Three-piece disposable absorbent article having an absorbent with cross-direction flexibility

A three-piece disposable absorbent article is disclosed having a longitudinal central axis and a transverse central axis. The disposable absorbent article includes front and back panels, each panel capable of being stretched and retracted in multiple directions. The back panel is also distinct and spaced apart from the front panel. The disposable absorbent article further includes an absorbent assembly situated between the front and back panels and which is attached to each by a first attachment member. The first attachment member is aligned along the longitudinal central axis. The disposable absorbent assembly includes a non-elastic absorbent that is capable of being elongated and contracted in only one direction, that direction being aligned approximately parallel to the transverse central axis.

BACKGROUND OF THE INVENTION

Disposable absorbent articles are available in many different sizes, styles and configurations and are designed for absorbing human exudate, such as urine and fecal matter. Such disposable absorbent articles are intended to be worn by infants, toddlers and adults and are designed for single use. By “single use” it is meant that the disposable absorbent article will be disposed of after being used once instead of being laundered or cleaned for reuse, as is typical of cloth underwear. Examples of some disposable absorbent articles include an infant diaper, a child training pant, a feminine menstrual pant and an adult incontinent undergarment. Many of such disposable absorbent articles are similar in appearance, size and shape as regular cloth underwear except that they are formed from a variety of materials, including absorbent and elastic materials. The absorbent materials allow the disposable absorbent article to absorb and retain body waste while the elastic materials permit the disposable absorbent article to closely conform to the anatomy of the user's torso.

Most manufacturers of such disposable absorbent articles are constantly looking to improve the appearance and normalcy of such articles to simulate cloth underwear. One important functional element is fit. The disposable absorbent article must fit comfortably against the wearer's body while preventing fluid leakage. It has been discovered that constructing a disposable absorbent article using three separate and distinct panels, instead of a single panel, allows for greater flexibility and better fit. In addition, the use of new elastic materials, which have the ability to stretch and retract in more than one direction, have allowed manufacturers to construct disposable absorbent articles that conform more closely to the wearer's torso. This is especially noticeable around the waist and leg openings and the areas overlaying the stomach and buttock regions. However, the crotch portion of many disposable absorbent articles still needs to be improved. The crotch portion needs to have resiliency mainly in the transverse or cross-body direction in order to elongate and rebound from movement of the wearer's thighs. As a wearer walks, his or her thighs move forward relative to each other and this causes the crotch portion to rope and twist. In addition, when the wearer moves his or her thighs closer together, the crotch portion will be subjected to compressive forces. Likewise, when the wearer moves his or her thighs apart, the crotch portion will need to quickly move back towards its original size and dimension. This need for the absorbent to elongate and contract in the transverse or cross-body direction is desirable in preventing fluid leakage.

Now a three-piece, disposable absorbent article has been invented that has an absorbent assembly that includes a non-elastic absorbent that is capable of being elongated and contracted in the transverse or cross-body direction as the backsheet is stretched and retracted.

SUMMARY OF THE INVENTION

Briefly, this invention relates to a three-piece disposable absorbent article having a longitudinal central axis and a transverse central axis. The disposable absorbent article includes front and back panels, each panel capable of being stretched and retracted in multiple directions. The back panel is also distinct and spaced apart from the front panel. The absorbent article further includes an absorbent assembly situated between the front and back panels. The disposable absorbent assembly is attached to the front and back panels by a first attachment member. The first attachment member is aligned along the longitudinal central axis. The disposable absorbent assembly includes a liquid permeable, elastic bodyside liner, a liquid-impermeable, elastic backsheet and a non-elastic absorbent positioned therebetween. The non-elastic absorbent is capable of being elongated and contracted approximately in the transverse or cross-body direction as the backsheet is stretched and retracted.

DETAILED DESCRIPTION

Referring toFIG. 1, a three-piece disposable absorbent article10is depicted that is designed for absorbing human exudate, such as urine and fecal matter. The three-piece disposable absorbent article10is intended to be worn by toddlers or adults who have the ability to step into the product. The three-piece disposable absorbent article10is designed for a single use and is meant to be disposed of after being used once instead of being laundered or cleaned for re-use. The three-piece disposable absorbent article10is designed to be pulled up around the user's torso without having to first open the absorbent article10in order to place it on a person's body. InFIG. 1, the three-piece disposable absorbent article10is shown as an adult incontinent undergarment. The three-piece disposable absorbent article10is shown having its normal appearance after it has been removed from its packaging and just prior to being pulled up along a user's legs and adjusted about the user's torso.

Referring toFIGS. 2 and 3, the three-piece disposable absorbent article10is depicted in an open configuration solely for the purpose of better showing the various components. The three-piece disposable absorbent article10has a longitudinal central axis X-X, a transverse central axis Y-Y and a vertical central axis Z-Z. The three-piece disposable absorbent article10includes a front panel12having a first end14spaced apart from a second end16and a first side edge18spaced apart from a second side edge20. Desirably, the first end14is linear although it could have a scalloped, serpentine or non-linear configuration, if desired. The front panel12has an interior surface22and an exterior surface24. The interior surface22faces and contacts the body of the user when the three-piece disposable absorbent article10is worn. The exterior surface24is aligned opposite to the interior surface22and faces away from the body of the user when the disposable absorbent article10is worn.

The front panel12is formed from an elastic material that is capable of being stretched and retracted in multiple directions. By “stretched” it is meant that the front panel12can be lengthened, widened, extended or increased in dimension by applying a force, such as by pulling. By “retracted” it is meant that the front panel12can be shortened, decreased or reduced in dimension or returned to or towards its original size after the force used to stretch the front panel12has been removed. Desirably, the front panel12will quickly retract or return to its original pre-stretched length once the force used to stretch the front panel12has been removed. For example, a 1 inch (2.54 cm) strip of material can be stretched to about 2 inches (about 5 cm) and then when the stretching force is removed, the material will retract to or towards its original pre-stretched length of 1 inch (2.54 cm). The original width of the front panel12is measured as the distance between the first and second side edges,18and20respectively. The retracted dimension is measured after the force required to stretch the material has been removed. By “multiple directions” it is meant that the front panel12can be stretched and retracted in at least three different directions. Desirably, the front panel12can be stretched and retracted in more than three directions.

The front panel12is formed from an elastic material that is stretchable and retractable in multiple directions. By “elastic” it is meant that the material is capable of being stretched when a tensile force is applied and the material can retract quickly or immediately to or towards its original dimension(s) once the force is removed. Examples of stretchable materials include natural and synthetic rubbers, elastic films, elastic filaments, elastic threads, elastic strands, laminates formed from two or more layers wherein at least one of the layers is elastic, etc. For example, a laminate formed from an elastic film sandwiched between two or more non-elastic layers. The front panel12can also be formed from an elastic net-like material or a material formed from a plurality of elastic strands aligned in two different planes. When a plurality of elastic strands is utilized, they can be positioned on a single carrier layer or be positioned between two or more layers. Other elastic materials that can be used include spunbond, a spunbond laminate, a neck bonded laminate, as well as other material known to those skilled in the art. Spunbond is a material manufactured and commercially sold by Kimberly-Clark Corporation, having an office at 401 North Lake Street, Neenah, Wis. 54956. Examples of some stretchable materials and/or the process for making such stretchable materials are taught and described in U.S. Pat. Nos. 4,720,415; 5,336,545; 5,366,793; 5,385,775 and in Patent Publication 2002/0119722A1 dated Aug. 29, 2002, all of which are incorporated by reference and made a part hereof.

The three-piece disposable absorbent article10also includes a back panel26having a first end28spaced apart from a second end30and a first side edge32spaced apart from a second side edge34. Desirably, the first end28is linear although it could have a scalloped, serpentine or non-linear configuration, if desired. The back panel26is elastic and has an interior surface36and an exterior surface38. The interior surface36faces and contacts the body of the user when the three-piece disposable absorbent article10is worn. The exterior surface38is aligned opposite to the interior surface36and faces away from the body of the user when the disposable absorbent article10is worn.

The same definitions recited above for the words “stretched, retracted, multiple directions and elastic” also apply to the back panel26. The original width of the back panel26is the distance between the first and second side edges,32and34respectively. The retracted dimension is measured after the force required to stretch the material has been removed.

The front and back panels,12and26respectively, are distinct members. By “distinct” it is meant that the front and back panels,12and26respectively, are separate and easily distinguishable from all other members. The front and back panels,12and26respectively, are spaced apart from one another and are discontinuous from one another along the longitudinal central axis X-X. For example, the front panel12can be spaced at least about 3 inches (about 76 mm) or more from the back panel26.

The interior surfaces22and36of the front and back panels,12and26respectively, are in direct contact with the user's skin when the three-piece disposable absorbent article10is being worn and are sometimes referred to as the bodyside surfaces. The exterior surfaces24and38are situated opposite to the interior surfaces22and36and are spaced away from the user's skin. The exterior surfaces24and38are sometimes referred to as the garment facing surfaces since they can be in direct contact with the inner surfaces of the user's outer clothing.

Each of the front and back panels,12and26respectively, is formed such that essentially the entire panel12and26is capable of being stretched and is also capable of being retracted. By “essentially the entire” it is meant that approximately between about 90% to 100% of the front panel12is stretchable and retractable and approximately between about 90% to 100% of the back panel26is stretchable and retractable.

Referring now toFIG. 3, each of the front and back panels,12and26respectively, is shown being formed as a three-layer laminate. Each of the front and back panels,12and26respectively, includes a first layer40, a second layer42, and a third layer44. The first and third layers,40and44respectively, are the outer layers and can be formed from the same material or from different materials. The first and third layers,40and44respectively, can be constructed from natural or synthetic fibers and can be a woven or non-woven material. The second or middle layer42has the elastic properties and is sandwiched between the first and third layers,40and44respectively. It should be noted that one or both of the outer layers40or44can be made from an elastic material and the second or middle layer can be made from a non-elastic material, if desired. Alternatively, the first, second and third layers can all be formed from an elastic material. The front and back panels,12and26respectively, can also be formed as a two-layer laminate with at least one of the layers being elastic, if desired.

The elastic laminate needs to provide stretch and retraction in at least three directions. Desirably, the stretch and retraction will be in more than three directions. Even more desirably, the stretch and retraction of the front and back panels,12and26respectively, are in directions approximately parallel to the X-X and Y-Y axes and directions at an angle to these two axes. It should be noted that when the three-piece disposable absorbent article10is worn, the transverse central axis Y-Y will extend laterally across the torso from the left hip to the right hip. Most desirably, the stretch and retraction of the front and back panels,12and26respectively, are in multiple directions, or stated another way, in three or more directions extending over an arc of 360 degrees. The ability of the front and back panels,12and26respectively, to stretch and retract will provide a confining force during use of the three-piece disposable absorbent article10to ensure that it comfortably conforms to the anatomy of the wearer's torso.

Desirably, the front and back panels,12and26respectively, are constructed from a stretch bonded laminate (SBL). Exemplary SBL materials are described in U.S. Pat. No. 4,720,415, which is hereby incorporated by reference and made a part hereof. In the stretch bonded laminate, the elastic core or middle layer42is elongated before the two outer nonwoven layers40and44are attached. The attachment can be by an adhesive, by heat, by pressure, by a combination of heat and pressure, etc. Another material option for the front and back panels,12and26respectively, is a necked bonded laminate (NBL). The NBL material is also a three layer laminate but the elastic core or middle layer42is not pre-stretched prior to being attached to the two outer nonwoven layers40and44. The outer layers40and44are necked stretched before the elastic core or middle layer42is attached to them. Exemplary NBL materials are described in U.S. Pat. No. 5,336,545, which is hereby incorporated by reference and made a part hereof. Other examples of elastomeric materials that can be used for the front and back panels,12and26respectively, include but are not limited to a continuous filament stretch bonded laminate (CFSBL) described in U.S. Pat. No. 5,385,775, a vertical filament laminate (VFL) described in Patent Publication 2002/0119722 A1 dated Aug. 29, 2002, a necked stretch bonded laminate (NSBL) and a necked thermal laminate (NTL). Combinations of the above materials can also be used.

It should also be noted that the front and back panels,12and26respectively, can be constructed from an elastic film that is capable of being stretched in at least three directions. Alternatively, the front and back panels,12and26respectively, can be formed from an elastic nonwoven that has multiple directions of stretch and retraction. Extensible materials can also be used to form the front and back panels,12and26respectively, of the three-piece disposable absorbent article10. Various other stretchable and elastic materials can also be used which are known to those skilled in the art.

Still referring toFIG. 3, the front and back panels,12and26respectively, can alternatively be formed from two outer layers40and44with a plurality of elastic strands46sandwiched therebetween. The elastic strands46can be formed from LYCRA. LYCRA is a registered trademark of E. I. Du Pont De Nemours & Co., having an office at 1007 Market Street, Wilmington, Del. 19898. The elastic strands46can be aligned approximately parallel to one another or be angled or skewed relative to one another. The elastic strands46can also be uniformly or randomly spaced apart from one another. The elastic strands46can vary in shape, size, configuration, and/or length. The diameter and/or cross-sectional configuration of the elastic strands46, the decitex (weight in grams per 10,000 meters of a strand) of the elastic strands46, and the tension imparted into the elastic strands46can all be varied to suit one's particular product needs. The elastic strands46can have a round, semi-circular, square, rectangular, oval or some other geometrical configuration. The elastic strands46can overlap, intersect or crisscross at least one other elastic strand46. The various ways of positioning, orienting, and adhering the elastic strands46to the two outer layers40and44are well known to those skilled in the art.

Referring again toFIGS. 1-3, the disposable absorbent article10also includes an absorbent assembly48which is secured to the interior surfaces22and36of the front and back panels,12and26respectively. The absorbent assembly48includes a liquid permeable bodyside liner50, a liquid-impermeable backsheet or outer sheet52, and a non-elastic absorbent54positioned therebetween. The bodyside liner50and the backsheet52are formed from an elastic material. The elastic material is capable of being stretched and retracted in at least one direction, with that direction being approximately parallel to the transverse central axis Y-Y. Desirably, the bodyside liner50and the backsheet52are capable of being stretched and retracted in at least two directions, with one of those directions being approximately parallel to the transverse central axis Y-Y and the other direction being approximately parallel to the longitudinal central axis X-X. Even more desirably, the bodyside liner50and the backsheet52are capable of being stretched and retracted in three or more directions, with one of those directions being approximately parallel to the transverse central axis Y-Y and a second direction being approximately parallel to the longitudinal central axis X-X. The absorbent54, by contrast, is non-elastic. By “non-elastic” it is meant that the absorbent54is formed from a material that can not stretch or retract an appreciable amount. By “an appreciable amount” it is meant that the material that can be stretched and retracted more than 10% from its original dimension in a given direction.

The absorbent54can be formed from natural or synthetic materials. The absorbent54can be made from cellulosic fibers, wood pulp, textile fibers or other absorbent materials known to those skilled in the art. A superabsorbent, in solid form and in the shape of small particles, granules, flakes, etc., can be mixed in with the absorbent material to increase the absorbent capacity of the absorbent54. The absorbent54is non-elastic but because of its unique configuration, it does have the ability to elongate and contract back towards its original dimension. By “elongate” it is meant that the absorbent54can be lengthened or extended in a particular direction. By “contract” it is meant that the absorbent54can be reduced in size or shortened in a particular direction after it has been elongated. More information about the shape and configuration of the absorbent54will be discussed later.

The absorbent assembly48can optionally include a surge layer56located between the bodyside liner50and the absorbent54. The surge layer56can function to rapidly acquire and temporarily retain body fluid, such as urine, before it can be absorbed into the absorbent54. Desirably, the surge layer56is also capable of wicking body fluid lengthwise and/or widthwise across its surface as well as directing the body fluid downward in a z-direction, toward the absorbent54.

The bodyside liner50and the backsheet52are secured together to completely enclose the non-elastic absorbent54. Desirably, the bodyside liner50and the backsheet52are secured together about their perimeters by an adhesive.

Referring toFIGS. 2 and 3, the absorbent assembly48has a first end58, a second end60, a first side edge62and a second side edge64. The absorbent assembly48is shown secured to the interior surfaces22and36of the front and back panels,12and26respectively, by a first attachment member66. The first attachment member66is aligned along the longitudinal central axis X-X of the three-piece disposable absorbent article10. The first attachment member66can be a line of adhesive. The first attachment member66can be a continuous line of adhesive or it can be an intermittent line of adhesive. When the first attachment member66is a line of adhesive, it will allow the backsheet52to stretch and retract as the front and back panels,12and26respectively, stretch and retract approximate the transverse central axis Y-Y. By “approximately in the transverse central axis Y-Y” it is meant within 30 degrees on each side of the transverse central axis Y-Y. Alternatively, the first attachment member66can be a narrow strip of adhesive aligned approximately along the longitudinal central axis X-X. It is also possible to secure the absorbent assembly48to the exterior surfaces24and38of the front and back panels,12and26respectively, if desired.

The absorbent assembly48can be secured to either the interior surfaces22and36or to the exterior surfaces24and38of the front and back panels,12and26respectively, after each panel12and26has been stretched a predetermined amount. The amount the front and back panels,12and26respectively, are stretched before the absorbent assembly48is attached can vary. One advantage of attaching the absorbent assembly48to the interior surfaces22and36of the front and back panels,12and26respectively, is that the absorbent assembly48will be in direct contact with the wearer's body. This design is beneficial for absorbing body fluids discharged by the wearer and thereby is better at preventing fluid leakage.

The first attachment member66can include permanent attachments as well as removable or releasable attachments. Desirably, the first attachment member66is a permanent attachment where it is not designed to be removed without destroying the bond. The first attachment member66can be formed by using glue, adhesive, ultrasonic bonds, thermal bonds, heat bonds, pressure bonds, heat and pressure bonds, or any other attachment mechanism known to those skilled in the art. The first attachment member66can also include a mechanical fastener, such as by sewing with thread, using buttons and button holes, using snaps, by employing hook and loop fasteners, etc. A hook and loop fastener is generally considered a releasable attachment. One type of hook and loop fastener is VELCRO wherein a hook material is releasably engaged into a loop material. VELCRO is a registered trademark of Velcro USA, Inc., having an office at 406 Brown Avenue, Manchester, N.H. 03103.

Alternatively, the first attachment member66can be formed over a surface area having a predetermined length and width. The first attachment member66can consist of intermittent point bonds that are spaced apart from one another. For example, the intermittent point bonds can be formed by using a hot or a cold melt adhesive or by forming ultrasonic bonds. Various bond formations can be used which are known to those skilled in the art. Desirably, the first attachment member66is formed using intermittent bonds because it allows the elastic material forming the front and back panels,12and26respectively, to gather the absorbent assembly48as the elastic contracts. This gathering feature causes the absorbent assembly48to remain in direct contact with the user's body prior to and during the time period that the absorbent assembly48is being insulted with body fluid.

The front and back panels,12and26respectively, can be stretched in a direction approximately parallel to the transverse axis Y-Y, or in any other direction or directions, before the absorbent assembly48is secured to it. The amount of stretch can vary. No stretch is required if one does not wish to do so. Desirably, the front and back panels,12and26respectively, are stretched at least about 5% from a relaxed state before the absorbent assembly48is secured thereto. Desirably, the front and back panels,12and26respectively, are stretched at least about 10% from a relaxed state before the absorbent assembly48is secured thereto. More desirably, the front and back panels,12and26respectively, are stretched at least about 25% from a relaxed state before the absorbent assembly48is secured thereto. Most desirably, the front and back panels,12and26respectively, are stretched from between about 25% to about 500% from a relaxed state before the absorbent assembly48is secured thereto. The front and back panels,12and26respectively, extend laterally, along the transverse central axis Y-Y, beyond the first and second side edges,62and64respectively, of the absorbent assembly48. The front and back panels,12and26respectively, also extend longitudinally, along the longitudinal central axis X-X, beyond the first and second ends,58and60respectively, of the absorbent assembly48. The size and location of the front and back panels,12and26respectively, allow the three-piece disposable absorbent article10to better conform to the torso of the wearer.

Still referring toFIG. 2, when the absorbent assembly48is secured to the front and back panels,12and26respectively, a crotch panel68is formed. The crotch panel68separates the front panel12from the back panel26and is designed to cover the perineum area of the wearer. The crotch panel68can cover a distance of a few inches in a child training pant to several inches in an adult incontinence garment. For example, a crotch panel68in a child training pant may range from about 2 inches (about 5 centimeters (cm)) to about 10 inches (about 25 cm); while in an adult incontinence garment, the crotch panel68may range from about 6 inches (about 15 cm) to about 20 inches (about 51 cm).

The bodyside liner50and the backsheet52are stretchable and retractable in relation to the front and back panels,12and26respectively. By constructing the bodyside liner50and the backsheet52to be stretchable and retractable in relation to the front and back panels,12and26respectively, it means that the three-piece disposable absorbent article10will be more suitably adapted to conform to the wearer's torso as he or she moves about. The reason for this is that the front, back and crotch panels12,26and68, will all be elastically stretchable and retractable and therefore can stretch and retract to snugly conform to the user's anatomy, especially to the wearer's torso. It is not necessary that the bodyside liner50and the backsheet52stretch and retract to the same extent as the front and back panels,12and26respectively. However, it is desirable if they do.

It should be noted that there is no need to have the absorbent assembly48gather as the front and back panels,12and26respectively, retract. However, if one so desires, the absorbent assembly48can be constructed and attached to the front and back panels,12and26respectively, in a way that will allow the absorbent assembly48to be gathered as the front and back panels,12and26respectively, elastically retract in a direction approximately parallel to the transverse central axis Y-Y.

The absorbent assembly48should remain over the perineum. As the absorbent assembly48receives body fluid and/or excrement discharged by the wearer, the middle section of the absorbent assembly48, which is situated adjacent to the transverse central axis Y-Y, will be displaced outward, away from the user's torso. The first attachment66will assure that the absorbent assembly48will be aligned over the perineum of the user while allowing the absorbent assembly48to move outward, in the z-direction, away from the torso as additional body fluid is received and retained.

Still referring toFIGS. 2 and 3, the absorbent assembly48also has at least one elastic member70positioned adjacent to and aligned approximately parallel to each of its first and second side edges62and64. Each of the elastic members70is situated between the bodyside liner50and the backsheet52. Each of the elastic members70provides a gasket to hold the side edges62and64of the absorbent assembly48against the user's body. Each of the elastic members70can be in the form of an elastic strand, ribbon or strip. Desirably, there are from about 2 to about 6 elastic members70positioned adjacent to each of the side edges62and64. InFIGS. 2 and 3, three elastic members70are shown positioned adjacent to each of the side edges62and64. The elastic members70can have a cross-sectional configuration that is round, square, rectangular or any other desired geometrical configuration. The elastic members70can be aligned parallel or at an angle to the longitudinal central axis X-X and should extend completely through the crotch panel68. Desirably, the elastic members70have an arcuate profile. The opposite ends of the elastic members70can terminate short of the front and back panels,12and26respectively, as shown inFIG. 2or they can extend into the front and back panels,12and26respectively, if desired.

Still referring again toFIGS. 2 and 3, the three-piece disposable absorbent article10also includes a waist band72formed from an elastic material. The waist band72is shown being secured to the exterior surfaces24and38of the front and back panels,12and26respectively. The waist band72can be attached in a non-stretched or semi-stretched condition. By “semi-stretched” it is meant that the waist band72is not stretched to stop or fully stretched. The waist band72can be secured to the front and back panels,12and26respectively, by using ultrasonics, by a thermal bond, by adhesive, by heat, by pressure, by a combination of heat and pressure, or a combination of any of the above. The waist band72can also be secured to the front and back panels,12and26respectively, by a mechanical attachment, such as by sewing with thread. Other means of securing the waist band72to the front and back panels,12and26respectively, which are known to those skilled in the art, can also be used.

The waist band72has a first end74, a second end76, a first side edge78and a second side edge80. As shown inFIGS. 1-3, the first end74is coterminuous with the first ends14and28of the front and panels,12and26respectively. The first end74can be spaced apart from the first ends14and28, if desired.

Referring again toFIG. 2, the first and second side edges,78and80respectively, of the waist band72are aligned with the first and second side edges,18and20respectively, of the front panel12and also with the first and second side edges,32and34respectively, of the back panel26. The waist band72has a width, denoted as (w), which can range from between about 3 millimeters (mm) to about 150 mm. Desirably, the width (w) of the waist band72will range from between about 5 mm to about 100 mm. More desirably, the width (w) of the waist band72will range from between about 10 mm to about 50 mm. Most desirably, the width (w) of the waist band72will range from between about 12 mm to about 25 mm.

Referring again toFIGS. 2 and 3, the waist band72can be constructed as a laminate consisting of two outer layers82and84having one or more elastic strands86secured therebetween. Desirably, multiple elastic strands86will be positioned between the two outer layers82and84. The two outer layers82and84can be formed from a non-elastic material. The non-elastic material can be various woven or non-woven materials. An example of a non-woven material that can be used to form one or both of the two outer layers82and84is polypropylene spunbond. The elastic strands86can be formed from LYCRA. At least one of the elastic strands86in the waist band72can extend from the first side edge78to the second side edge80. Desirably, all of the elastic strands86in the waist band72will extend from the first side edge78to the second side edge80, as is depicted inFIG. 2. Alternatively, one or more of the elastic strands86in the waist band72will not extend from the first side edge78to the second side edge80. For example, one or more of the elastic strands86in the waist band72can extend over only a portion of the distance located between the first and second side edges,78and80respectively.

The elastic strands86can be aligned approximately parallel to one another or be angled or skewed relative to one another. The elastic strands86can also be uniformly or randomly spaced apart from one another. The elastic strands86can vary in shape, size, configuration, and/or length. The diameter and/or cross-sectional configuration of the elastic strands86, the decitex (weight in grams per 10,000 meters of a strand) of the elastic strands86, and the tension imparted into the elastic strands86can all be varied to suit one's particular product needs. The elastic strands86can have a round, semi-circular, square, rectangular, oval or some other cross-sectional configuration. The elastic strands86can overlap, intersect or crisscross at least one other elastic strand86. The various ways of positioning, orienting or securing the elastic strands86to the two outer layers82and84are well known to those skilled in the art.

The number of elastic strands86can range from 1 to about 20. The exact number of elastic strands86that are present will depend on the width (w) of the waist band72, the diameter of each elastic strand86, the arrangement of the elastic strands86on the two outer layers82and84, etc. Desirably, from about 2 to about 10 elastic strands86are present in the waist band72. More desirably, from about 3 to about 8 elastic strands86are present in the waist band72. Most desirably, from about 4 to about 6 elastic strands86are present in the waist band72. InFIGS. 2 and 3, three elastic strands86are depicted in the waist band72.

Referring again toFIGS. 1 and 2, the three-piece disposable absorbent article10also includes a pair of leg bands88and90. The leg band88is secured to the interior surface22of the front panel12and the leg band90is secured to the interior surface36of the back panel26. Each of the pair of leg bands88and90is positioned adjacent to one of the second ends16and30of the front and back panels12and26respectively, and approximate leg openings92and94, seeFIG. 1.

Still referring toFIGS. 1 and 2, the absorbent assembly48is capable of being folded transversely, approximate the transverse central axis Y-Y. This folding enables the front panel12to overlap the back panel26. When the absorbent assembly48is folded, the first and second side edges,18and20respectively, of the front panel12will align with the first and second side edges,32and34respectively, of the back panel26. In addition, the first and second side edges,78and80respectively, of the waist band72will be aligned with the first and second side edges18and20of the front panel12. After being folded, a pair of side seams96and98are formed which join the front panel12to the back panel26to create a closed unitary article, seeFIG. 1. By “a closed unitary article” it is meant that the article, upon removal from its packaging, will appear similar to cloth underwear. A close unitary article is not similar to an infant diaper that has an open configuration and must be fastened to itself once it is positioned around a baby's torso.

The pair of side seams96and98form a secure bond that is normally unbreakable during use of the three-piece disposable absorbent article10. However, the pair of side seams96ands98can be easily broken by the user or by a caregiver when the three-piece disposable absorbent article10is to be removed from the user's torso. By breaking the pair of side seams96and98, the three-piece disposable absorbent article10can be quickly removed from the user's body and be discarded. Desirably, the pair of side seams96and98will form a bond that is not easily broken or opened during use but will be easily broken for removal. The pair of side seams96and98can be made using ultrasonics, heat, pressure, heat and pressure, adhesive, glue, or a combination of any of the aforementioned. In addition, the pair of side seams96and98can be formed by a chemical bond or by a mechanical bond, such as by sewing with a thread. These and other types of bonds are well known to those skilled in the art. Desirably, the pair of side seams96and98is formed using ultrasonic equipment.

Returning toFIG. 1, once the pair of side seams96and98is formed, the three-piece disposable absorbent article10acquires a pant-like appearance. The pant-like appearance will be very similar to cloth underwear. The three-piece disposable absorbent article10will have a waist opening100formed adjacent to the first ends14and28of the front and back panels,12and26respectively. The waist opening100is spaced apart from the pair of leg openings92and94. Since the front and back panels,12and26respectively, are formed from an elastic material, the waist opening100and the pair of leg openings92and94can stretch and retract to accommodate the anatomy of the user and movement of the user's body.

Referring now toFIG. 4, the three-piece disposable absorbent article10is shown with a partial cut away view exposing the absorbent assembly48. In this view, one can clearly see that the absorbent54has a length l1and a width w1. The length l1is aligned parallel to the longitudinal central axis X-X and the width w1is aligned parallel to the transverse central axis Y-Y.

Referring now toFIGS. 5 and 6, the absorbent54includes a pair of planar regions102and104separated by a non-planar region106extending across its width w1. In other words, the non-planar region106is located in between the two planar regions102and104. InFIG. 6, the planar region102is shown having an upper surface108and a lower surface110and the planar region104is shown having an upper surface112and a lower surface114. The non-planar region106includes a plurality of alternating ridges116and valleys118. The ridges and valleys,116and118respectively, can also be characterized as folds, pleats, bellows, undulations, creases, wrinkles, corrugations, rugosities or one or more z-folds. Each ridge116has a peak120and each valley118has a bottom point122. Each of the peaks120extends above the upper surfaces108and112of the two planar regions,102and104respectively. In addition, each of the bottom points122is aligned parallel with the lower surfaces110and114of the two planar regions,102and104respectively. Alternatively, each of the bottom points122can be aligned below the lower surfaces110and114of the two planar regions,102and104respectively, if desired.

Still referring toFIG. 6, the vertical distance d located between a peak120and an adjacent bottom point122should be less than about 1 inch (about 25.4 mm). Desirably, the vertical distance d located between a peak120and an adjacent bottom point122should be less than about 0.75 inches (about 19 mm). More desirably, the vertical distance d located between a peak120and an adjacent bottom point122should be less than about 0.5 inches (about 12.7 mm).

The above described construction(s) are beneficial in keeping the non-planar region106close to the user's body. By so configuring the non-planar region106, one can be assured that the non-planar region106is positioned to better receive body fluid and prevent fluid leakage from the three-piece disposable absorbent article10.

Even when the non-planar region106is elongated, the peaks120of the ridges116will be aligned even with or be located above the upper surfaces108and112of the two planar regions,102and104respectively. Likewise, when the non-planar region106is elongated, the bottom points122of the valleys118will be evenly aligned with or be situated below the lower surfaces110and114of the two planar regions102and104.

Referring again toFIG. 5, the three-piece disposable absorbent article10further includes a second attachment member124spaced apart from a third attachment member126. The second attachment member124is located between the planar region102and the backsheet52just to the left of the non-planar region106. The third attachment member126is located between the planar region104and the backsheet52just to the right of the non-planar region106. The second and third attachment members,124and126respectively, can be adhesive, multiple adhesive bonds or one or more lines of adhesive. The line(s) of adhesive can be continuous or intermittent. When one or more lines of adhesive are used, they should be aligned parallel to the longitudinal central axis X-X. The lines of adhesive can extend along the length l1of the absorbent54or along a portion of the length l1of the absorbent54. Desirably, the second and third attachment members,124and126respectively, can extend along at least about 50% of the length l1of the absorbent54. More desirably, the second and third attachment members,124and126respectively, will extend along at least about 75% of the length l1of the absorbent54. Even more desirably, the second and third attachment members,124and126respectively, can extend along from between about 75% to 100% of the length l1of the absorbent54.

The second and third attachment members,124and126respectively, function to retain the non-planar region106in its initial configuration until the elastic backsheet52is stretched parallel to the direction of the transverse central axis Y-Y. When the elastic backsheet52is stretched to an extended state along the transverse central axis Y-Y, the second and third attachment members,124and126respectively, will be drawn further apart. This action will cause the non-planar region106to flatten to or towards a planar configuration. As this happens, the alternating ridges116and valleys118will acquire a flattened configuration. It should be noted that the non-elastic absorbent54can be elongated and contracted in only one direction when the elastic backsheet52is stretched and retracted, and that direction is aligned parallel to the transverse central axis Y-Y.

When the force used to stretch the elastic backsheet52is removed, the backsheet will retract to or towards its original dimension. As this occurs, the second and third attachment members,124and126respectively, will move closer together and cause the non-planar region106to again acquire a non-planar configuration.

While the invention has been described in conjunction with several specific embodiments, it is to be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the aforegoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations that fall within the spirit and scope of the appended claims.