more separate components as is known in the art.

The diaper10may also include a fastener system43. The fastener system43may include one or more back fasteners44and one or more front fasteners45(seeFIG. 2for example). Portions of the fastener system43may be included in the front portion22, the back portion24, or both. The fastener system43is adapted to secure the diaper10about the waist of a wearer and maintain the diaper10in place during use.

The diaper10may also include a surge portion33joined to the absorbent core34and/or the bodyside liner30. As used herein, reference to a front portion22refers to that part of the diaper which is generally located on the front of a wearer when in use. Reference to the back portion24refers to the portion of the diaper generally located at the back of the wearer when in use, and reference to the crotch portion26refers to that portion which is generally located between the legs of the wearer when in use.

The crotch portion26has opposite longitudinal side portions28which may include a pair of elasticized, longitudinally-extending leg cuffs36. The leg cuffs36are generally adapted to fit about the legs of a wearer in use and serve as a mechanical barrier to the lateral flow of body exudates. The leg cuffs36may be elasticized by a pair of leg elastics38. The diaper10may further include a front waist elastic40(seeFIG. 5for example) and/or a back waist elastic42.

The back portion24may have a straight back waist edge46, an arcuate back waist edge46, or a back waist edge46cut in other shapes as are known in the art. The front portion22may have a straight front waist edge48, an arcuate front waist edge48, or a front waist edge48cut in other shapes as are known in the art. As used herein, the term “straight” refers to edges or portions of edges that are substantially free from curves, bends, angles, notches or irregularities. For example, the back waist edge46ofFIG. 1is a straight edge whereas, the front waist edge48has two straight portions divided by an arcuate portion.

The diaper10may also include a pair of containment flaps52that may extend longitudinally along the diaper10and may also be adapted to provide a barrier to the flow of body exudates. It should be recognized that individual components of the diaper10may be optional depending upon the intended use of the diaper10.

The bodyside liner30of the diaper10, as representatively illustrated inFIG. 1, suitably presents a body facing surface which is intended to be worn adjacent the body of the wearer and is compliant, soft feeling and nonirritating to the wearer's skin. Further, the bodyside liner30may be less hydrophilic than the absorbent core34and may be sufficiently porous to be liquid permeable. A suitable bodyside liner30may be manufactured from a wide selection of web materials, such as porous foams, reticulated foams, apertured plastic films, natural fibers (for example, wood or cotton fibers), synthetic fibers (for example, polyester or polypropylene fibers), or a combination of natural and synthetic fibers. The bodyside liner30is suitably employed to help isolate the wearer's skin from fluids held in the composite absorbent core34.

The outer cover32of the diaper10, as representatively illustrated inFIG. 2, suitably presents a garment facing surface which is intended to be worn adjacent the clothing of the wearer. The outer cover32may include a polyethylene film. Alternative constructions of the outer cover32may comprise a woven or non-woven fibrous web layer which has been totally or partially constructed or treated to impart a desired level of liquid impermeability to selected regions of the outer cover that are adjacent or proximate the absorbent core34. For example, a clothlike outer cover may be composed of polypropylene spunbond fabric which is laminated and thermally bonded to a stretch-thinned polypropylene film. In such embodiments, the polypropylene spunbond fabric may be referred to as the outer cover facing material35and the polypropylene film may be referred to as the outer cover material32. In other embodiments, the woven or non-woven fibrous web layers and other layers may be collectively referred to as the outer cover. The outer cover32may optionally include a micro-porous, “breathable” material which permits vapors to escape from diaper10while still preventing liquid exudates from passing through. For example, the outer cover32may be composed of a microporous polymer film or a nonwoven fabric which has been coated or otherwise treated to impart a desired level of liquid impermeability. The outer cover32can also be embossed or otherwise provided with a matte finish to exhibit a more aesthetically pleasing appearance. The size of outer cover32is typically determined by the size of diaper10and the exact diaper design selected.

The bodyside liner30and outer cover32are generally joined in facing relationship with the absorbent core34located therebetween. The bodyside liner30and the outer cover32may be joined to each other around the outer periphery of the diaper10by any means known to those skilled in the art such as adhesive bonds, sonic bonds, thermal bonds, and the like, and combinations thereof. As used herein, the term “join”, and derivatives thereof, encompass configurations wherein an element is directly secured to the other element by affixing the element directly to the other element, and configurations wherein the element is indirectly secured to the other element by affixing the element to intermediate member(s) which in turn are affixed to the other element.

The leg cuffs36are suitably formed by portions of the outer cover32, and/or bodyside liner30, which extend beyond the longitudinal sides of the absorbent core34. Alternatively, the leg cuffs36can be formed from separate materials joined to the outer cover32and/or bodyside liner30. In some embodiments, the leg cuffs36may have an arcuate shape resulting from a leg cut out37. In other embodiments, the leg cuffs36may have a generally straight leg cut out37.

The leg cuffs36may include leg elastics38. Front waist elastics40and/or back waist elastic42may also be provided. The leg elastics38may be arranged to draw and hold the diaper10against the legs of the wearer. The waist elastics40and42may also be arranged to draw and hold the diaper10against the wearer, particularly at the waist. Materials suitable for use in forming leg elastics38and/or waist elastics40and42are known to those skilled in the art. Exemplary of such materials are strands or ribbons of a polymeric, elastomeric material which are adhered to the diaper10in a stretched position, or which are attached to the diaper while the diaper is pleated, such that elastic constrictive forces are imparted to the diaper10. The leg elastics38and/or waist elastics40and42may have any configuration which provides the desired performance. The leg elastics38may be generally straight or optionally curved to more closely fit the contours of the legs and buttocks of the wearer and better contain bodily exudates. The leg elastics38and/or waist elastics40and42may be attached to the diaper10in any of several ways which are well known to those skilled in the art. For example, the elastics may be joined to the diaper10by ultrasonic bonding, thermal bonding, adhesive bonding, and the like, and combinations thereof.

The front ears23and/or the back ears25are suitably formed by portions of the outer cover32, and/or bodyside liner30, which extend beyond the longitudinal sides of the absorbent core34. For example, inFIG. 1, the front ears23are illustrated as portions of both the outer cover32and the bodyside liner30. Alternatively, the front ears23and/or back ears25may be formed from separate materials which are joined to the outer cover32and/or bodyside liner30. For example, inFIG. 1, the back ears25are illustrated as separate pieces of material attached to the bodyside liner30.

The front ears23and/or the back ears25of the present invention may comprise one or more materials joined together to form a composite ear as is well known in the art. One or more of the materials may be elastomeric. Elastomeric ears can be formed from any type of an elastomeric material capable of performing as described herein. Generally, the elastomeric material will be stretchable in at least one direction. Preferably, the elastomeric material will be stretchable in two directions. When the elastomeric material is stretchable in a single direction, the stretch direction of the elastomeric material will be oriented so as to provide elastomeric forces which tend to pull the front and back portions of the diaper towards one another such that the diaper is maintained about the waist of a wearer.

The elastomeric material may be an inherently elastomeric material, that is, one which is formed in an elastomeric state, or may be rendered elastomeric through processing subsequent to formation. For example, the elastomeric material may be heat or pressure activated. In particular embodiments of the invention, portions of the ears may comprise an elastomeric material, such as a stretch-bonded-laminate (SBL) material, a neck-bonded-laminate (NBL) material, an elastomeric film, an elastomeric foam material, or the like, or combinations thereof.

In some embodiments, the back fasteners44may be joined to the back portion24, the back ears25or both and the front fasteners45may be joined to the front portion22, the front ears23, or both. The back fasteners44may be one or more discrete pieces of material joined to the diaper10and adapted to align with and work in conjunction with the front fasteners45, which may be one or more discrete pieces of material joined to the diaper10. For example, the front fastener45may be a piece of loop material joined with the outer cover32in the front portion22and configured to engage hook-type back fasteners44when the diaper10is wrapped about the waist and legs of a user.

Alternatively, the one or more front fasteners45may include portions of the outer cover32, the bodyside liner30, or both and be configured to engage hook-type back fasteners44. For example, the outer cover32may be configured to include a non-woven material suitable for engagement with hook materials. In such an embodiment, hook-type fasteners44may be located at the back ears25and wrapped around the waist of the wearer. The hook-type fasteners44may then be engaged directly with the nonwoven outer cover32to join the back portion24with the front portion22and secure the diaper10about the waist of the wearer.

Alternatively, the one or more front fasteners45may include hook-type fasteners and the one or more back fasteners44may include one or more complementary loop-type fasteners. In various embodiments, the one or more back fasteners44and/or the one or more front fasteners45may comprise any suitable materials adapted to join the back portion24to the front portion22of the diaper10thus securing the diaper about the waist of a wearer. Suitable fastening materials include hook and loop materials, adhesives, adhesive tapes, cohesives, snaps, buttons, latches, hooks, and the like, and combinations thereof. In some embodiments both the front portion22and/or the back portion24may include dual fasteners as is known in the art.

The absorbent core34is positioned between the bodyside liner30and the outer cover32to form the diaper10. The absorbent core34is generally conformable and capable of absorbing and retaining body exudates. The absorbent core34may include superabsorbent material, staple fibers, binder fibers, and the like, and combinations thereof as is known in the art. The absorbent core34may have any of a number of shapes and sizes. For example, the composite absorbent core may be rectangular, I-shaped or T-shaped. The size and absorbent capacity of the absorbent core34should be compatible with the size of the intended wearer and the fluid loading imparted by the intended use of the diaper.

In various embodiments, the surge portion33serves to quickly collect and temporarily hold discharged fluids and then to eventually release the fluids into the absorbent core34. Various woven and nonwoven materials can be used to construct the surge portion33. For example, the surge portion33may be a layer of a spunbonded or meltblown web of polyolefin fibers. The surge portion33may also be a bonded carded web of natural and synthetic fibers. The surge portion33may be a substantially hydrophobic material and, optionally, can be treated with a surfactant or otherwise to impart a desired level of wettability and hydrophilicity.

Containment flaps52may be connected to the bodyside liner or other components as is well known in the art. Suitable configurations of the containment flaps52are described, for example, in U.S. Pat. No. 5,599,338 issued Feb. 4, 1997, to K. Enloe, the entirety of which is incorporated herein by reference where not contradictory.

Referring again, toFIG. 1, the front portion22of the diaper10includes a front waist region47defined in part by the front waist edge48. Likewise, the back portion24of the diaper10includes a back waist region49defined in part by the back waist edge46. In various embodiments, the front waist region47and/or the back waist region49may include a front waist relief area56and/or a back waist relief area58(See for example,FIG. 8) respectively.

As used herein, the term “waist relief area” describes a portion of the front waist region and/or the back waist region wherein a portion of one or more materials has been removed proximate the waist edge. Waist relief areas may be utilized to minimize contact with the healing umbilical area of newborns and/or provide a soft edge proximate the healing umbilical area and/or generally increase comfort in the waist regions and/or increase the retractive forces in the waist regions of various absorbent articles.

To better illustrate the details of an exemplary waist relief area, a portion ofFIG. 1, identified as “A”, is enlarged and illustrated inFIG. 1A. Referring now toFIGS. 1 and 1A, the front waist relief area56is defined in part by a first material cut edge60and a second material cut edge62. In the illustrated embodiment, the first material is the outer cover32and the second material is the bodyside liner30. The first material cut edge60defines a first relief depth64and the second material cut edge62defines a second relief depth66. The cut edges60and64extend to different lengths in the waist relief area56to provide a soft edge. In other words, in this embodiment, the liner cut edge62extends past the outer cover cut edge60to provide a fringe74in the waist relief area56. In various embodiments, the second relief depth66is at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, or at least 10 mm less than the first relief depth64. Thus, in various embodiments, the fringe74may be at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, or at least 10 mm in length as measured from the first cut edge60to the second cut edge62.

As used herein, the term “relief depth” refers to the distance from a respective material cut edge60or62to the extended waist edge54and is measured at the longitudinal centerline68. For example, referring toFIG. 1A, the first relief depth64is the distance from the first material cut edge60to the extended waist edge54as measured at the longitudinal centerline68. Likewise, the second relief depth66is the distance from the second material cut edge62to the extended waist edge54when measured at the longitudinal centerline68.

In various embodiments, the first relief depth64may be at least 10 mm, at least 20 mm, at least 30 mm, or at least 40 mm. In various embodiments, the second relief depth66may be less than 30 mm, less than 20 mm, or less than 10 mm. In some embodiments, the second relief depth66may be 0 mm. In these embodiments, the second cut edge62extends all the way to the front waist edge48and/or the back waist edge46(seeFIG. 9for example).

As used herein, the term “extended waist edge” refers to the imaginary line54intersecting the longitudinal centerline68and connecting one straight portion of a waist edge to another straight portion of the same waist edge. For example,FIG. 1Aillustrates an extended waist edge54connecting one straight portion of front waist edge48to another straight portion of front waist edge48.

As used herein, the term “straight” describes waist edges or portions of waist edges that are generally parallel with the lateral direction14and generally perpendicular with the longitudinal direction12. For example, inFIG. 1, the back waist edge46is a straight waist edge and the front waist edge48includes two straight portions80on either side of the front waist relief area56.

As used herein, the term “relief width” describes the distance, as measured in the lateral direction14, between the points wherein the first material cut edge60intersects the straight portion of the front waist edge48or the back waist edge46. For example, inFIG. 1A, the relief width70is illustrated as the distance between a first point76and a second point78. The first point76is defined by the first intersection of the first material cut edge60and the straight portion80of the front waist edge48. The second point78is defined by the second intersection of the first material cut edge60and the straight portion80of the front waist edge48. The relief width70may be any suitable distance. For example, in some embodiments, the relief width70may be at least 25 mm, at least 30 mm, at least 40 mm, at least 50 mm, or at least 60 mm. In some embodiments, the relief width70may be at least 30%, at least 40%, or at least 50% the total length of the front waist edge48and/or back waist edge46, as measured in the lateral direction14. In some embodiments, the relief width70may be less than 90%, less than 80%, or less than 70% the length of the front waist edge48and/or back waist edge46, as measured in the lateral direction14.

In various embodiments, the first material and the second material that define the front waist relief area56and/or the back waist relief area58may be any suitable materials. Likewise, the fringe74in the front waist relief area56and/or back waist relief area58may be made of any suitable material or materials. For example, the fringe74may be composed of the bodyside liner30, the front waist elastic40, the back waist elastic42, the front fastener material45, the outer cover facing material37, or combinations thereof. Additionally, the fringe74may extend beyond the cut edge of the bodyside liner30, the front waist elastic40, the back waist elastic42, the front fastener material45, the outer cover facing material37, the outer cover material32, or combinations thereof. For example, the absorbent article10illustrated inFIG. 1includes the outer cover32as the first material and the bodyside liner30as the second material. As illustrated, the cut edge62of the bodyside liner30extends past the cut edge60of the outer cover32to create the fringe74. In some embodiments, the cut edge62of the bodyside liner30may extend all the way to the front waist edge48as illustrated inFIG. 3.

Referring now toFIG. 4, an absorbent article10is illustrated in an unfastened condition. The surface of the diaper10which contacts the wearer is facing the viewer in this illustration. The diaper10ofFIG. 4includes a front waist relief area56defined in part by a first material cut edge60and a second material cut edge62wherein the first material is the outer cover32and the second material is the front waist elastic40. In the illustrated embodiment, the cut edge62of the front waist elastic40extends beyond the cut edge60of the outer cover32to create a fringe74. In some embodiments, the cut edge62may also include the bodyside liner30. In these embodiments, the front waist elastic40and the bodyside liner30would both extend beyond the cut edge60of the outer cover32to define the fringe74. In yet other embodiments, the cut edge62of the front waist elastic40may extend all the way to the front waist edge48as illustrated inFIG. 5. In some embodiments, the cut edge62may also include the bodyside liner30wherein both the bodyside liner30and the front waist elastic40extend all the way to the front waist edge48in the front waist relief area56.

In some embodiments, the front waist relief area56and/or back waist relief area58may be defined in part by a first material cut edge60and second material cut edge62wherein the first material includes the outer cover material32and the second material includes an outer cover facing material35. For example, as illustrated inFIG. 6, an absorbent article10includes a front waist relief area56defined in part by a first cut edge60and second cut edge62. The outer cover facing material35extends beyond the outer cover material32to define the fringe74in a portion of the front waist relief area56.

In some embodiments, the front waist relief area56and/or the back waist relief area58may be defined in part by a first material cut edge60and a second material cut edge62wherein the first material includes the outer cover material32and the second material includes a fastener material. For example, as illustrated inFIG. 7, an absorbent article10includes a front waist relief area56defined, in part, by a first cut edge60of the outer cover32and a second cut edge62of the front fastener material45. The front fastener material45extends beyond the cut edge of the outer cover material32to define the fringe74.

In various embodiments, the first material and/or the second material that define the front waist relief area56and/or the back waist relief area58may extend all the way to the front waist edge48and/or the back waist edge46of the diaper10in areas outside the front waist relief area56and/or back waist relief area58. For example, as illustrated inFIG. 4, the outer cover32is the first material and extends to the front waist edge48in areas80outside the waist relief area56. Likewise, the front waist elastic40is the second material and extends to the front waist edge48in areas80outside the waist relief area56. In some embodiments, the first material and/or the second material that define the front waist relief area56and/or the back waist relief area58may not extend all the way to the front waist edge48and/or the back waist edge46of the diaper10in areas80outside the front waist relief area56and/or back waist relief area58. For example, as illustrated inFIG. 7, the outer cover32is the first material and extends to the front waist edge48in areas80outside the waist relief area56. In contrast, the fastener material45is the second material and does not extend to the front waist edge48in areas80outside the waist relief area56. In these situations, the relief depth of the fastener material45is the distance from the extended waist edge54of the outer cover32to the material cut edge of the fastener material45as measured at the longitudinal centerline68, not the extended waist edge54of the fastener material45.

In various embodiments, the second material cut edge62may have the same relative shape as the first material cut edge60such that the fringe74extends beyond the first material cut edge60by a uniform amount along substantially the entire width70of the front waist relief area56and/or back waist relief area58. For example,FIG. 4representatively illustrates a second cut edge62and first cut edge60defining a fringe74that extends beyond the first material cut edge60by a uniform amount along substantially the entire width of the front waist relief area56.

In some embodiments, the second material cut edge62may have a different relative shape as compared to the first material cut edge60such that the fringe74extends beyond the first material cut edge60by different amounts along the width70of the front waist relief area56and/or the back waist relief area58. For example,FIG. 3representatively illustrates a second cut edge62having a straight shape and a first cut edge60having an arcuate shape. This combination of shapes results in a fringe74that extends beyond the first material cut edge60by a greater distance as measured near the longitudinal centerline as compared to the distance as measured near the intersection of the first material cut edge60and the front waist edge48.

In various embodiments, the absorbent article10may include a front waist relief area56and a back waist relief area58. For example, as illustrated inFIG. 8, an absorbent article10is illustrated in an unfastened condition. The surface of the diaper10which contacts the wearer is facing the viewer in this illustration. The diaper10ofFIG. 8includes a front waist relief area56defined in part by a first material front cut edge60and a second material front cut edge62wherein the first material is the outer cover32and the second material is the front waist elastic40. Likewise, the diaper10includes a back waist relief area58defined in part by a first material back cut edge61and a second material back cut edge63wherein the first material is the outer cover32and the second material is the back waist elastic42. In the illustrated embodiment, the second material front cut edge62of the front waist elastic40extends beyond the first material front cut edge60of the outer cover32to create a front fringe74and the second material back cut edge63of the back waist elastic42extends beyond the first material back cut edge61of the outer cover32to create a back fringe75.

In some embodiments, the second material front cut edge62may also include the bodyside liner30. In these embodiments, the front waist elastic40and the bodyside liner30would both extend beyond the first material front cut edge60of the outer cover32to define the front fringe74in the front waist relief area56. Likewise, the back waist elastic42and the bodyside liner30would both extend beyond the first material back cut edge61of the outer cover32to define the back fringe75in the back waist relief area58. In yet other embodiments, the second material front cut edge62of the front waist elastic40may extend all the way to the front waist edge48and the second material back cut edge63of the back waist elastic42may extend all the way to the back waist edge46as illustrated inFIG. 9.

In some embodiments, the second material front cut edge62may extend beyond the first material front cut edge60to define the front fringe74in the front waist relief area56while the second material back cut edge63of the back waist relief area58may extend all the way to the back waist edge46as illustrated inFIG. 9A. Referring toFIG. 9A, the front waist elastic40extends beyond the first material front cut edge60of the outer cover32to define the front fringe74in the front waist relief area56. The front waist elastic40has a relief depth66of greater than zero mm illustrated in this embodiment. The back waist elastic42ofFIG. 9Aextends beyond the first material back cut edge61of the outer cover32in the back waist relief area58to define the back fringe75. The second material back cut edge63of the back waist elastic42extends all the way to the back waist edge46.

In some embodiments, the fringe74may include an anchor tab72joined thereto. For example, as illustrated inFIG. 10, a diaper10includes a front waist relief area56defined in part by a first material cut edge60and a second material cut edge62. The first material includes the outer cover32and the second material includes the front waist elastic40. The cut edge62of the front waist elastic40extends beyond the cut edge60of the outer cover32to create a fringe74. The diaper10includes an anchor tab72joined to the fringe74. The anchor tab72is provided as an optional feature on some embodiments to allow a user or caregiver to deflect the fringe74away from the front waist edge48and anchor the fringe74in a position that maintains the deflection of the fringe74. For example,FIG. 11illustrates the diaper10ofFIG. 10wherein the anchor tab72has been joined with the front fastener45to maintain the fringe74in a deflected position.

The diapers10of the various embodiments of the present invention may be manufactured by any suitable apparatus and/or method. In some embodiments, a method of making an absorbent article with a waist relief area includes the steps of providing a first web of material moving in a machine direction; cutting a plurality of first relief holes in the first web of material; at least partially covering the plurality of first relief holes with an overlay material; and cutting the web of material in a cross-machine direction to define a plurality of discrete absorbent articles wherein the cross-machine cut extends at least partially through each first relief hole. The resulting discrete absorbent articles include one or more waist relief areas corresponding to the location of the relief holes.

For example,FIG. 12representatively illustrates a method100of making absorbent articles110with waist relief areas112. The method100includes providing a first web of material113, such as a web of outer cover material114, moving in a machine direction116. As used herein, the direction perpendicular to the machine direction116will be referred to as the cross-machine direction118.

In various embodiments, the method may also include providing a plurality of absorbent cores120. In the illustrated embodiments, the absorbent cores120are illustrated as discrete shaped pads being placed on the web of outer cover material114. However, the absorbent cores120may be provided as discrete units or may be provided as a continuous web of interconnected cores or combinations thereof. Likewise, the absorbent cores120may have any suitable shape, composition, or construction as is known in the art. Additionally, the absorbent cores120may be introduced into the absorbent article at any suitable position.

The method100may further include creating a plurality of first relief holes122in the web of outer cover material114. As illustrated inFIG. 12, the first relief holes122may be cut using a rotating die roll124in cooperation with a rotating anvil roll126to separate a plurality of oval-shaped relief hole trim pieces136.

The first relief holes122may be created using any suitable method and apparatus. For example, the first relief holes122may be cut using high pressure water, die cutters, ultrasonic cutters, and the like, and combinations thereof. The first relief holes122and/or the second relief holes146may have any suitable shape and any suitable orientation. For example, the first relief holes122and/or the second relief holes146may be generally oval in shape, circular in shape, triangular in shape, diamond-shaped, or shaped like the letter “D” (D-shaped). The first relief holes122, as illustrated inFIG. 12, have an oval shape with the longer axis oriented in the cross-machine direction118.

The method100also includes the step of at least partially covering the plurality of first relief holes122with an overlay material128. The overlay material128may be any suitable material or materials. For example, the overlay material may be the bodyside liner, the front waist elastic, the back waist elastic, the front fastener material, the outer cover facing material, or the like, or combinations thereof. In the embodiment illustrated inFIG. 12, the overlay material128is a bodyside liner130.

The overlay material128may completely cover the plurality of first relief holes122, as illustrated inFIG. 12, or may only partially cover the first relief holes122. The portion of the overlay material128spanning the first relief holes122defines a fringe101. In various embodiments, the overlay material128may also cover any other suitable component of the absorbent article110. For example, the overlay material128(bodyside liner130) ofFIG. 12overlays the outer cover114, the absorbent cores120, and the first relief holes122.

The method100also includes the step of cutting the web of outer cover material114in the cross-machine direction118to define a plurality of discrete absorbent articles110wherein each cut extends at least partially through each first relief hole122. For example,FIG. 12illustrates a cutoff roll132working in conjunction with an anvil roll134to cut the web of outer cover material114and the web of bodyside liner material130in the cross machine direction118to define a plurality of discrete absorbent articles110. The cut extends through the first relief holes122to create waist relief areas112having a fringe101in the discrete absorbent articles110. In various embodiments, the cutting step may be performed with any suitable method or apparatus.

In some embodiments, the method of making absorbent articles with a waist relief area may include at least partially covering the plurality of first relief holes with a plurality of discrete overlay materials. In various embodiments, the discrete overlay materials may have elasticity in the cross-machine direction118and/or the machine direction116.

For example,FIG. 13representatively illustrates a method100of making absorbent articles110with waist relief areas112. The method100includes providing a first web of material113, such as a web of outer cover material114, moving in a machine direction116. The method may also include providing a plurality of discrete absorbent cores120on the web of outer cover material114. The method may also include additional web materials. For example, the embodiment ofFIG. 13illustrates a bodyside liner material130being added in facing relation with the outer cover material114with the absorbent cores120located therebetween. Optionally, in some embodiments, an outer cover facing material138may be joined with the outer cover material to provide a cloth-like feel as is known in the art.

The method100ofFIG. 13further includes creating a plurality of first relief holes122in the web of outer cover material114, the web of liner material130, and the web of outer cover facing material138. The first relief holes122may be cut using a rotating die roll124in cooperation with a rotating anvil roll126to separate a plurality of oval-shaped relief hole trim pieces136.

The method100also includes the step of at least partially covering the plurality of first relief holes122with an overlay material128. In this embodiment, the overlay materials128are discrete waist elastics140. The discrete waist elastics140may completely cover the plurality of first relief holes122, as illustrated inFIG. 13, or may only partially cover the first relief holes122. The portions of the discrete waist elastics140spanning the first relief holes122define a fringe101.

The method100also includes the step of cutting the web of outer cover material114, bodyside liner material130, and outer cover facing material138in the cross-machine direction118to define a plurality of discrete absorbent articles110wherein each cut extends at least partially through each first relief hole122to create waist relief areas112having a fringe101in the discrete absorbent articles110. The cutting step may also sever the discrete waist elastics140such that a portion of the discrete waist elastic remains in a front portion142of the absorbent article110and a portion of the discrete waist elastic remains in a back portion144. The cutting step may be phased to create waist relief areas112in the front portion142of the absorbent article110, in the back portion144of the absorbent article110, or both the front portion142and the back portion144, as illustrated.

In some embodiments, the plurality of first relief holes156may be covered with a web of outer cover facing material138and the cutting step may include cutting the outer cover facing material138in the cross-machine direction118. For example,FIG. 14representatively illustrates a method100of making absorbent articles110with waist relief areas112. The method100includes providing a first web of material113, such as a web of outer cover material114, moving in a machine direction116. The method100also includes providing a plurality of discrete absorbent cores120on the web of outer cover material114. The method100ofFIG. 14further includes creating a plurality of first relief holes122in the web of outer cover material114. The first relief holes122may be cut using a rotating die roll124in cooperation with a rotating anvil roll126to separate a plurality of oval-shaped relief hole trim pieces136.

The method100also includes the step of at least partially covering the plurality of first relief holes122with one or more overlay materials128. The embodiment ofFIG. 14illustrates a bodyside liner material130being added in facing relation with the outer cover material114wherein the absorbent cores120are located therebetween. Additionally, an outer cover facing material138is joined with the outer cover material114. Thus, in this embodiment, the overlay materials128are the bodyside liner material130and the outer cover facing material138. The overlay materials128completely cover the plurality of first relief holes122. The portion of the overly materials128that span the first relief holes122define a fringe101.

The method100also includes the step of cutting the web of outer cover material114, the bodyside liner material130, and outer cover facing material138in the cross-machine direction118to define a plurality of discrete absorbent articles110wherein each cut extends at least partially through each first relief hole122to create waist relief areas112in the discrete absorbent articles110. The cutting step may be phased to create waist relief areas112having a fringe101in the front portion142of the absorbent article110, in the back portion144of the absorbent article110, or both the front portion142and the back portion144, as illustrated.

Referring now toFIG. 15, a method100of making an absorbent article110with a waist relief area112is illustrated. The method100may include providing a first web of material113, such as a web of outer cover material114, moving in a machine direction116. The method110may further include a plurality of discrete absorbent cores120spaced and placed upon the web of outer cover material114. The method further includes cutting a plurality of first relief holes122in the web of outer cover material114. The first relief holes122may be cut using a rotating die roll124in cooperation with a rotating knife anvil roll126to separate a plurality of oval-shaped relief hole trim pieces136.

The method100further includes covering the plurality of first relief holes122with an overlay material128, such as bodyside liner130. The portion of the bodyside liner130that spans the first relief holes122defines a fringe101. The method100continues with cutting a plurality of second relief holes146in at least a portion of the overlay material128spanning the first relief holes (i.e., the fringe101) using a second rotating die roll150in cooperation with a second rotating anvil roll152to separate a plurality of oval-shaped relief hole trim pieces154. The web of outer cover material114and the web of liner material130are cut in the cross-machine direction118to define a plurality of discrete absorbent articles110. Each cross-machine cut extends at least partially through each first relief hole122and each second relief hole146to create waist relief areas112with fringe101in the front portion142, back portion144, or both the front portion142and the back portion144as illustrated.

In various embodiments, each of the second relief holes146may be registered within each of the first relief holes122as illustrated inFIG. 15. In some embodiments, the second relief holes146may be centered in the first relief holes122relative to the machine direction116, the cross machine direction118, or both as illustrated inFIG. 15. In various embodiments, each of the first relief holes122define a first relief hole area156and each of the second relief holes146define a second relief hole area158less than the first relief hole area156as illustrated inFIG. 15. As such, at least a portion of the fringe101remains in the waist relief areas112of the absorbent articles110.

In some embodiments, the overlay material128may be a plurality of discrete waistbands having elasticity in the cross machine direction118. For exampleFIG. 16representatively illustrates a method100of making an absorbent article110with waist relief areas112. The method100includes providing a first web of material113, such as a web of outer cover material114, moving in a machine direction116. The method110further includes providing a plurality of discrete absorbent cores120spaced and placed upon the web of outer cover material114. The absorbent cores120are positioned between the outer cover material114and a bodyside liner material130. Optionally, an outer cover facing material138may be joined with the outer cover material114. The method further includes cutting a plurality of first relief holes122in the web of outer cover material114, the bodyside liner material130, and the outer cover facing material138. The first relief holes122may be cut using a rotating die roll124in cooperation with a rotating knife anvil roll126to separate a plurality of oval-shaped relief hole trim pieces136.

The method100further includes covering the plurality of first relief holes122with an overlay material128, such as plurality of discrete waist elastic material140. The portion of the waist material140spanning the first relief holes122defines a fringe101. The method100continues with cutting a plurality of second relief holes146in at least a portion of the overlay material128spanning the first relief holes (i.e. the fringe101) using a second rotating die roll150in cooperation with a second rotating anvil roll152to separate a plurality of oval-shaped relief hole trim pieces154. The web of outer cover material114, the web of liner material130, the web of outer cover facing material138, and the discrete waist elastic material140are cut in the cross-machine direction118to define a plurality of discrete absorbent articles110. Each cross-machine cut extends at least partially through each first relief hole122and each second relief hole146to create waist relief areas112with fringe101in the front portion142, back portion144, or both the front portion142and the back portion144as illustrated. The second relief holes146are registered within each of the first relief holes122as illustrated inFIG. 15. Additionally, the second relief holes146are centered in the first relief holes122relative to both the machine direction116and the cross-machine direction118as illustrated inFIG. 15. Each of the first relief holes define a first relief hole area156and each of the second relief holes define a second relief hole area158less than the first relief hole area156thereby leaving some fringe101in the absorbent article110as illustrated inFIG. 16.

FIG. 17representatively illustrates a method100of making an absorbent article110with waist relief areas112. The method100includes providing a first web113, such as a web of outer cover material114, moving in a machine direction116. The method110further includes providing a plurality of discrete absorbent cores120spaced and placed upon the web of outer cover material114. The method further includes cutting a plurality of first relief holes122in the web of outer cover material114. The first relief holes122may be cut using a rotating die roll124in cooperation with a rotating knife anvil roll126to separate a plurality of oval-shaped relief hole trim pieces136.

The method100further includes covering the plurality of first relief holes122with two overlay materials128, such as bodyside liner material130and outer cover facing material138. The portions of the bodyside liner material130and outer cover facing material138overlying the first relief holes122define a fringe101. The method100continues with cutting a plurality of second relief holes146in at least a portion of the overlay materials128spanning the first relief holes (i.e., the fringe101) using a second rotating die roll150in cooperation with a second rotating anvil roll152to separate a plurality of oval-shaped relief hole trim pieces154. The web of outer cover material114, the web of liner material130, and the web of outer cover facing material138are cut in the cross-machine direction118to define a plurality of discrete absorbent articles110. Each cross-machine cut extends at least partially through each first relief hole122and each second relief hole146to create waist relief areas112with fringe101in the front portion142, back portion144, or both the front portion142and the back portion144as illustrated. The second relief holes146are registered within each of the first relief holes122as illustrated. Additionally, the second relief holes146are centered in the first relief holes122relative to both the machine direction116and the cross-machine direction118. Each of the first relief holes define a first relief hole area156and each of the second relief holes define a second relief hole area158less than the first relief hole area156thereby leaving some fringe101in the waist relief areas112of the absorbent articles110as illustrated.

The method of the present invention may include creating any suitable shape for the first relief holes122and/or the second relief holes146. The method of the present invention may include any suitable relative size between the first relief holes122and the second relief holes146. For example, the first relief holes122may have a first relief hole area156and the second relief holes146may have a second relief hole area158that is less than the first relief hole area156.

The method of the present invention may also include any suitable combination of phasing of the first relief holes122and/or the second relief holes146relative to the position of the front waist edge48and/or back waist edge46. For example, in some embodiments, the first relief holes122and/or the second relief holes146may be phased such that they are predominately in the front waist portion47, predominately in the back waist region49, or substantially equal in both the front waist region47and the back waist region49. In some embodiments, the cutting step may be phased to provide at least 90% of the second relief hole area158in the front waist region47of the discrete absorbent articles10and less than 10% of the second relief hole area158in the back waist region49. In some embodiments, the method may further include phasing to provide at least ¼ the first relief hole area156in a front waist region47and at least ¼ the first relief hole area156in the back waist region49of the discrete absorbent articles10.

Referring now toFIG. 18, a top plan view of a portion of an exemplary web before and after being cut into discrete absorbent articles10is illustrated. The absorbent articles10illustrated inFIG. 18are exemplary of those described herein and include a front waist relief area56. In this example, the first relief holes122have a D-shape and the second relief holes146have a D-shape. Also, in this embodiment, the second relief holes146are registered relative to the first relief holes122such that the straight portion of the D-shapes are generally aligned. The first relief holes122and second relief holes146are phased relative to the cut such that 100% of the first relief hole area156and 100% of the second relief hole area158are in the front waist region47. In various embodiments, the first relief holes122and second relief holes146are phased relative to the cut such that at least 95% of the first relief hole area156and at least 95% of the second relief hole area158are in the front waist region47. In some embodiments, the first relief holes122and second relief holes146are phased relative to the cut such that at least 90% of the first relief hole area156and at least 90% of the second relief hole area158are in the front waist region47.

In some embodiments, the first relief holes122may have an oval-shape and the second relief holes146may have a D-shape. For example,FIG. 19illustrates an exemplary web before and after being cut into discrete absorbent articles10. In this embodiment, the first relief holes122are phased relative to the cut such that about ½ the first relief hole area156is in the front waist region47and about ½ the first relief hole area156is in the back waist region49. Likewise, the second relief holes146are phased relative to the cut such that 100% of the second relief hole area158is in the front waist region47and none of the second relief hole area158is in the back waist region49. In some embodiments, the second relief holes146are phased relative to the cut such that at least 95% of the second relief hole area158is in the front waist region47and less than 5% of the second relief hole area158is in the back waist region49. In some embodiments, the second relief holes146are phased relative to the cut such that at least 90% of the second relief hole area158is in the front waist region47and less than 10% of the second relief hole area158is in the back waist region49.