Packaged body adhering absorbent article and method of applying such article to a wearer

In a packaged feminine care absorbent article and method of applying such an article to a wearer, an absorbent article includes an absorbent structure and a shell, with the absorbent structure configured for disposition adjacent a female wearer's vaginal region. The shell is configured for supporting the absorbent structure and has adhesive on a body-facing surface thereof for adhering the shell directly to the wearer. The absorbent article has a packaged configuration and a use configuration, at least a portion of the absorbent article being in overlapping relationship with another portion of the absorbent article in the packaged configuration, and with these respective portions being free from overlapping relationship in the use configuration. The article may be adhered to the wearer while in its packaged configuration and then converted to its use configuration.

BACKGROUND

The present invention relates generally to an absorbent article for absorbing bodily fluids.

Absorbent personal care articles intended to absorb discharged bodily fluids are well known in the art. Such absorbent articles generally comprise a fibrous mass or other absorbent core which can absorb and hold body fluids. Similarly, it is well known that feminine care articles have been employed to absorb and hold liquids, such as urine and/or menses. A typical structure of an absorbent article includes a fluid impermeable back sheet, a fluid permeable top sheet and an absorbent core positioned between the back sheet and the top sheet. Prior absorbent articles have also included various other features to improve fluid handling, such as intake layers, distribution layers, retention layers and the like. In these absorbent personal care articles, the top sheet is the body-facing side of the absorbent article and the back sheet is the garment-facing side of the absorbent article.

Generally, the absorbent articles are held in place during use by using the wearer's waist and elastic materials in the waist portion of the absorbent product in place during use, in the case of pant-like garments, such as diapers and training pants, or by attaching the absorbent article to the underwear or undergarment of a wearer, in the case of pads or liners. Current methods of attaching the absorbent article to the underwear or undergarment of a wearer include placing an adhesive on the garment-facing side of the back sheet, having optional flaps (wings) that extend from the longitudinal sides of the absorbent article which wrap around the crotch portion of the underwear or undergarment of the wearer and a combination of the adhesive and the flaps.

It has also been suggested to use an adhesive to adhere the absorbent article to the skin of the wearer. However, the design of these absorbent articles was essentially the same as the absorbent articles which were attached to the underwear or undergarment of the wearer. That is, the adhesive is applied to the body-facing surface of the top sheet. Alternatively, in another design, a portion of the back sheet was wrapped around and over the top sheet. This portion of the back sheet which is wrapped around and over the top sheet becomes a body facing surface. An adhesive is applied to the portion of the back sheet which is wrapped over the top sheet. While these designs were effective for adhering the absorbent article to the skin of a wearer, these absorbent articles were not comfortable for wearers to wear, since the shape and size of the absorbent articles were the same as those absorbent articles which were attached to the undergarment or underwear of the wearer.

Similarly, absorbent articles that are attached to the underwear or undergarment of a wearer can also be uncomfortable for the wearer. This is because during normal movement of the body, portions of the body place opposed forces on the undergarment, which may cause the undergarment to be bunched or twisted. When this occurs, any absorbent article attached to the underwear or undergarment may also become bunched or twisted, causing discomfort to the wearer of the absorbent article. For example, the presence and absence of pressure from the absorbent article on the inner thighs as the wearer moves, which is often described by wearers as feeling “like a diaper”, is one source which compromises comfort for wearers of conventional absorbent articles, including liners, ultra-thin absorbent pads and maxi pads. In addition, the movement of the wearer or deformation of the underwear while being worn may also cause the absorbent article to have a poor fit against the body of the wearer, which could result in leaks from the absorbent article.

Another disadvantage of conventional absorbent articles is that the silhouette or outline of the absorbent article may be visible to others through the clothing of the wearer. Even currently available ultra-thin absorbent articles may be visible through tight fitting outer clothing of a wearer. Therefore, conventional absorbent personal care articles do not always provide discretion for wearers.

There is a need in the art to provide wearers of absorbent articles with a discrete absorbent product, which is as easy to use as a conventional pad and is comfortable to wear and will effectively prevent or reduce premature leakage from the absorbent article.

SUMMARY

In one embodiment, a packaged feminine care absorbent article generally comprises an absorbent article including an absorbent structure and a shell, with the absorbent structure being configured for disposition adjacent a female wearer's vaginal region to absorb bodily fluids discharged by the wearer. The shell is configured for supporting the absorbent structure at the vaginal region and has a body-facing surface, a garment-facing surface and adhesive on the body-facing surface for adhering the shell directly to the wearer. The absorbent article has a packaged configuration and a use configuration, at least a portion of the absorbent article being in overlapping relationship with another portion of the absorbent article in the packaged configuration, and with these respective portions being free from overlapping relationship in the use configuration.

In another embodiment, a packaged feminine care absorbent article generally comprises an absorbent structure configured for disposition adjacent a female wearer's vaginal region to absorb bodily fluids discharged by the wearer. A shell is configured for supporting the absorbent structure at the vaginal region, and has a body-facing surface and a garment-facing surface. The body-facing surface of the shell has an adhesive thereon for adhering the shell directly to the wearer. A cover overlies the adhesive on the body-facing surface of the shell.

In one embodiment, a method of applying a feminine care absorbent article to a wearer thereof generally comprises adhering a posterior region of a packaged absorbent article to a gluteal region of the wearer using adhesive located on the shell of the article. The absorbent article is then converted from a packaged configuration wherein at least a portion of the absorbent article is in overlapping relationship with another portion of the absorbent article to a use configuration wherein these respective portions are free from overlapping relationship. A central region of the article is then adhered to the wearer adjacent the wearer's vaginal region.

DEFINITIONS

It should be understood that the term “absorbent product” or “absorbent article”, as used herein, refers to any article used to control bodily fluids that are configured to absorb and retain bodily exudates, including urine, blood, menses, and other bodily discharges, such as sweat and vaginal secretions resulting from sexual activity and the like. In addition, the term is intended to include odor absorbing articles.

As used herein, the term “polymer” generally includes, but is not limited to, homopolymers, copolymers, such as, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic and random symmetries.

As used herein, “body-facing surface” means that surface of the absorbent article which is intended to be disposed toward or placed adjacent to the body of the wearer during ordinary use. The “garment-facing surface” is on the opposite side of the absorbent article from the body-facing surface. The garment-facing surface is an outward surface of the absorbent article and is intended to be disposed to face away from the wearer's body during ordinary use. The garment-facing surface is generally arranged to face toward or placed adjacent to the wearer's undergarments when the absorbent article is worn.

As used herein, the term “connected” is intended to mean directly connected and indirectly connected. By directly connected, it is intended that the connected elements are in contact with one another or affixed to one another. By indirectly connected, it is intended that one or more intervening or intermediate elements are between the two elements which are secured or “connected” together. The intervening elements may be affixed.

As used herein, the term “absorbent structure” is intended to mean a configuration of an absorbent material which allows bodily fluids to be absorbed by the absorbent material.

DETAILED DESCRIPTION

The absorbent product of the present invention provides an absorbent article which is designed to adhere to the body of a wearer in the area of the body of the wearer which may need bodily fluids absorbed. In one particular use of the absorbent article, the absorbent article is attached to the body of a female wearer to or around the vulva region of the body. By “to or around the vulva region”, it is meant adjacent regions of the body of a female including the pubic region and the perinea region. When applied to or around the vulva region of the female body, the absorbent article may be used as a panty-liner, sanitary napkin or incontinence article. In addition, the absorbent article may be worn as an underwear substitute since the absorbent article of the present invention does not need underwear to hold the absorbent article in place. As an underwear substitute, the absorbent article provides protection to the vulva area by creating a barrier between the outer clothing and the vulva of a wearer. When worn as an underwear substitute, the absorbent article serves to protect the outer clothing of the wearer from bodily discharges from the vulva region of the wearer's body. In addition, when the absorbent article is worn as an underwear substitute, the absorbent article also serves to protect the sensitive skin and body features of the vulva region from roughness of the outer clothing, thereby preventing or alleviating irritation to the sensitive skin and body features of the vulva region.

To gain a better understanding of the present invention, attention is directed to the Figures of the present specification. As is shown in each of the Figures, in particularFIGS. 1 and 2, the absorbent article100has a longitudinal direction1and a lateral direction2. One component of the absorbent article100is a shell114. This shell114has a first side115, as shown inFIGS. 1 and 2, and a second side117, as is shown inFIGS. 3 and 4. The shell114serves to provide the overall contour or silhouette of the absorbent article of the present invention. In addition, the shell114also provides a surface for attachment or adhesion of the absorbent article100to the body of a wearer.

The first side115of the shell114is the body facing side of the absorbent article100and the second side117of the shell114is the garment facing side of the absorbent article. The shell114of the absorbent article100has a first region101. This first region101has a pair of lateral side regions102,102′ extending from the first region. This pair of lateral side regions each has a proximate end103,103′ adjacent the first region101and a distal end104,104′. The pair of lateral side regions102,102′ and the first region101together define an opening105in the shell114. This opening105may be open near the distal ends104,104′ of the lateral side regions102,102′, as is shown inFIG. 1or, as shown inFIG. 2, the lateral side regions102,102′ may be joined at the distal end104,104′ to form a second region107. The portions of the lateral side regions102,102′ and the first region101adjacent the opening105form a circumference or edge106around the opening105. This circumference or edge106typically has thickness in the z-direction3which is about equal to the thickness of the shell. However, the thickness of the edge may be increase or decreased to improve comfort for a wearer or performance of the absorbent article.

The absorbent article100further has an absorbent structure121attached to the second side117of the shell114, as is shown inFIGS. 1-6. At least a portion of the absorbent structure121is positioned in the absorbent article such that a majority of the opening105in the shell has the absorbent structure121positioned therein, as can be seen inFIGS. 1 and 2. In one particular embodiment, the entire area of the opening105has the absorbent structure121positioned therein. Generally to hold the absorbent structure in place, a portion of the absorbent structure121is attached to the second side117of the shell114. Suitable methods of attaching the absorbent structure121to the second side117of the shell114includes adhesives, mechanically bonding the absorbent structure121to the second side117using bonding means such as ultrasonic bonding, heat and pressure bonding and the like, which are discussed in more detail below.

In one embodiment of the present invention, the opening105in the shell may be a hole, which is devoid of any material, or and in another embodiment of the present invention the opening105may be a region which is permeable to body fluids. If the opening is a region which is permeable, the opening may have a material such as hydrogel or similar material that will allow body fluids to flow through the material.

In one embodiment, the first side115of the shell114is adapted to be the body contacting side of the absorbent article. The first region101, the lateral sides regions102,102′ and the second region107, when present, on the first side115of the shell114are designed or adapted to contact, attach or adhere to the wearer's skin. In one particular embodiment, the first region101of the shell114is designed or adapted to contact a female wearer's skin surrounding the vulva region of the female torso when the absorbent article100is applied to the wearer. By “designed or adapted to contact a female wearer's skin surrounding the vulva region of the female torso”, it is meant that the size and shape of the shell114, including the first region and the lateral side regions and second region, if present, is such that the shell114fits in the vulva region and possibly the surrounding pubic region and perinea regions of the female torso. Generally, the shell114is sized and shaped such that the extent of the first side115of the shell114only contacts and attaches or adheres to the skin surrounding and proximate to the vulva area and possibly the pubic and perinea regions of the wearer. In addition to contacting the skin in the vulva, pubic and perinea regions of the wearer, the first side115of the shell114may also contact and attach or adhere to any hair in the vulva area of the wearer which may be present. The first side115of the shell114is what holds the absorbent article in place on the body of a wearer.

To gain a better understanding of the vulva region and surrounding regions of the female body, a general description of the anatomical structures can be found in The Illustrated Running Press Edition of the American Classic Gray's Anatomy (1974) by Henry Gray and Structure and Function in Man (1974) by Stanley W. Jacob, M.D., F.A.C.S. and relevant portions are included herein by reference. The general form can be found in Anatomy for an Artist: Elements of Form by Eliot Goldfinger and relevant portions are included herein by reference. The general description of the pubic hair covering these regions can be found in Woman's Body: A Manual for Life and relevant portions are included herein by reference.

The female anatomical structures to be described include the leg and the lower torso. The external anatomical structures of the lower torso include gluteal region and perineum region. The gluteal region includes the buttocks and the anus. The anatomical structure involved on the leg is the medial surface of the upper thigh.

The gluteal region includes generally the buttocks and anus and is typically bound in front by the line of the buttocks and the gluteal folds, in the back by the sacral triangle and the sides by lines extending through the greater trochanters. The shape of the gluteal region is roughly hemi-spherical and convex, and is determined by a series of muscles including the gluteus maximus and a series of fat pads including the posterior gluteal fat pad. The line of the buttocks separates the gluteal region and the perineum region.

The upper thigh region includes typically the right and left thigh and is typically bound on top by the thigh lines and the sides by the front and back of the leg. The thigh lines are two lines that are on either side of the labia and each of the lines runs along the line of the inguinal ligment to the gluteal folds and marks where the upper thigh meets the lower torso. The shape of the region is roughly a portion of a tapered cylinder and convex, and is shaped by a series of muscle groups including the gracilis, pectineus, adductor longus, adductor brevis, and adductor magnus and series of fat pads including the inner thigh fat pad.

The perineum region, which extends from the inferior outlet of the pelvis to the bony structure of the coccyx, is comprised of two divisions, the urogenital triangle and the anal division or obstetrical perineum. The region includes the external organs of reproduction; the mons pubis, labia majora and minora, clitoris, meatus urinarius and the opening to the vagina. The region is generally bound in front by the lower abdominal line, on the sides the thigh lines, and in the back the line of the buttocks. The abdominal line is a line that passes across the top of the pubis. The lines of the buttocks are lines that connect the thigh lines to the gluteal cleft. For convenience in describing the form and created spaces in the perineum region, this region will be subdivided into three regions an anterior region including the mons pubis, a central region including the labia majora and minora, and posterior region. The anterior region is bound in front by the lower abdominal line, in back by anterior commissure, and on the sides by line of the labia. The central region is bound in front by the anterior commissure, in the back by the posterior commissure, and on the side by the line of the labia. The posterior region is bound in front by the line of the labia, in the back by the lines of the buttocks, and on the sides the thigh line.

The vulva region includes the female external genitalia and generally includes the anterior and central regions of the perineum. The mons pubis [or veneris] is generally a rounded eminence in front of the symphysis pubis, formed by a collection of fatty tissue including the pubic fat pad beneath the integument and is generally covered with pubic hair. The labia majora are generally two prominent longitudinal cutaneous folds extending downward from the mons veneris to the anterior boundary of the perineum, and generally enclosing the common urinary-sexual opening. The space between the two folds is the labial cleft. Each labium has generally two surfaces, an outer, which is pigmented and covered generally with strong, crisp pubic hairs, and an inner within the labia cleft, which is smooth and is beset with large sebaceous follicles and is continuous with the genito-urinary mucous tract; between the two there is considerable quantity of areolar tissue, fat including the labia fat pad, and tissue besides vessels, meeting the anterior commissure. Posteriorly they are typically not joined, but generally appear to become lost in the neighboring integument, terminating close to, and nearly parallel with each other. Together with the connecting skin between them, they form the posterior commissure or posterior boundary of the vulval orifice. The interval between the posterior commissure and the anus constitutes the perineum region. The fourchette is the anterior edge of the perineum, and between it and the hymen is a depression, the fossa navicularis. The line of the labia separates the labia and the perineum region.

The labia minora are two small cutaneous folds, situated generally within the labia majora, and extending from the clitoris obliquely downward, outward, and backward on each side of the orifice of the vagina.

The form of the perineum, gluteal, and upper thigh regions combine to form a very intricate skin topography and spaces. The roughly two-hemispherical-like forms of the buttocks, the roughly tapered-cylinder-like form of the upper thigh, split-teardrop-like form of the vulvar region create intricate generally convex topography with intersections to form a series of recesses. The generally convex topography of the buttocks, the vulvar region, and upper thigh join to create spaces including two inner thigh grooves along two thigh lines, a depression in the posterior perineum region and a cleft extending through the labia and gluteal clefts. The grooves, depression, and cleft are like interconnected recesses in the topography. The central region general has lateral sides separated by a distal surface created by the labial cleft and includes the labial cleft.

Pubic hair generally cover some of these regions and fill in a portion of these recesses especially the labial cleft and the portion of the groove of the thigh parallel to the labial cleft to create a hair surface topography. The hair topography is the surface topography of an imaginary distal surface created by the hair. The depression of the perineum, thigh groove parallel to the gluteal cleft, and the gluteal cleft generally has little or no pubic hair. The skin topography combines with the hair topography to create an overall body topography.

This intricate space created by the intricate body form in this region of the body varies between women in both size and form, and varies with the position and movement of the women. Some of these variations are summarized in “Female genital appearance: ‘normality’ unfolds” by Jillian Lloyd et. al., BJOG: An International Journal of Obstetrics and Gynecology, May 2005, Vol. 112, pp. 643-646 and is included herein by reference.

As a woman ages, many changes occur to the vulva region. Skin begins to lose its elasticity and hangs more loosely from the body. In addition, the fat pads tend to be reduced, changing the topography of the vulva region. As a result, there is a need for a product which can be adapted to these changing conditions.

When the absorbent article of the present invention is positioned for use on a wearer, generally the first side115of the shell, including the first region101, the lateral side regions102,102′ and the second region107, if present, are positioned on the wearer outside the labia majora of the wearer. This will allow any fluid coming from the vulvo-vaginal area of the body of a wearer to pass through the opening105present in the shell114, so that the fluid may flow into the absorbent structure121. The opening105could be an area which is devoid of the shell material or any other material. Alternatively, the opening may be a permeable area, which is permeable to body fluids, containing a material which is permeable. Typically, the absorbent structure121is the portion of the absorbent article which provides absorbency to the absorbent article. In an alternative embodiment, the first side115of the shell114may also provide some absorbency to the absorbent article. For example, the second first side115of the shell114may contain an absorbent material integrated into the shell114, such that the first side of the shell114has some degree of absorbency. The first side115of the shell114may have an absorbent material coated or impregnated into the shell material.

When the second region107is present, as shown inFIG. 2, the entire opening105is surrounded by the shell114. When the second region107is not present, as shown inFIG. 1, the opening105has an unbound end, meaning that the distal ends104,104′ of the lateral side regions102,102′ are not connected. Each configuration of the absorbent articles shown inFIGS. 1 and 2have advantages. For example, the configuration shown inFIG. 1, where the second region107is not present in the absorbent article100, the absorbent article100may provide more comfort to the wearer when being worn. That is, in use of the absorbent article100, the first region101is designed to be placed towards the anterior region of the vulva region of the wearer. By not having the second region, the absorbent article100will not be positioned in the perinea region of the wearer, which may provide improved comfort to the wearer. Alternatively, by having the second region107present, the absorbent article may provide superior leak protection to the wearer, by creating a seal completely surrounding the labia majora of a wearer. As a result, any and all fluid leaving the vaginal cavity will be confined to the absorbent article.

The shell114of the absorbent article100may be prepared from a variety of materials. The shell may include a layer constructed of any material which will function to be operatively liquid impermeable. The shell114may, for example, include a polymeric film, a woven fabric, a nonwoven fabric or the like, as well as combinations or composites thereof. For example, the shell114may include a polymer film laminated to a woven or nonwoven fabric. A laminate shell114structure is shown inFIG. 6, having an upper layer141and a lower layer142, wherein the upper layer141is the body-facing side of the shell114and the lower layer142is the garment facing side of the shell114. In a particular feature, the polymer film can be composed of polyethylene, polypropylene, polyester, silicone or the like, as well as combinations thereof. Additionally, the polymer film may be micro-embossed, have a printed design, have a printed message to the consumer, and/or may be at least partially colored. Suitably, the shell114can operatively permit a sufficient passage of air and moisture vapor out of the absorbent article100, particularly out of an absorbent structure121while blocking the passage of bodily fluids and odors often associated with bodily fluids. An example of a suitable shell material can include a breathable, microporous film, such as those described in, for example, U.S. Pat. No. 6,045,900 to Haffner et al., the entire disclosure of which is incorporated herein by reference and made a part hereof. Other shell materials which are extensible may be used in the present invention, including, for example foams. One example of a suitable foam is a polyurethane foam with a negative Poissons ratio. Examples of extensible backsheet materials are described in U.S. Pat. No. 5,611,790, issued Mar. 18, 1997, to Osborn, III et al., herein incorporated by reference in its entirety. Other materials that are inherently breathable, such as polyurethanes, may be used to form the shell114.

In one particular embodiment of the present invention, the shell114may be a laminate of a woven or nonwoven fabric with a silicone polymer, wherein the silicone polymer has adhesive properties. The second side117of the shell will be woven or nonwoven fabric and the first side115of the shell will be silicone polymer. One commercially available laminate is an Oleeva Fabric® 1 available from Bio Med Sciences, Inc., which have offices at 7584 Morris Court, Suite 218 Allentown, Pa. 18106. The Oleeva Fabric® is a silicone sheeting having adhesive properties laminated to a fabric backing. The silicone sheeting will form the body facing first side115of the shell material. Relating this particular structure to the Figures, inFIG. 6, the silicone polymer is the upper layer141of the shell114and the nonwoven or woven layer is the lower layer142of the shell.

Bicomponent films or other multi-component films can also be used as the shell114material. In addition, woven and/or nonwoven fabrics which have been treated to render them operatively liquid-impermeable can also be used as an effective shell114material. Another suitable shell material can include foams. Examples of foam include a closed-cell polyolefin foam, a foam with a negative Poissons ration and other similar foams. Other suitable polymeric materials include a polyurethane polymer material, a silicone polymer or other similar materials. Silicone polymers having naturally occurring adhesive properties, or silicone polymers having a silicone adhesive layer applied thereto are of particular interest for the shell material. Such silicone polymers will allow the first side115of the shell114to adhere to the body of the wearer without the need of an additional adhesive. These materials may be laminated to another material, such that the second side117of the shell114, which is the garment facing side of the absorbent article100is laminated to the other material, so that the adhesive nature of the silicone polymer does not adhere the garment to the undergarments of the wearer. In another embodiment of the present invention, the shell material may be prepared from an interpenetrating polymer network or two or more polymers. Generally, one of the polymers of the interpenetrating polymer network may be a silicone material. Examples of interpenetrating polymer networks are described in U.S. Pat. No. 5,759,560, issued to Dillion, which is hereby incorporated by reference in its entirety.

The shell material should be selected such that the overall properties of the shell allow the shell material to move with the skin of the wearer during normal use and normal movements by the wearer during use. By “normal movement by the wearer” it is meant any movement that normally occurs during use of the absorbent article, including walking, running, sitting, standing, kneeling, riding a bicycle, exercising, playing sports, getting into and out of an automobile, and other similar movements made by wearers when wearing an absorbent article. The shell should not be too rigid, such that the shell detaches from the skin of the wearer during use and the shell should not be so flexible that the shell tends to twist and bunch during use. The shell should have sufficient flexibility to conform to the skin of the wearer and become similar to a second skin of the wearer. The shell should also have the ability to remain attached to the body of the wearer under moist or wet conditions.

Generally, the shell material should have sufficient thickness to allow the shell114to mold to the body of the wearer, but not too thick that the shell114becomes uncomfortable for the wearer to wear. In addition, the shell114should not be so thin that it ineffectively forms a seal with the skin of the wearer when applied to the wearer, or becomes detached from the skin of the wearer during use and normal movement of the wearer during use or that it does not adequately conform to the shape and skin of the wearer at the point of attachment to the wearer. Depending on the material used for the shell, the typical thickness of the shell is between 0.03 mm and about 5.0 mm, more particularly between 0.1 mm and 3.0 mm. In one particular embodiment, the thickness of the shell is between 0.25 mm and about 3.0 mm. Again, the actual thickness used is dependent of several factors including rigidity of the material, the flexibility of the material and the ability of the material to assume the shape of the skin of the wearer at the location of use, which is typically the vulva region of a wearer.

The second side117of the shell114may form a portion of the garment-facing side of the absorbent article100when worn by a wearer. The shell material should be selected such that the second side117of the shell will freely move against the undergarment or clothing of a wearer. One way to achieve this result is to construct the second side117of the shell114to have a fairly low coefficient of friction. This will allow the second side117of the shell114to freely move against the undergarment or other clothing worn by the wearer. If the second side117of the shell114, does not freely move against the undergarment or other clothing worn by the wearer, the absorbent article may catch on the undergarment or clothing, which may result in the absorbent article being prematurely and undesirably removed from the wearer or may cause the absorbent article to be shifted from its desired placement against the body of a wearer.

In order to achieve the desired coefficient of friction on the second side117of the shell114, the materials used to prepare the shell could be selected such that the second side117of the shell material will inherently have the desired coefficient of friction. Alternatively, the second side117of the shell114may be treated with a coating composition, such a polytetrafluoroethylene containing coating, a silicone containing coating or other similar coating having low coefficient of friction properties. Alternatively, the shell114could be made from a laminate of two or more materials such that the first side115of the shell114is prepared from a material which meets the needed properties of the first side115, while the material selected for the second side117of the shell114meets the desired coefficient of friction such that the second side117will move freely against the undergarment or garment being worn by a wearer.

The shell114of the absorbent article100may be flat or may have a three-dimensional shape. As is shown inFIG. 5, which is a cross-sectional side view of the absorbent article, the shell114has a three-dimensional concave shape. Alternatively, as is shown in cross-sectional side views ofFIG. 6, the shell114may have a generally flat shape. By providing the absorbent article100with a three-dimensional concave shape, as is shown inFIG. 5, placement of the article may be easier for the wearer. Generally, the three-dimensional shape could be such that it closely matches the overall general curvature of the vulva region and optionally the pubic and perinea regions of most women, when the absorbent article is used as a panty-liner, sanitary napkin or a feminine incontinence article. To form the shell114with a three-dimensional shape, the shell may be molded in any manner known to those skilled in the art, for example heat molding. The manner in which the three-dimensional shape is imparted to the shell114is not critical to the present invention.

When the shell114is a generally flat shape, for example as shown inFIG. 6, meaning that the shell does not have a third dimension other than thickness, the shell114should be made to be flexible enough that the shell114can conform to the body of the wearer at the point of attachment. In addition to being flat, the overall shape of the shell114may be contoured, as is shown inFIG. 1. In one embodiment, the contour shape may be such that the narrowest point of the contour is in the crotch area of the shell114nearest the vulva region, as is shown inFIG. 1. The contour shape shown inFIG. 1is one of many possible shapes, in which the shell114and absorbent article may be prepared. Other shapes may be used, without departing from the scope of the present invention. Generally, the shape selected should be such that the shell114and absorbent article100are comfortable for the wearer to wear, while providing leakage protection to the wearer. It is noted that a contour shape may also be used in conjunction with a three-dimensional shell. Further discussion of the overall shape of the absorbent article may be found below.

The shell may be any desired color or may be translucent. In addition, the shell may have a matte finish, satin finish or a smooth finish. The particular finish color or translucency can be a matter of choice for the manufacturer of the absorbent article of the present invention. However, providing a shell which is translucent may assist the wearer in placing the absorbent article100prior to use, since the wearer may be able to see where the article is placed compared to the genitalia of the wearer.

The absorbent structure121is designed to absorb body exudates, including menstrual fluid, blood, urine, and other bodily fluids, such as sweat and vaginal discharges. The absorbent structure121has a longitudinal direction1and a lateral direction2and is shown inFIGS. 1-4, and a thickness in the z-direction3, as is shown inFIGS. 5 and 6. This absorbent structure121may be a single layer or may be multiple layers. Typically, the absorbent structure121has an absorbent core122and a generally liquid impermeable backsheet123. This absorbent core122may contain one or more layers of absorbent materials. That is, the absorbent core122may be a single layer of absorbent materials or may be a multilayer structure. Each of the layers of the absorbent core122can contain similar materials or different materials. In the absorbent article100of the present invention, the materials which may be used to form the absorbent core122include those materials conventionally used in absorbent articles and includes materials, such as, for example, cellulose, wood pulp fluff, rayon, cotton, and meltblown polymers such as polyester, polypropylene or coform. Coform is a meltblown air-formed combination of meltblown polymers, such as polypropylene, and absorbent staple fibers, such as cellulose. A desired material is wood pulp fluff, for it is low in cost, relatively easy to form, and has good absorbency.

The absorbent core122can also be formed from a composite comprised of a hydrophilic material which may be formed from various natural or synthetic fibers, wood pulp fibers, regenerated cellulose or cotton fibers, or a blend of pulp and other fibers. One particular example of a material which may be used as the absorbent core is an airlaid material. The absorbent core122may have other properties including extensibility, which will allow the absorbent core to be extended or fit to a particular wearer. One example of extensible absorbent cores is described in U.S. Pat. No. 5,611,790, issued Mar. 18, 1997, to Osborn, III et al., herein incorporated by reference in its entirety.

In one embodiment, the absorbent core122may also include a superabsorbent material, in addition to or in place of the hydrophilic material, which increases the ability of the absorbent core to absorb a large amount of fluid in relation to its own weight. Generally stated, the superabsorbent material can be a water-swellable, generally water-insoluble, hydrogel-forming polymeric absorbent material, which is capable of absorbing at least about 15, suitably about 30, and possibly about 60 times or more its weight in physiological saline (e.g., saline with 0.9 wt % NaCl). The superabsorbent materials can be inserted as particles or in sheet form. The superabsorbent material may be biodegradable or bipolar. The hydrogel-forming polymeric absorbent material may be formed from organic hydrogel-forming polymeric material, which may include natural material such as agar, pectin, and guar gum; modified natural materials such as carboxymethyl cellulose, carboxyethyl cellulose, and hydroxypropyl cellulose; and synthetic hydrogel-forming polymers. Synthetic hydrogel-forming polymers include, for example, alkali metal salts of polyacrylic acid, polyacrylamides, polyvinyl alcohol, ethylene maleic anhydride copolymers, polyvinyl ethers, polyvinyl morpholinone, polymers and copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides, polyvinyl pyridine, and the like. Other suitable hydrogel-forming polymers include hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, and isobutylene maleic anhydride copolymers and mixtures thereof. The hydrogel-forming polymers may be lightly crosslinked to render the material substantially water insoluble. Crosslinking may, for example, be by irradiation or covalent, ionic, Van der Waals, or hydrogen bonding. Hydroxyfunctional polymers have been found to be good superabsorbents for sanitary napkins. Such superabsorbents are commercially available from Dow Chemical, Hoechst-Celanese, and Stockhausen, Incorporated, among others, and are a partially neutralized salt of cross-linked copolymer of polyacrylic acid and polyvinyl alcohol having an absorbency under load value above 25 grams of absorbed liquid per gram of absorbent material (g/g). Other types of superabsorbent materials known to those skilled in the art can also be used.

Selection of the actual materials used for the absorbent core122is within the skill of those skilled in the art. The actual materials used for the absorbent core are not critical to the present invention.

The generally liquid impermeable backsheet123is present in the absorbent structure121to prevent fluid entering the absorbent core122from flowing through the absorbent core122and onto a garment or undergarment being worn by a wearer. Suitable liquid impermeable backing sheets include, for example, a polymeric film, a woven fabric, a nonwoven fabric or the like, as well as combinations or composites thereof. Generally, any material that may be used as the shell material describe above may be used as the backsheet123of the absorbent structure121. The liquid impermeable backsheet123may be a polymeric film, a woven fabric, a nonwoven fabric or the like, as well as combinations or composites thereof. For example, the liquid impermeable backsheet123may include a polymer film laminated to a woven or nonwoven fabric. In a particular feature, the polymer film can be composed of polyethylene, polypropylene, polyester, silicone or the like, as well as combinations thereof. Additionally, the polymer film may be micro-embossed, have a printed design, have a printed message to the consumer, and/or may be at least partially colored. Suitably, the liquid impermeable backsheet123can operatively permit a sufficient passage of air and moisture vapor out of the absorbent article100, particularly out of an absorbent structure121while blocking the passage of bodily fluids and odors often associated with bodily fluids. An example of suitable materials for the liquid impermeable backsheet123can include a breathable, microporous film, such as those described in, for example, U.S. Pat. No. 6,045,900 to Haffner et al., the entire disclosure of which is incorporated herein by reference and made a part hereof.

The side of the backsheet123which faces the undergarment or garments of a wearer should have a low coefficient of friction for the same reasons that the second side117of the shell should have a low coefficient of friction. This will allow the garment facing side of the backsheet123to move freely against the undergarment or clothing of a wearer. If the garment facing side of the backsheet123does not freely move against the undergarment or other clothing worn by the wearer, the absorbent article may catch on the undergarment or clothing, which may result in the absorbent article or the absorbent structure being prematurely and undesirably removed from the wearer or may cause the absorbent article to be shifted from its desired placement against the body of a wearer. In addition by having both the garment facing side of the backsheet123and the second side117of the shell freely move against the undergarment or clothing of the wearer, the body attached absorbent article will be comfortable for a wearer to wear and may provide improved protection since the undergarment or clothing will not cause the absorbent article to shift during use.

Generally, the absorbent structure will be positioned adjacent to the second side117of the shell114, as can be clearly seen inFIGS. 1-6. By “adjacent to the shell”, it is meant that the that the absorbent structure121is directly in contact with the second side117of the shell114or may be separated by one or two additional layers or a construction or pressure sensitive adhesive. The absorbent structure should be positioned such that the absorbent core122is beneath the opening105so that any fluid flowing through the opening105will come into contact with the absorbent core122.

In addition to the absorbent core122, the absorbent structure121may have other additional layers which aid the absorbent core122in capturing and holding the bodily fluid into the absorbent core122. These other layers, when present and in combination with the absorbent core122, form the absorbent structure121of the absorbent article100. There may be a single layer or multiple layers in addition to the absorbent core122in the absorbent structure121.

One particular example of an additional layer which may be used in addition to the absorbent core122in the absorbent structure121is a top sheet124, which is generally a liquid permeable material, which allows bodily fluids to pass through the top-sheet into the absorbent core. The top sheet124also may provide a wearer with a dry feeling by separating the absorbent core122from the body of the wearer. That is, the top sheet124is placed between the absorbent core122and the body of the wearer and such that the absorbent core122is between the top sheet124and the shell114.

Optionally, the top sheet124may be formed from one or more materials. The top sheet124should be able to manage different body excretions depending on the type of product. In feminine care products, often the top sheet124must be able to handle menses and urine. In addition, the top sheet124may be comfortable, soft and friendly to the wearer's skin. In the present invention, the top sheet124may include a layer constructed of any operative material, and may be a composite material. For example, the top sheet can include a woven fabric, a nonwoven fabric, a polymer film, a film-nonwoven fabric laminate or the like, as well as combinations thereof. Examples of a nonwoven fabric useable in the top sheet124include, for example, an airlaid nonwoven web, a spunbond nonwoven web, a meltblown nonwoven web, a bonded-carded web, a hydroentangled nonwoven web, a spunlace web or the like, as well as combinations thereof. Other examples of suitable materials for constructing the top sheet124can include rayon, bonded-carded webs of polyester, polypropylene, polyethylene, nylon, or other heat-bondable fibers, finely perforated film webs, net-like materials, and the like, as well as combinations thereof. These webs can be prepared from polymeric materials such as, for example, polyolefins, such as polypropylene and polyethylene and copolymers thereof, polyesters in general including aliphatic esters such as polylactic acid, nylon or any other heat-bondable materials. When the top sheet is a film or a film laminate, the film should be apertured or otherwise be made to allow fluids to flow through the top sheet to the absorbent core.

Other examples of suitable materials for the top sheet124are composite materials of a polymer and a nonwoven fabric material. The composite materials are typically in the form of integral sheets generally formed by the extrusion of a polymer onto a nonwoven web, such as a spunbond material. In a particular arrangement, the top sheet124can be configured to be operatively liquid-permeable with regard to the liquids that the article is intended to absorb or otherwise handle. The operative liquid-permeability may, for example, be provided by a plurality of pores, perforations, apertures or other openings, as well as combinations thereof, which are present or formed in the liner or body contacting layer. The apertures or other openings can help increase the rate at which bodily liquids can move through the thickness of the liner or body contacting layer and penetrate into the other components of the article (e.g. into the absorbent core122). The selected arrangement of liquid permeability is desirably present at least on an operative portion of the top sheet124that is appointed for placement on the body-side of the article. The top sheet124can provide comfort and conformability, and can function to direct bodily exudates away from the body and toward the absorbent core122. The top sheet124can be configured to retain little or no liquid in its structure, and can be configured to provide a relatively comfortable and non-irritating surface next to the body tissues of a wearer. In the present invention, the top sheet124positioned over the absorbent core may have a surface which is embossed, printed or otherwise imparted with a pattern.

Additional layers or substrates, including for example, the liquid acquisition and distribution layer, also referred to as a surge or transfer layer, and an optional tissue layer are also incorporated into the absorbent structure121of the absorbent product100, for example, between the top sheet124and the absorbent core122. The distribution layer may be shorter than the absorbent core or have the same length as the absorbent core122. The distribution layer serves to temporarily hold an insulting fluid to allow the absorbent core sufficient time to absorb the fluid, especially when a superabsorbent material is present.

In another embodiment, the absorbent core, transfer layer and other components, such as tissue layers, may be free floating (unattached) between the shell114and the top sheet124, and only are secured along only the peripheral edges thereof. Alternatively, the absorbent core122, transfer layer, if present, and any other layer or component, if present, may be attached to one or both of the second side117of the shell114and top sheet124and/or to each other.

The absorbent structure121, including the absorbent core122, is generally attached to the second side117of the shell114, such that the absorbent core is positioned under the opening105in the shell. The absorbent structure121may be attached to the shell114in a permanent manner, meaning that the absorbent structure is generally intended not to be removable by the wearer of the absorbent article100. Alternatively, the absorbent structure121may be made to be removably attached to the shell, such that the absorbent structure121may be removed by a wearer of the absorbent article100and replaced with the same absorbent structure121or with another new absorbent structure121. When the absorbent structure121is attached to the shell114in a permanent manner, meaning that the absorbent structure is not intended to be removed by the wearer, a construction adhesive may be used. Examples of useable construction adhesives include any adhesive which will effectively hold the absorbent structure121in place, so as not to be separated from the shell114. Commercially available construction adhesives usable in the present invention include, for example Rextac adhesives available from Huntsman Polymers of Houston, Tex., as well as adhesives available from Bostik Findley, Inc, of Wauwatosa, Wis. Other means may be used to hold the absorbent structure121to the shell, including heat bonding, ultrasonic bonding or other similar mechanical attachments.

When the absorbent structure121is removably attached, the absorbent structure121is held in place to the second side117of the shell114by a means which will allow the wearer to remove the absorbent structure. One such means of holding the absorbent structure is by using a pressure sensitive adhesive. Suitable pressure sensitive adhesives include any commercially available pressure sensitive adhesive. Examples of suitable pressure sensitive adhesives usable to removably hold the absorbent structure121in place on the second side117of the shell114include pressure sensitive adhesives available from National Starch and, having offices in Bridgewater, N.J. 08807. By providing an absorbent structure121which is removable, the shell114may be reused several times without the need to again place the shell114when the absorbent structure needs to be replaced. Other means, such as mechanical attachment may also be used to removably attach the absorbent structure121to the shell114. Also by having a removable absorbent structure121, the absorbent structure can be selected by the wearer prior to use. This would allow the wearer to select an appropriate level of protection for a given day or allow the wearer to select a size or shape of the absorbent which the wearer finds to be more comfortable. When the absorbent structure121is removable, and adhesively attached to the shell114, the adhesive could be designed to remain on the shell or remain only on the absorbent structure. Generally, the adhesive should be placed on the absorbent structure121, since this will provide fresh adhesive to hold the new absorbent in place each time the absorbent structure121is replaced. If the adhesive is present on the absorbent structure121, a release sheet may be place over the adhesive so that the adhesive is not contaminated with dirt or debris which may have an adverse effect in holding the absorbent structure121to the shell114.

To aid a wearer in replacing the absorbent structure121, placement aid may be present on the shell114and/or the absorbent structure. Suitable placement aids include the use of color, tactile indicators or any other means that would assist the wearer in replacing a removed absorbent structure.

Another important advantage of having an absorbent structure, which is removable, is that the wearer may be able to perform normal bodily functions, such as urination. By having the absorbent which is removable, a wearer could remove the absorbent, urinate and replace the absorbent. This would alleviate the need of a wearer to have to replace the entire absorbent article100in order to form bodily functions. As another alternative, the absorbent structure121could be attached to the shell in such a manner that the absorbent structure is hinged with a hinging means, as is shown inFIG. 7.

The absorbent structure121may be a relatively flat structure, as shown inFIG. 6or the absorbent structure121may be curved to match the shape of the shell114, as is shown inFIG. 5. The size, location and shape of the absorbent structure121may also be selected for an intended use. For example, in an overnight use, the absorbent may be located further back on the wearer towards the perinea region of the wearer. In an overnight use, the absorbent structure may be larger than in a product intended for daytime use. In a daytime use, the absorbent structure will generally be centrally located in the vulva region.

In an alternative embodiment of the present invention, the shell114material may also be provided with some absorbency in addition to the absorbent structure121. One way to achieve absorbency in the shell is to have the shell114prepared from a material which is a laminate of two or more materials. The first side115of the shell114contains an absorbent material within the body facing side of the laminate. For example, superabsorbent particles or materials may be incorporated into the material making up the body facing layer of the laminate. Another way is to place a very light coating onto the first side115of the shell material, wherein the coating contains a superabsorbent particles or materials. Of course other absorbent materials, other than superabsorbent materials may be used in place of or in addition to the superabsorbent materials.

The absorbent core122of the absorbent structure121may be located entirely within the opening105in the shell114, or the absorbent core122of the absorbent structure may extend past the opening105in the shell, as is shown inFIGS. 5 and 6, meaning that a portion of the absorbent core122contacts or is facing the second side117of the shell114. Alternatively, the absorbent structure121may extend past the ends104,104′ of the shell114or the second region107of the shell.

The liquid backsheet123may be a polymeric film, a woven fabric, a nonwoven fabric or the like, as well as combinations or composites thereof. For example, the liquid backsheet123may include a polymer film laminated to a woven or nonwoven fabric. In a particular feature, the polymer film can be composed of polyethylene, polypropylene, polyester, silicone or the like, as well as combinations thereof. Additionally, the polymer film may be micro-embossed, have a printed design, have a printed message to the consumer, and/or may be at least partially colored. Suitably, the liquid backsheet123can operatively permit a sufficient passage of air and moisture vapor out of the absorbent article100, particularly out of an absorbent structure121while blocking the passage of bodily fluids and odors often associated with bodily fluids. An example of a suitable material for the liquid backsheet123can include a breathable, microporous film, such as those described in, for example, U.S. Pat. No. 6,045,900 to Haffner et al., the entire disclosure of which is incorporated herein by reference and made a part hereof. Other materials that may be used in preparing the backsheet123include materials which are inherently breathable, such as polyurethanes.

As is stated above, the first side115of the shell114either directly or indirectly attaches to the body of a wearer. Stated another way, the shell is the body attachment member and the first area115is the portion of the shell114which is attached to the body of the wearer. Depending on the material selected for the shell, the shell may actively attach to the body of the wearer using electrostatic means; suction means or a body adhesive may be placed on the first side115of the shell114to attach the absorbent article to the body of a wearer. Electrostatic means which can be used is by selecting the shell material to be a material which has an affinity for the body of a wearer, such that the shell material “clings” to the body of the wearer. Examples of such materials include ethylene vinyl acetate, low density polyethylene and other similar materials know to those skilled in the art. Suction means may be achieved by shaping the shell to conform to the body of the wearer, much like a contact lens fits to the eye. Generally, suction means can be achieved by forming the shell114into a three-dimensional shape. The easiest way to achieve body attachment is to place a body adhesive in the first side115of the shell114.

A body adhesive144is positioned on the first side115of the shell114. The body adhesive144contacts the skin and hair, if present, in the vulva region and possibly the pubic region and/or the perinea region of the wearer's body, thereby supporting and holding the absorbent article100against the body of the wearer during use. The body adhesive144can overlie a portion of the first side115or can overlie the first side115of the shell114. Generally, the body adhesive144will be present on at least the outer portion first side of the shell near the edge120of the absorbent article100. The adhesive may cover the entire first side115of the absorbent article (not shown in the drawings). Alternatively, the body adhesive144may be placed on a portion of the first side, as is shown inFIGS. 1 and 2. The body adhesive144may also be placed in a pattern of the first side115of the absorbent article. The body adhesive144can be applied to the first side115of the shell114of using any known process including inkjet printing, screen printing or extruding the body adhesive144from one or more nozzles, slot coating and the like.

Generally, any pressure sensitive adhesive known to those skilled in the art may be used, provided that the pressure sensitive adhesive is not a known irritant to human skin or that the adhesive is so aggressive that it causes pain to the wearer when the absorbent article is removed from the skin. It is also desirable that the adhesive is selected such that the adhesive does not leave a substantial amount of an adhesive residue on the surface of the skin of the wearer, when the absorbent article100is removed by the wearer after use. Particularly suitable pressure sensitive adhesive materials are disclosed in the commonly assigned U.S. Pat. No. 6,213,993 to Zacharias et al., U.S. Pat. No. 6,620,143 to Zacharias et al., the entire disclosure of each is incorporated herein by reference and made a part hereof. Other suitable adhesives are disclosed in U.S. Pat. No. 5,618,281 to Batrabet et al., the entire disclosure of which is incorporated herein by reference and made a part hereof. Other known body adhesives, such as those described in U.S. Pat. No. 6,316,524 to Corzani et al. which is hereby incorporated in its entirety, may also be used. Additional examples of pressure sensitive adhesives include hydrogels, hydrocolloids, acrylics based adhesives, and rubber based adhesives, such as Kraton based adhesives.

The body adhesive144may be positioned on the first side115of the shell114in an open pattern or a closed pattern. By “open pattern” is meant that the adhesive can have an intermittent or discontinuous pattern which does not substantially encircle the entire opening105. For example, there may be breaks in the body adhesive at certain portions of the first side115. “Closed pattern” means the adhesive144would encircle the entire opening105in the shell. In one embodiment, the pattern of the body adhesive144will substantially surround the cover of the first side115and substantially surround the opening105. An example of an “open” pattern of the adhesive would be to have individual beads of adhesive applied in a discontinuous fashion. In the present invention, the closed pattern can be advantageous since the body adhesive144may form a seal with the body of the wearer which will assist in preventing leaks from the absorbent article100. The body adhesive may form a dam, which may prevent leaks from the entire perimeter of the absorbent article100.

In one embodiment of the present invention, the body adhesive144may be placed on the entire first side115of the shell114, as is shown inFIG. 1. In another alternative embodiment of the present invention, as is shown inFIG. 2, the body adhesive144may placed along the outer portions of the first side115near the periphery of the shell114, such that no adhesive is near the opening105. The body adhesive144may also be placed on the absorbent structure121positioned on the second side117of the shell114to help hold the absorbent article in place on the wearer. Generally, however, the body adhesive144is confined to being placed on the first side115of the shell114, since placing the body adhesive on an area of the absorbent product100which contacts the female genitalia such as the labia majora may cause discomfort to the wearer of the absorbent product100.

The adhesive may be applied in a pattern of small discrete dots so as to leave numerous areas free from adhesive. Alternatively, the adhesive may be applied as a continuous bead, or may be applied as a series of semi-continuous beads. Other suitable adhesive patterns may be selected for applying the body adhesive144to the body-contacting first side115of the absorbent article100. For example, adhesive patterns can be oval, swirls, various linear or non-linear arrays of adhesive longitudinally, and/or transversely oriented and reticulated webs having unobstructed interstices between the adhesive fibers or combinations thereof. As stated above, the adhesive patterns may be open or closed. The weights of adhesives are limited to less than about 800 g/m2, and generally less than about 400 g/m2. Generally, the weight of the adhesive is at least 20 g/m2. Typically, the adhesive is applied in an amount of about 100 to about 400 g/m2. The limitations on the basis weight of the adhesive are important to provide the correct adhesive characteristics for applying directly to the wearer's vulva region and optionally the pubic and perinea regions of the wearer's body. If the basis weight is too high, the absorbent article will have a sticky feeling or otherwise uncomfortable feeling. If the basis weight of the adhesive is too low, there may be insufficient adhesion to the body of the wearer.

Generally, the body adhesive144is applied in a manner which is symmetrical about the longitudinal axis which bisects the absorbent article100and divides the absorbent article100into substantially equal portions. This symmetrical pattern provides the wearer a balanced feel when wearing the absorbent article100. The symmetrical pattern also reduces the perception of any associated discomfort when the absorbent article100is removed from the body.

As is shown inFIGS. 8A and 8B, to protect the body adhesive144, a peel sheet or release sheet146may be used to prevent the body adhesive144from becoming contaminated, thus loosing its ability to stick to the body of an wearer and/or prematurely adhering to an unintended surface. Suitable materials for use as a peel strip146are well known in the art and are commercially available. Examples of suitable peel sheets or release sheets include, a silicone coated Kraft paper, a silicone coated film or the like. Other release coating includes coating containing polytetrafluoroethylene. The peel sheet or release sheet146may extend beyond one or both of the ends and/or sides of the shell, as shown inFIG. 8B. Alternatively, the release sheet46may be sized to only cover the body adhesive on the first side115of the shell114, as is shown inFIG. 8A. In yet another embodiment of the present invention, the release sheet may extend beyond the adhesive at one or more locations, such as one of the ends or one of the sides of the shell as is shown inFIG. 8Cby providing the release sheet146with a tab147for the wearer to grasp to remove the release sheet146from the absorbent article100and the body adhesive144on the absorbent article100. When the release sheet146extends beyond the adhesive, it is generally easier for the wearer to remove the release sheet146to place the absorbent article100for use.

Alternatively, the release sheet146may be provided with a pressure sensitive adhesive to hold the release sheet146in place when the absorbent article is devoid of an adhesive for body attachment. In this configuration, the release sheet146serves to protect the absorbent structure and first side of the shell from dirt and damage prior to use.

In another alternative, a release sheet may not be necessary. For example, the absorbent article may be rolled, folded onto itself or stacked upon each other. In these configurations, a release sheet is not needed. If rolled, the body adhesive144will generally contact the second side117of the shell114or the liquid impermeable backsheet123of the absorbent structure. The body adhesive144should releasably stick to one second side of the shell by readily releasing when unrolled by the wearer or wearer. In addition, the body adhesive144should not leave a residue on the second side117of the shell114, of the backsheet123. This should similarly occur when the absorbent articles100are stacked upon each other such that the body adhesive144of one article will attach the second side117of the shell and/or backing sheet of a second article. In another possible configuration, the absorbent article100may be folded along the longitudinal axis1of the lateral axis such that the body adhesive144in one area comes into contact with body adhesive in another area. In the folded configuration, the body adhesive should be selected such that the body adhesive will release from itself when manipulated by a wearer.

The dimensions and shape of the shell114should be such that it is appropriately sized for its intended use. The same is true for the size and shape of the absorbent structure121and the size of the opening105. Generally, the size and shape of the absorbent structure121will dictate the size of the shell114. The shape of the shell114is selected so that the absorbent article will have a comfortable feeling for the wearer, thereby providing protection against leaks and preventing the absorbent article from becoming dislodged from the body of the wearer during use. Generally, the shell114will be curved to fit the body of a wearer. The shell114also generally gives the absorbent article100its overall size and shape in the longitudinal1and lateral2directions. That is, the shell is generally longer and wider than the absorbent structure, as can be seen in the figures. In other words, the shell114will be wider in the lateral direction2than the absorbent structure121, and the shell will be longer in the longitudinal direction1than the absorbent structure121. As is mentioned above, it is possible for the absorbent structure121to be longer than the shell114but it is not generally wider.

When the absorbent article100is intended for use as a pantiliner, a sanitary napkin or a feminine incontinence article, the shell114should be wider and longer than the absorbent structure121attached to the second side117of the shell114. The opening105in the shell114should generally be at least as wide and as long as the labia majora of the wearer. This will prevent the shell114from contacting the sensitive parts of a wearer's body. The absorbent structure121should be as large as or larger than the opening105. As a result, to fit most women, the absorbent structure121is longer in the longitudinal direction1than it is wide in the lateral direction2of the absorbent structure. Generally, for most women, the labia majora are generally between about 40 mm and about 70 mm in width and between about 80 mm and 150 mm in length. Ideally, the absorbent structure121and opening105should be wider than the labia majora and slightly longer than the labia minora and slightly longer than or equal to the labia majora. Generally, the absorbent structure121and opening105should be between about 40 mm and 90 mm in width in the lateral direction2and between about 95 mm and about 150 mm in length in the longitudinal direction1. The shape of the absorbent structure121and opening105will generally tend to be oblong and may be an oval, a rectangle, tear drop shaped, hourglass shaped or racetrack shaped. As can be seen inFIGS. 1 and 2, the absorbent structure121may be generally elliptical or oval in shape to match the size and shape of the vaginal area of most women.

Generally, the shape of the shell114may vary from a generally oval shape, as shown inFIGS. 2 and 4, to a shape which is a generally hourglass-like shape, shown inFIGS. 1 and 3. By a generally hourglass shape, it is meant shape in which the sides119of the shell114converge towards one another at a point along the longitudinal axis of the shell114to form a narrowest portion133of the absorbent article100. Generally, the hourglass-like shape provides a cut-out for the wearer's legs. By having an hourglass-like shape, the shell114will not be attached to the legs of a wearer during use. This will provide more comfort for the wearer of the absorbent article100. The shape of the shell114should be selected such that the absorbent article100will be comfortable to wear, while providing very effective leakage protection to the wearer. The shell114and the absorbent structure121should be able to adapt to the curvature of a wearers body during use. Other possible shapes for the shell114not specifically shown may also be used, provided that the shape will provide comfort to the wearer of the absorbent article.

To obtain an effective attachment of the absorbent article to the wearer, when the absorbent article is used as a sanitary napkin or an incontinence article, generally the width of the of the shell should be at least 10 mm on either side of the labia majora. Generally, the shell114of the absorbent article100will have a width, in the lateral direction2, between about 50 mm up to 200 mm or more. Typically, the shell will be between about 60 and 120 mm at its narrowest point. This will allow the shell114to have a first side115that can be effectively attached to the skin of a wearer on either side of the labia majora.

In addition, the absorbent article100may also be configured to have an anterior region164, a central region165and a posterior region166, as is shown inFIG. 1. As used herein, the term “anterior” refers to the direction towards the front of the wearer during use. As used herein, the term “posterior” refers to the direction towards the back of the wearer during use. A particular embodiment is shown inFIG. 1of an absorbent article having a configuration designed to fit specific areas of the vulva region of a wearer. By providing specific portions for attachment to specific areas of the body of the wearer, the absorbent article may be configured to better fit the body of the wearer. The anterior region164of the absorbent article will be the portion of the absorbent article between the absorbent structure121and the first end161of the absorbent article100. The posterior region166of the absorbent article100will be the portion of the absorbent article between the absorbent structure121and the second end162of the absorbent article100. Generally, the posterior region166will be designed to be placed between the vagina area and the anal area of the wearer. The anterior region164is designed to be placed on the mons Veneris region of a female wearer. The central region165of the absorbent article100is designed to cover the vagina area of the wearer and the skin area surrounding the lateral sides of the labia majora, when the absorbent article is used as a pantiliner, sanitary napkin or an incontinence article. In an alternative use, the absorbent article of the present invention may also be used as an underwear replacement, or a guard for a swimming suit.

To obtain an effective attachment to the body of the wearer, the shell114can be configured to be anatomically correct for a wearer. As is shown inFIG. 9A, the shape of the absorbent article100is such that it will correctly and securely fit in the vulva region of a wearer. The general shape of the absorbent article shown inFIG. 9Ahas been found to effectively attach to the vulva region of female wearers of the absorbent article. Additional features may be included to ensure an anatomically correct shape. For example, in the posterior region of the absorbent article100, more particularly, the posterior region of the shell on the first side115, the shell114may be imparted with a three-dimensional protrusion167, as shown inFIGS. 9A and 9B. The protrusion167acts to fit comfortably in the perinea region of the wearer. The protrusion167may be formed from the shell material or may be formed from the body adhesive144. By providing the three-dimensional protrusion167, the absorbent article100can effectively fit to the typical body shape of the female wearer, thereby preventing leaks form the posterior region of the absorbent article. The protrusion167may also serve as a guide to the wearer in placement of the absorbent article100on the body of a wearer prior to use.

The absorbent article100of the present invention may have other features which aid the wearer to place and remove the absorbent article from the body. As is shown inFIGS. 10A and 10B, the second side117of the shell114or the backsheet123may be provided with positioning aids such as a finger pocket199, shown inFIG. 10A, or finger grooves in the shell114(not shown) material or backsheet123of the absorbent structure121as is shown inFIG. 10A. Generally, the finger pocket199has an opening198positioned such that a wearer inserts their fingers towards the posterior region166or second end162of the absorbent article100. The pocket199gives the wearer a location to place her fingers during placement of the absorbent article100onto the wearer's body. The pocket199may be an opening wide enough for the wearer to place at least two fingers in the pocket. Alternatively, there may be two or more openings which allow the wearer to place only one finger in each opening. Other similar positioning aids may be used to help guide a wearer to properly place the absorbent article for use. For example, grooves may be placed in the second side117of the shell114or backsheet123of the absorbent structure. This may allow the wearer to feel the location of the absorbent structure relative to the vulva region during application of the absorbent article100to the vulva region of the body. The pocket199may also assist the wearer in removing the absorbent article from their body or removing the absorbent structure when it needs to be replaced.

The absorbent article100may also be provided with a removal aid which provides the wearer with an easy way to grasp and remove the absorbent article applied to the body. One particular removal aid is shown inFIG. 10Bincluding a tab192located on the first end161of the shell which is not adhered to the body or is devoid of adhesive. Alternatively, other removal aids, such as having an area of the first end161being devoid of the body attaching adhesive144may be used. Other types of removal aid which may be present include loops and pull strings. The removal aid allows the wearer to effectively begin the process of gently removing the absorbent article from the body of the wearer, without the need of having to find a portion of the shell which may not be completely attached.

Other features or additives may be incorporated into the absorbent article of the present invention. For example, the absorbent article may contain an odor control agent, or a fragrance, skin wellness agents and other similar additives used in currently available absorbent articles. Any odor control agent or fragrance known to those skilled in the art may be used in the absorbent article100of the present invention. The odor control agent or fragrance may be added in various components of the absorbent article, including the shell114, the absorbent structure121, or the body adhesive144. Skin wellness additives may be added onto the absorbent structure, any portion of the first surface115of the shell114attached to the wearer or in the body adhesive144.

Generally, to apply the absorbent article100to the body of a wearer, the release sheet146, protecting the absorbent structure and adhesive, if present, is removed from first surface of the shell. Next, the wearer positions the absorbent structure of the portion of the body in which absorbency is needed. If positioning pockets or other positioning aids are present on the absorbent structure, the wearer may optionally use these positioning aids to properly place the absorbent article for use. In the case of sanitary napkins and incontinence absorbent articles for females, the absorbent is positioned over the vagina area such that the absorbent structure will absorb body fluids. The wearer then checks to ensure that the first region101of the shell or the adhesive144, if present, is contacting the skin around the vagina area.

If the absorbent article is intended to have a front and a back portion, the wearer first identifies the anterior region164and/or the posterior region166of the absorbent article. To aid in identification of the anterior and posterior regions, indicia located on the release sheet146, shell114or absorbent structure121viewable through the opening105in the shell114to indicate the anterior region and/or posterior region of the absorbent article may be present. Indicia can be simply lettering or a picture to indicate the front or back of the absorbent article. Once the anterior region and posterior region are identified by the wearer, the wearer places the absorbent article in the same manner described above. Examples of indicia which may be used include, color, wording, diagrams and the like, which would indicate to a wearer the anterior and posterior regions of the absorbent article.

In each case, the absorbent structure, which is designed to cover the labia majora of the wearer, may be positioned with the aid of the absorbent structure121or the opening105. More specifically, the absorbent structure and/or the opening, when sized and shaped to the approximate size of the labia majora, can serve to guide the placement of the absorbent structure121over the labia majora. Once properly placed, pressure is applied by the wearer to the second side117and or backsheet123of the shell which will allow the first surface of the shell to contact the skin of the wearer, or to allow any adhesive applied to the first surface to be applied to the skin of the wearer.

By having the absorbent article100attached to the body of a wearer, the absorbent article100will tend to move with the skin of the wearer. This results in a comfortable to wear absorbent article which will be less likely to leak than conventional absorbent articles. The absorbent article has a very close-to-the-body fit which may provide improved discretion for the wearer.

Other benefits of the absorbent article100of the present invention may also be provided. For example, when the first side115of the shell has an adhesive applied thereto, upon removal of the absorbent article after use, the wearer may fold the first side of the shell onto itself to dispose of the used absorbent article. An effective seal may be formed around the perimeter of the shell, thereby effectively encapsulating the absorbent structure within a closure and the backing sheet of the absorbent layer. As a result, any odors associated with the absorbed fluids will be contained within the shell material and backing layer. Another use of the absorbent article of the present invention is a tampon backup absorbent article. The absorbent article could be effective in hiding the withdraw string of a tampon, while providing additional leakage protection.

The absorbent article described above can be an individual absorbent article or may be part of an absorbent system, offering the wearer a wide variety of options to fill the needs of the wearer. For example, the shell could be provided to wearers in a variety of shapes or sizes to allow wearers to select the appropriate shape or size for their given body shape. Likewise, the body adhesive may be provided in a variety of adhesive strengths to match the adhesive strength needed or desired by the wearer. By providing a variety of adhesive or other attachment means, a wearer could select the shells to match body type, body condition and other various factors that may vary from one wearer to another. Similarly, the absorbent structure could be provided in various absorbent capacities so that the wearer could select the appropriate absorbency to match the wearer's needs.

The absorbent system may be provided to wearers in a variety of packaging arrangements. In one packaging arrangement, a plurality of shells having different properties may be provided in separate packages or could be provided in a single package. It is generally a better packaging arrangement if shells having similar properties, shapes or sizes are provided in a single package. That is, in a given package, the wearer is provided with a plurality of shells all having the same shape, size, and properties, such as the body attachment properties. Regarding the absorbent structures, the absorbent structures could be provided to the wearer in packages sorted by absorbent capacity or various absorbent capacity structures could be provided in a single package. By having all absorbent structures in a single package with a single absorbent capacity, a wearer is able to select the correct absorbent capacity for their typical needs. However, by providing different absorbent capacity absorbent structures in a single package, the wearer will be provided with the ability to select the absorbent structure with the appropriate absorbent capacity for a given situation, without the need to purchase multiple packages of absorbent structures.

In another embodiment, a body adhesive absorbent article200, which is illustrated inFIGS. 11-18, also comprises a shell214and an absorbent structure221and has a longitudinal axis X and a transverse axis Y. The shell214has a first region201, a pair of lateral side regions202,202′ extending from the first region, and an opening205(FIG. 12) extending longitudinally at least in part between the side regions. The shell214also has a first side215, which defines a body-facing surface (FIG. 11), and a second side217, which defines a garment-facing surface (FIG. 14). In the illustrated embodiment, the first side215of the shell214has a body adhesive244on at least a portion thereof for adhering the absorbent article200directly to the wearer's skin, and particularly, to a female wearer's skin surrounding her vulva region for the illustrated absorbent article. The body adhesive244contacts the skin and hair, if present, in the vulva region and possibly the pubic region and/or the perinea region of the wearer's body, thereby supporting and holding the shell214and absorbent structure221against the body of the wearer during use. A peel sheet or release sheet (not shown) may be used to prevent the body adhesive244from becoming contaminated, thus losing its ability to stick to the body of the wearer and/or prematurely adhering to an unintended surface.

Generally, the size and shape of the absorbent structure221, depending on its intended use, will dictate the size of the shell214. The shape of the shell214is selected so that the absorbent article200will have a comfortable feeling for the wearer and inhibit the absorbent article against becoming detached from the body of the wearer during use thereby providing protection against leaks. In one suitable embodiment, the absorbent article200, including the shell214and absorbent structure221, is dimensioned and shaped to fit approximately 75 percent of adult females. It is understood, however, that the absorbent article200can be dimensioned and shaped to fit more or fewer females. It is also contemplated that different sizes of the absorbent article200may be provided to accommodate a greater percentage of females.

With reference toFIG. 13, the absorbent article200(and hence the shell214) can be suitably divided into three general longitudinal regions: an anterior region264, a posterior region266and a central region265extending longitudinally between and interconnecting the anterior and posterior regions. Each of these regions264,265,266is sized and shaped for alignment with different body regions of a wearer of the absorbent article. More specifically, the anterior region264of the article200is adapted to be disposed adjacent the wearer's lower abdomen region. The central region265is adapted to be disposed between the upper thigh region of the wearer to cover the wearer's perineum region and vaginal region. The posterior region266of the article200is adapted to be disposed in the gluteal region of the wearer.

In the illustrated embodiment, the anterior region264, the central region265, and the posterior region266of the absorbent article200are of roughly equal length, with each region corresponding generally to about ⅓ of a total length L1of the absorbent article200. The length L1is defined herein as the longitudinal distance from a longitudinally outermost extent of the article200(and in the illustrated embodiment, the shell214) in the anterior region264to a longitudinally outermost extent of the article (and in the illustrated embodiment, the shell) in the posterior region266. As an example, the length L1of the shell214(and hence the absorbent article200in the illustrated embodiment) may suitably be in the range of about 170 mm to about 220 mm, and more suitably in the range of about 190 mm to about 200 mm. As an additional example, the absorbent article200, and more particularly the shell214, has a length L1of about 194 mm. It is understood that the absorbent article200may have a length L1different that those set forth above without departing from some aspects of this invention. It is also contemplated that two or all three of the article regions264,265,266may instead be of unequal lengths depending on the desired fit and the intended body placement of the article without departing from the scope of this invention.

The absorbent structure221ofFIGS. 11-18is suitably adhered to the first side (i.e., body-facing surface)215of the shell214and is sized and located relative to the shell such that the shell extends both longitudinally and transversely outward beyond the periphery of the absorbent structure in at least the anterior region264and the central region265, and more suitably in at least a portion of the posterior region266as well. The absorbent structure221is offset longitudinally, i.e., not centered lengthwise on the transverse or lateral axis of the absorbent article, such that the shell214extends longitudinally outward beyond the absorbent structure a greater distance in the anterior region264of the article200than in the posterior region. It is understood, though, that the absorbent structure221may be longitudinally centered so that the shell214extends equally longitudinally outward beyond the absorbent structure, or may be offset longitudinally toward the anterior region264so that the outward longitudinal extension of the shell beyond the absorbent structure is greater in the posterior region265than in the anterior region without departing from the scope of this invention.

As illustrated inFIG. 13, the anterior region264of the absorbent article200comprises the first region201of the shell214and includes a portion of the absorbent structure221. Since much of the first side (i.e., body-facing surface)215of the shell214is exposed (i.e., not covered by the absorbent structure221) in the anterior region264of the absorbent article200, a relatively large surface area of the first side of the shell has body adhesive244applied thereto for adhering the shell, and hence the absorbent article, to the wearer.

A first end261of the absorbent article200, and more particularly a longitudinal edge of the anterior region264defining this first end of the absorbent article200, is suitably contoured along the width of the shell at this first end to accommodate the lower abdomen region of the wearer. In the illustrated embodiment, for example, the longitudinal extent (e.g., length) of the shell214relative to the transverse axis of the article is non-uniform across the width of the shell at the first end261of the article, and more suitably increases as the shell extends transversely outward from the longitudinal axis of the article to transversely, or laterally opposite sides219of the article and more particularly laterally opposite side edges of the shell. Accordingly, a greatest longitudinal extent of the shell214is generally adjacent the intersection of the longitudinal end261with the respective sides219of the article (i.e., the shell in the embodiment ofFIG. 13). More suitably, the longitudinal edge of the shell214(i.e., at first end261of article200in the illustrated embodiment) is generally arcuate as it extends across the width of the shell at its longitudinal edge. It is understood, however, that the contour of the longitudinal edge of the shell214in the anterior region264of the article may be V-shaped, U-shaped or other suitable shape without departing from the scope of this invention.

The contoured longitudinal edge of the shell214(i.e., first end261of the article200in the illustrated embodiment) thus broadly defines a recess in the anterior region264of the article (and thus of the shell in this instance). This recess defines a longitudinal distance D1between the longitudinally outermost extent of the longitudinal edge of the shell214in the anterior region264and the longitudinal extent of the longitudinal edge of the shell at the longitudinal axis of the article200in the anterior region. In one suitable embodiment, the distance D1of the recess is in the range of about 5 mm to about 35 mm, and more suitably about 12 mm to about 18 mm. As one example, the distance D1of the recess at the anterior region264in the embodiment ofFIG. 13is approximately 15 mm.

The sides219of the illustrated article200are suitable defined by transversely opposite side edges of the shell214. These side edges of the shell214are contoured so that the overall width of the article200(i.e., the distance between the transversely opposite sides219thereof), and more particularly the width of the shell in the illustrated embodiment, is non-uniform along the length L1of the article to define leg cutouts for accommodating the upper thighs of the wearer. In one suitable embodiment, the width of the article200and hence the shell214increases from a narrowest width W2in the central region265of the article toward each of the longitudinally opposite ends (261and204,204′) of the article. Still more suitably, the width of the article200and more suitably the shell214is also greater in the anterior region264of the article than in the posterior region266. In the illustrated embodiment, for example, a greatest width W1of the article200is defined by the transverse side edges of the shell214adjacent the longitudinal edge of the shell (e.g., first end261of the article200) in the anterior region264of the article. As additional examples, the greatest width W1of the article200and more particularly the shell214is in the range of about 52 mm to about 180 mm and more suitably about 140 mm to about 170 mm. In the illustrated embodiment ofFIG. 13, the greatest width W1of the article200is approximately 150 mm. The narrowest width W2of the article200and more particularly the shell214is in the range of about 45 mm to about 85 mm, and more suitably about 60 mm to about 80 mm. In the illustrated embodiment, for example, the narrowest width W2of the shell214is approximately 78 mm. In other embodiments, a ratio of the length L1of the shell214(and hence the article200in the illustrated embodiment) to the narrowest width W2of the shell214(and hence article200) is in the range of about 3 to about 1, and more suitably about 2 to about 1.

In the article200illustrated inFIG. 13, the sides219of the article200and more particularly the transverse side edges of the shell214are generally arcuate along substantially the entire length L1of the article. Alternatively, the sides219may be arcuate along only a portion of the length L1of the article. It is also understood that the sides219defining the leg cutouts may be V-shaped, U-shaped or other suitably shape, or it they may be uniform (e.g., straight or longitudinal) along substantially the entire length L1of the article200. It is also understood that the sides219of the article may be contoured to define article200widths other than those set forth above without departing from the scope of this invention. It is further understood that the greatest width of the article200may be other than in the anterior region264, and/or the narrowest width may be other than in the central region265of the article and remain within the scope of this invention.

Still referring toFIG. 13, the contoured longitudinal edge of the shell214(e.g., first end261of the article200) at the anterior region264, together with the contoured transverse side edges of the shell (e.g., article sides219) where these side edges generally intersect the longitudinal edge of the shell, define a pair of transversely spaced tabs220in the anterior region. Each tab220has a central axis CA extending in part transversely outward of the shell214and in part longitudinally outward of the shell. Each of the tabs220suitably has body adhesive244on the body-facing surface (e.g., first side215) for adhering the tabs directly to the wearer and more suitably to the abdomen region of the wearer. In one particularly suitable embodiment, the tabs220are sized to extend to a region of the wearer that has little or no pubic hair to facilitate better adherence to the wearer's skin. For example, in one embodiment each of the tabs220extends outward along its central axis CA away from the peripheral edge of the absorbent structure221a distance D5in the range of about 20 mm to about 90 mm, and more suitably about 45 mm to about 70 mm. Each tab220also has a transversely outermost extent (which in the illustrated embodiment defines the greatest width W1of the shell214and hence the article200) defining a distance D6from the longitudinal axis of the article to the transversely outermost extent of a respective one of the tabs (which is approximately half of the width W1of the shell). In a particularly suitable embodiment, a ratio of the distance D6(that the tab220extends transversely outward) to the distance D5(the length of the tab along its central axis CA) is in the range of about 1 to about 2. In another suitable embodiment, a ratio of the distance D6to a distance between the longitudinal axis of the shell214and a side edge of the absorbent structure221(i.e., about half of the width W5shown inFIG. 18) is in the range of about 2 to about 5.

Each of the tabs220further has a longitudinally outermost extent (which in the illustrated embodiment defines the outermost extent of the longitudinal edge of the shell214) in the anterior region264defining a length L2from the transverse axis of the shell214to the longitudinally outermost extent of the tab220. This length L2is suitably in the range of about 50 mm to about 120 mm, and more suitably about 70 mm to about 100 mm. As illustrated inFIG. 3, the absorbent structure221extends longitudinally into the anterior region264of the article and has a longitudinally outermost extent defining a length L3from the transverse axis to the longitudinally outermost extent of the absorbent structure in the anterior region. For example, this length L3may suitably be in the range of about 30 mm to about 90 mm, and more suitably about 50 mm to about 70 mm. In another embodiment, a ratio of the length L2(the longitudinally outermost extent of the tabs220) to the length L3(the longitudinally outermost extent of the absorbent structure221in the anterior region264) is in the range of about 3 to about 1 and more suitably about 2 to about 1.

With reference now toFIG. 17, the posterior region266of the absorbent article200includes the opening205in the shell214with portions of the lateral side regions202,202′ broadly defining a pair of transversely spaced tabs disposed on opposite sides of the opening. The posterior region266disposition of these tabs is such that the tabs are aligned generally with the buttocks of the wearer rearward of the perineal region. In the illustrated embodiment, the opening205is in the form of a generally V-shaped ingress extending longitudinally on the longitudinal axis of the article200such that the tabs are free to flex relative to the central region265of the article and generally independent of each other to accommodate normal movement of the wearer's thighs and buttocks. In one particularly suitable embodiment, the ingress205extends longitudinally inward from the distal end204,204′ of the absorbent article200(and more particularly a greatest longitudinal extent of the shell in the posterior region266) a distance D2in the range of about 5 mm to about 100 mm, and more suitably about 50 mm to about 80 mm. In the illustrated embodiment, for example, the ingress205has a distance D2of about 75 mm. In another embodiment, the distance D2of the ingress205is in the range of about 5 percent to about 60 percent of the length L1of the shell214, and more suitably about 25 percent to about 40 percent of the length L1. In other embodiments, a ratio of the distance D1of the recess in the anterior region264of the shell214to the distance D2of the ingress205in the posterior region266is in the range of about 4 to about 1, and more suitably between about 3 and about 1. In still another embodiment, a ratio of the distance D1of the recess in the anterior region264of the shell214to the total length L1of the shell is suitably in the range of about 0.03 to about 0.2 and more suitably in the range of about 0.06 to about 0.09. It is understood, however, that the ingress205can be larger or smaller without departing from some aspects of this invention.

Turning now toFIGS. 15 and 16, the absorbent structure221may comprise a single layer structure or be constructed of multiple layers. The illustrated absorbent structure221, for example, comprises an absorbent core222, an intake layer225, a top sheet224, and a liquid impermeable backsheet223. A total thickness T1of the absorbent article200is suitably in the range of about 1 mm to about 12 mm, and more suitably about 2.5 mm to about 5 mm. As one example, the thickness T1of the illustrated absorbent article is approximately 3.5 mm. It understood, however, that the thickness T1may be other than as set forth above depending at least in part on the intended use of the absorbent article200. For example, an absorbent article200in which the absorbent structure221is intended to be used in the manner a maxi-pad may have a greater thickness T1than an absorbent article in which the absorbent structure is to be used in the manner of a panty-liner. In another suitable embodiment, the absorbent structure221has a thickness T2in the range of about 1 mm to about 12 mm, and more suitably in the range of about 1.5 mm to about 5 mm. In the illustrated embodiment, for example, the thickness T2of the absorbent structure is approximately 3 mm. The shell214itself may have a thickness T3between about 0.03 mm and about 5.0 mm, and more suitably about 0.1 mm to about 3.0 mm. In one particularly suitable embodiment, the thickness T3of the shell214is between 0.25 mm and about 3.0 mm. In the illustrated embodiment, for example, the shell214has a thickness T3of about 0.5 mm.

With reference now toFIG. 18, the illustrated absorbent structure221has an upper portion235, a middle portion237, and a lower portion239. The absorbent structure is generally hourglass shaped, with the upper portion235suitably having a width W4between about 10 mm and about 80 mm, and more suitably about 30 mm to about 60 mm. In the illustrated embodiment, for example, the width W4of the upper portion235is approximately 47 mm. The middle portion237, which is the narrowest portion of the absorbent structure221, may have a width W5between about 10 mm and about 80 mm, and more suitably about 30 mm to about 60 mm. In the illustrated embodiment, the width W5of the middle portion237is approximately 40 mm. The lower portion239has a width W6between about 10 mm and about 120 mm, and more suitably about 40 mm to about 80 mm. In the illustrated embodiment, for example, the width W6of the lower portion239is approximately 63 mm. In another suitable embodiment, the absorbent structure221has a longitudinal length L4in the range of about 80 mm and about 180 mm, and more suitably about 110 mm to about 150 mm. As one example, the longitudinal length L4of the illustrated absorbent structure221is about 145 mm. It is understood, however, that the absorbent structure may sized in width and/or length other than as set forth above without departing from the scope of this invention. It is also understood that the absorbent structure221may be any suitable shape other than a generally hourglass shape within the scope of this invention.

With reference back toFIG. 13, the absorbent structure221is secured to the first side (i.e., body-facing surface)215of the shell214, such that at least a portion of the absorbent structure covers the opening or ingress205in the shell. The absorbent structure221may be attached to the shell214in a permanent manner, meaning that the absorbent structure is generally intended not to be removable by the wearer of the absorbent article200. Alternatively, it may be removably and in some embodiments refastenably) attached to the shell214, such that the absorbent structure221may be removed (and in some embodiments reattached) by a wearer.

The shell214and absorbent structure221are sized relative to each other such that a portion of the shell extends outward beyond the peripheral edge of the absorbent structure along at least a portion of the peripheral edge of the absorbent structure. In this manner, a portion of the shell214about the periphery of the absorbent structure221is uncovered with the first side (i.e., body-facing surface)215of the shell exposed and available for adhesion to the wearer. For example, the shell214in one suitable embodiment extends outward beyond the peripheral edge of the absorbent structure200at least in the anterior region264and central region265, and more suitably also in a portion of the posterior region266. In accordance with one embodiment, for example, the shell214extends outward of the peripheral edge of the absorbent structure221a distance D3in the range of at least about 3 mm, more suitably in the range of about 5 mm to about 15 mm and even more suitably about 8 mm to about 13 mm. In one embodiment, the entire first side215of the uncovered portion of the shell214has body adhesive244thereon for adhering the shell and thereby the absorbent article to the wearer.

As illustrated inFIG. 13, the distance that the shell214extends outward beyond the peripheral edge of the absorbent structure221is suitably non-uniform about the periphery of the absorbent structure. More particularly, the shell214extends transversely outward beyond each of the side edges of the absorbent structure221a greater distance in the anterior region264than in the central region265. It is understood, however, that shell214may extend a uniform distance outward of the absorbent structure221, or may extend outward according to a different pattern than illustrated inFIG. 13, and remain within the scope of this invention. In another suitable embodiment, the first side (i.e., body-facing surface)215of the shell214has a total surface area in the range of about 50,000 mm2to about 20,000 mm2, and more suitably about 30,000 mm2to about 40,000 mm2. The absorbent structure221has a total body-facing surface area of about 4,500 mm2to 45,000 mm2and more suitably about 15,000 mm2to about 20,000 mm2. Thus, between about 10,000 mm2and about 45,000 mm2, and more suitably about 18,000 mm2to about 22,000 mm2of surface area of the first side215of the shell214remains uncovered by the absorbent structure221. Stated another way, about 40 percent to about 95 percent, and more suitably about 40 percent to about 65 percent of the shell214is uncovered by the absorbent structure221.

As one example, in the illustrated embodiment the shell214has a total surface area of about 34,000 mm2of which about 20,000 mm2is uncovered and available to have body adhesive244applied thereto. The illustrated absorbent structure221has a total body-facing surface area of about 18,000 mm2of which about 14,500 mm2covers or overlies the shell214. Accordingly, about 60 percent of the illustrated shell214has body adhesive244and can be used to adhere the absorbent article200to the wearer's skin. It is understood, however, that less than the entire exposed area of the shell214can have body adhesive244thereon. It is also understood that body adhesive can be applied to the absorbent structure221to adhere or partially adhere the absorbent structure to the wearer's skin.

Additional embodiments of an absorbent article10of the present specification are illustrated inFIGS. 19A through 29B. As in the previous embodiments, one component of the absorbent article10is a shell14having a first side15and a second side17. The shell14serves to provide the overall contour or silhouette of the absorbent article of the present invention. In addition, the shell14also provides a surface for attachment or adhesion of the absorbent article10to the body of a user.

The first side15of the shell14is the body facing side of the absorbent article10and the second side17of the shell14is the garment facing side of the absorbent article. The first side15of the shell14has a first area11and a second area12. The first area11surrounds or bounds the majority of the second area12, as is clearly shown inFIG. 19A. By “surrounds or bounds the majority”, it is meant that at least 51% of a circumference12C of the second area12contacts the first area11. Generally, at least 60% of the circumference12C of the second area12contacts the first area11. In a particular embodiment, at least 75% of the circumference12C of the second area12is in contact with the first area11. In another particular embodiment, at least 90% of the circumference12C of the second area12is in contact with the first area11. In a further embodiment of the present invention, at least 95% of the circumference12C of the second area12is in contact with the first area11. In still a further embodiment of the present invention, the first area11completely surrounds the second area12of the shell14as is shown inFIG. 19B.

In one embodiment, the first area11of the first side of the shell14is designed or adapted to contact, attach or adhere to the wearer's skin. In one particular embodiment, the first area11of the shell14is designed or adapted to contact a female wearer's skin surrounding the vulva region of the female torso when the absorbent article10is applied to the wearer. Generally, the shell14is sized and shaped such that the extent of the first area of the shell only contacts and attaches or adheres to the skin surrounding and proximate to the vulva area and possibly the pubic and perinea regions of the wearer. In addition to contacting the skin in the vulva, pubic and perinea regions of the wearer, the first area11of the first area of the shell14may also contact and attach or adhere to any hair in the vulva area of the user which may be present. The first area11is the portion of the first side15of the shell14which holds the absorbent article in place on the user.

Generally, the second area12of the shell14is the portion of the shell14which provides absorbency to the absorbent product. That is, the second area12of the first side to the shell is any area of the first side of the shell which has an absorbent structure attached thereto, or has absorbent properties. In one particular embodiment of the present invention, the second area12of the shell14has an absorbent structure21contained therein or attached to the shell14in the second area. It is noted that the second area12may be a single contiguous area or may be two or more distinct areas. Generally, the second area12is a single contiguous area from an ease of manufacturing standpoint. In an alternative embodiment, the second area12of the shell may contain an absorbent material integrated into the shell14, such that the second area12of the shell is absorbent without the presence of an additional absorbent structure. The second area12shell may have an absorbent material coated or impregnated into the shell material.

The shell14of the absorbent article10may be prepared from a variety of materials. The shell may include a layer constructed of any material which will function to be operatively liquid impermeable. The shell14may, for example, include a polymeric film, a woven fabric, a nonwoven fabric or the like, as well as combinations or composites thereof. For example, the shell14may include a polymer film laminated to a woven or nonwoven fabric. A laminate shell14structure is shown inFIG. 20A, having an upper layer141and a lower layer142, wherein the upper layer is the body-facing side of the shell14and the lower layer142is the garment facing side of the shell14. In a particular feature, the polymer film can be composed of polyethylene, polypropylene, polyester, silicone or the like, as well as combinations thereof. Additionally, the polymer film may be micro-embossed, have a printed design, have a printed message to the consumer, and/or may be at least partially colored. Suitably, the shell14can operatively permit a sufficient passage of air and moisture vapor out of the absorbent article10, particularly out of an absorbent structure21while blocking the passage of bodily fluids and odors often associated with bodily fluids. An example of a suitable shell material can include a breathable, microporous film, such as those described in, for example, U.S. Pat. No. 6,045,900 to Haffner et al., the entire disclosure of which is incorporated herein by reference and made a part hereof. Other shell materials which are extensible may be used in the present invention. Examples of extensible backsheet materials are described in U.S. Pat. No. 5,611,790, issued Mar. 18, 1997, to Osborn, III et al., herein incorporated by reference in its entirety.

In one particular embodiment of the present invention, the shell14may be a laminate of a woven or nonwoven fabric with a silicone polymer, wherein the silicone polymer has adhesive properties. The second side17of the shell will be woven or nonwoven fabric and the first side15of the shell will be silicone polymer. One commercially available laminate is an Oleeva Fabric® 1 available from Bio Med Sciences, Inc., which have offices at 7584 Morris Court, Suite 218 Allentown, Pa. 18106. The Oleeva Fabric® is a silicone sheeting having adhesive properties laminated to a fabric backing. The silicone sheeting will form the body facing first side15of the shell material. Relating this particular structure to the Figures, inFIG. 20A, the silicone polymer is the upper layer141of the shell14and the nonwoven or woven layer is the lower layer142of the shell.

Bicomponent films or other multi-component films can also be used as the shell14material. In addition, woven and/or nonwoven fabrics which have been treated to render them operatively liquid-impermeable can also be used as an effective shell14material. Another suitable shell material can include a closed-cell polyolefin foam, a polyurethane polymer material, a silicone polymer or other similar materials. Silicone polymers having naturally occurring adhesive properties, or silicone polymers having a silicone adhesive layer applied thereto are of particular interest for the shell material. Such silicone polymers will allow the first area11of the shell14to adhere to the body of the user without the need of an additional adhesive. These materials may be laminated to another material such that the second side17of the shell14, which is the garment facing side of the absorbent article10, so that the adhesive nature of the silicone polymer does not adhere the garment of under garments of the user. In another embodiment of the present invention, the shell material may be prepared from an interpenetrating polymer network or two or more polymers. Generally, one of the polymer of the interpenetrating polymer network may be a silicone material. Examples of interpenetrating polymer networks are described in U.S. Pat. No. 5,759,560, issued to Dillion, which is hereby incorporated by reference in its entirety.

The shell material should be selected such that the overall properties of the shell allow the shell material to move the skin of the user during normal use and normal movements by the user during use. The shell14should not be too rigid, such that the shell detaches from the skin of the user during use and the shell should not be so flexible that the shell tends to twist and bunch during use. The shell14should have sufficient flexibility to conform to the skin of the user and become similar to a second skin of the user.

Generally, the shell material should have sufficient thickness to allow the shell14to mold to the body of the user, but not too thick that the shell14becomes uncomfortable for the user to wear. In addition, the shell14should not be so thin that it ineffectively forms a seal with the skin of the user when applied to the user, or becomes detached from the skin of the user during use and normal movement of the user during use or that it does not adequately conform to the shape and skin of the user at the point of attachment to the user. Depending on the material used for the shell, the typical thickness of the shell is between 0.03 mm and about 5.0 mm, more particularly between 0.1 mm and 3.0 mm. In one particular embodiment, the thickness of the shell is between 0.25 mm and about 3.0 mm. Again, the actual thickness used is dependent of several factors including rigidity of the material, the flexibility of the material and the ability of the material to assume the shape of the skin of the user at the location of use, which is typically the vulva region of a user.

The second side17of the shell14forms the garment-facing side of the absorbent article when worn by a user. The shell14material should be selected such that the second side of the shell will freely move against the undergarment or clothing of a user. One way to achieve this result is to have the second side17of the shell14to have a fairly low coefficient of friction. This will allow the second side17of the shell14to freely move against the undergarment or other clothing worn by the user. If the second side17of the shell14does not freely move against the undergarment or other clothing worn by the user, the absorbent article may catch on the undergarment or clothing, which may result in the absorbent article being prematurely and undesirably removed from the user or may cause the absorbent article to be shifted from its desired placement against the body of a user.

In order to achieve the desired coefficient of friction on the second side17of the shell14, the materials used to prepare the shell could be selected such that the second side17of the shell material will inherently have the desired coefficient of friction. Alternatively, the second side17of the shell14may be treated with a coating composition, such a polytetrafluoroethylene containing coating, a silicone containing coating or other similar coating having low coefficient of friction properties. Alternatively, the shell14could be made from a laminate of two or more materials such that the first side15of the shell14is prepared from a material which meets the needed properties of the first side15, while the material selected for the second side17of the shell14meets the desired coefficient of friction such that the second side17will free move against the undergarment or garment being worn by a user.

The shell14of the absorbent article10may be flat or may have a three-dimensional shape. As is shown inFIG. 21, which is a side perspective view of the absorbent article the shell14has a three-dimensional concave shape. Alternatively, as is shown in cross-sectional side views ofFIGS. 20,20A and22, the shell14may have a generally flat shape. By providing the absorbent article10with a three-dimensional concave shape as is shown inFIG. 21, placement of the article may be easier for the user. Generally, the three-dimensional shape could be such that it closely matches the overall general curvature of the vulva region and optionally the pubic and perinea regions of most women, when the absorbent article is used as a pantiliner, sanitary napkin or a feminine incontinence article. To form the shell14with a three-dimensional shape, the shell may be molded in any manner known to those skilled in the art, for example heat molding. The manner in which the three-dimensional shape is imparted to the shell14is not critical to the present invention.

When the shell14is a flat shape, meaning that the shell does not have a third dimension other than thickness, the shell14should be made to be flexible enough that the shell14can conform to the body of the user at the point of attachment. In addition to being flat, the overall shape of the shell14may be contoured, as is shown inFIGS. 23,23A and23B. In one embodiment, the contour shape may be such that the narrowest point of the contour is in the crotch area of the shell14nearest the vulva region, as is shown inFIG. 23A. The contour shape shown inFIG. 23is one of many possible shapes the shell14and absorbent article may be prepared. Other shapes may be used, without departing from the scope of the present invention. Generally, the shape selected should be such that the shell14and absorbent article10are comfortable for the user to wear, while providing leakage protection to the user. It is noted that a contour shape may also be used in conjunction with a three-dimensional shell. Further discussion of the overall shape of the absorbent article may be found below.

The shell may be any desired color or may be translucent. In addition, the shell may have a matt finish, satin finish or a smooth finish. The particular finish color or translucency can be a matter of choice for the manufacturer of the absorbent article of the present invention. However, by providing a shell which is translucent may assist the user in placing the absorbent article10prior to use, since the user may be able to see where the article is placed compared to the genitalia of the user.

The absorbent structure21is designed to absorb body exudates, including menstrual fluid, blood, urine, and other bodily fluids, such as sweat and vaginal discharges. The absorbent structure21has a longitudinal direction1and a lateral direction2. This absorbent structure21may be a single layer or may be multiple layers. Typically, the absorbent structure21has an absorbent core22. This absorbent core22may contain one or more layers of absorbent materials. That is the absorbent core22may be a single layer of absorbent materials or may be a multilayer structure. Each of the layers can contain similar materials or different materials. In the absorbent article10of the present invention, the materials which may be used to form the absorbent core22include those materials conventionally used in absorbent articles and includes materials, such as, for example, cellulose, wood pulp fluff, rayon, cotton, and meltblown polymers such as polyester, polypropylene or coform. Coform is a meltblown air-formed combination of meltblown polymers, such as polypropylene, and absorbent staple fibers, such as cellulose. A desired material is wood pulp fluff, for it is low in cost, relatively easy to form, and has good absorbency.

The absorbent core22can also be formed from a composite comprised of a hydrophilic material which may be formed from various natural or synthetic fibers, wood pulp fibers, regenerated cellulose or cotton fibers, or a blend of pulp and other fibers. One particular example of a material which may be used as the absorbent core is an airlaid material. The absorbent core22may have other properties including extensibility, which will allow the absorbent core to be extended or fit to a particular user. One example of extensible absorbent cores is described in U.S. Pat. No. 5,611,790, issued Mar. 18, 1997, to Osborn, III et al., herein incorporated by reference in its entirety.

In one embodiment, the absorbent core22may also include a superabsorbent material, in addition to or in place of the hydrophilic material, which increases the ability of the absorbent core to absorb a large amount of fluid in relation to its own weight. Generally stated, the superabsorbent material can be a water-swellable, generally water-insoluble, hydrogel-forming polymeric absorbent material, which is capable of absorbing at least about 15, suitably about 30, and possibly about 60 times or more its weight in physiological saline (e.g. saline with 0.9 wt % NaCl). The superabsorbent materials can be inserted as particles or in sheet form. The superabsorbent material may be biodegradable or bipolar. The hydrogel-forming polymeric absorbent material may be formed from organic hydrogel-forming polymeric material, which may include natural material such as agar, pectin, and guar gum; modified natural materials such as carboxymethyl cellulose, carboxyethyl cellulose, and hydroxypropyl cellulose; and synthetic hydrogel-forming polymers. Synthetic hydrogel-forming polymers include, for example, alkali metal salts of polyacrylic acid, polyacrylamides, polyvinyl alcohol, ethylene maleic anhydride copolymers, polyvinyl ethers, polyvinyl morpholinone, polymers and copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides, polyvinyl pyridine, and the like. Other suitable hydrogel-forming polymers include hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, and isobutylene maleic anhydride copolymers and mixtures thereof. The hydrogel-forming polymers may be lightly crosslinked to render the material substantially water insoluble. Crosslinking may, for example, be by irradiation or covalent, ionic, Van der Waals, or hydrogen bonding. Hydroxyfunctional polymers have been found to be good superabsorbents for sanitary napkins. Such superabsorbents are commercially available from Dow Chemical, Hoechst-Celanese, and Stockhausen, Incorporated, among others, and are a partially neutralized salt of cross-linked copolymer of polyacrylic acid and polyvinyl alcohol having an absorbency under load value above 25 grams of absorbed liquid per gram of absorbent material (g/g). Other types of superabsorbent materials known to those skilled in the art can also be used.

Generally, the absorbent core22will be positioned adjacent the shell14, as is shown inFIGS. 20,20A and22. In addition, the absorbent core22may be recessed into the shell14as is shown inFIG. 22.

In addition to the absorbent core22, the absorbent structure21may have other additional layers which aid the absorbent core22in capturing and holding the bodily fluid into the absorbent core22. These other layers, when present and in combination with the absorbent core22, form the absorbent structure21of the absorbent article10. There may be a single layer or multiple layers in addition to the absorbent core in the absorbent structure21. Alternatively, the absorbent structure21may have a single layer, which is generally the absorbent core22.

One particular example of an additional layer which may be used in addition to the absorbent core22in the absorbent structure21is a body-side liner or top sheet24, which is generally a liquid permeable material, which allows bodily fluids to pass through the top-sheet into the absorbent core. It is noted that the terms “body-side liner” and “top sheet” may be used interchangeable. The body side liner24also may provide a user with a dry feeling by separating the absorbent core22from the body of the user. That is, the body-side liner24is placed between the absorbent core22and the body of the user and such that the absorbent core22is between the body side liner24and the shell14.

In the present invention, generally the body side liner24will only extend to the edge25of the absorbent core, as is shown inFIG. 20. However, the body side liner24may extend beyond the edge25of the absorbent core22and may be attached to the first side of the shell. Generally, if the body side liner24extends beyond the absorbent core22, the body side liner will be attached to the first side15of the shell14. Also, if the body side liner24extends beyond the absorbent core22, the body side liner24will generally not cover the entire first area11of the first side15of the shell14.

Optionally, the body side liner24may be formed from one or more materials. The body-side liner or top sheet24should be able to manage different body excretions depending on the type of product. In feminine care products, often the body-side liner or top sheet24must be able to handle menses and urine. In the present invention, the body-side liner or top sheet24may include a layer constructed of any operative material, and may be a composite material. For example, the body-side liner or body-contacting layer can include a woven fabric, a nonwoven fabric, a polymer film, a film-nonwoven fabric laminate or the like, as well as combinations thereof. Examples of a nonwoven fabric useable in the body-side liner or top sheet24include, for example, an airlaid nonwoven web, a spunbond nonwoven web, a meltblown nonwoven web, a bonded-carded web, a hydroentangled nonwoven web, a spunlace web or the like, as well as combinations thereof. Other examples of suitable materials for constructing the body-side liner or top sheet24can include rayon, bonded-carded webs of polyester, polypropylene, polyethylene, nylon, or other heat-bondable fibers, finely perforated film webs, net-like materials, and the like, as well as combinations thereof. These webs can be prepared from polymeric materials such as, for example, polyolefins, such as polypropylene and polyethylene and copolymers thereof, polyesters in general including aliphatic esters such as polylactic acid, nylon or any other heat-bondable materials. When the body-side liner is a film or a film laminate, the film should be apertured or otherwise be made to allow fluids to flow through the body-side liner to the absorbent core.

Other examples of suitable materials for the body-side liner or top sheet24are composite materials of a polymer and a nonwoven fabric material. The composite materials are typically in the form of integral sheets generally formed by the extrusion of a polymer onto a nonwoven web, such as a spunbond material. In a particular arrangement, the body-side liner or top sheet layer24can be configured to be operatively liquid-permeable with regard to the liquids that the article is intended to absorb or otherwise handle. The operative liquid-permeability may, for example, be provided by a plurality of pores, perforations, apertures or other openings, as well as combinations thereof, which are present or formed in the liner or body contacting layer. The apertures or other openings can help increase the rate at which bodily liquids can move through the thickness of the liner or body contacting layer and penetrate into the other components of the article (e.g. into the absorbent core22). The selected arrangement of liquid permeability is desirably present at least on an operative portion of the body-side liner or top sheet24that is appointed for placement on the body-side of the article. The body-side liner or top sheet24can provide comfort and conformability, and can function to direct bodily exudates away from the body and toward the absorbent core22. The body-side liner or top sheet24can be configured to retain little or no liquid in its structure, and can be configured to provide a relatively comfortable and non-irritating surface next to the body tissues of a wearer. In the present invention, the top sheet or body-facing surface of each absorbent article may be embossed, printed or otherwise imparted with a pattern.

Additional layers or substrates, including for example, the liquid acquisition and distribution layer, also referred to as a surge or transfer layer, and an optional tissue layer are also incorporated into the absorbent structure21of the absorbent product10, for example, between the body-side liner or top sheet24and the absorbent core22. The distribution layer may be shorter than the absorbent core or have the same length as the absorbent core22. The distribution layer serves to temporarily hold an insulting fluid to allow the absorbent core sufficient time to absorb the fluid, especially when a superabsorbent material is present.

In another embodiment, the absorbent core, transfer layer and other components, such as tissue layers, may be free floating (unattached) between the shell14and the top sheet24, and only are secured along only the peripheral edges thereof. Alternatively, the absorbent core22, transfer layer, if present, and any other layer or component, if present, may be attached to one or both of the shell14and top sheet24and/or to each other.

The absorbent structure21, including the absorbent core, is generally attached to the first side15of the shell14in the second area12of the shell. The attachment may be in a permanent manner, meaning that the absorbent structure is generally intended not to be removable by the user of the absorbent article10. Alternatively, the absorbent structure21may be made to be removable by the user, meaning that the absorbent structure21may be removed and replaced with another absorbent structure21by the user of the absorbent article10. When the absorbent structure21is attached to the shell14in a permanent manner, meaning that the absorbent structure is not intended to be removed by the user, a construction adhesive may be used. Examples of useable construction adhesives include any adhesive which will effectively hold the absorbent structure21in place, so as not to be separated from the shell14. Commercially available construction adhesives usable in the present invention include, for example include Rextac adhesives available from Huntsman Polymers of Houston, Tex., as well as adhesives available from Bostik Findley, Inc, of Wauwatosa, Wis. Other means may be used to hold the absorbent structure21to the shell including other bonding means, including heat bonding and ultrasonic bonding. When the absorbent structure21is removably attached, the absorbent structure21is held in place on the shell14by a means which will allow the user to remove the absorbent structure. One such means of holding the absorbent structure is by using a pressure sensitive adhesive. Suitable pressure sensitive adhesives include any commercially available pressure sensitive adhesive. Examples of suitable pressure sensitive adhesives usable to removably hold the absorbent structure21in place on the shell14include pressure sensitive adhesives available from National Starch and, having offices in, Bridgewater, N.J. 08807. By providing an absorbent structure which is removable, the shell may be reused several times without the need to again place the shell when the absorbent needs to be replaced. Also by having a removable absorbent structure, the absorbent structure can be selected by the user prior to use. This would allow the user to select an appropriate level of protection for a given day or allow the user to select a size or shape of the absorbent which the user finds to be more comfortable.

As is stated above, the absorbent structure21is located in the second area12of the shell14and on the first side15of the shell member. This size and shape of the absorbent structure may be varied depending of the intended use of the absorbent article and will be discussed in more detail below.

The absorbent structure21may have a relatively flat structure, as shown inFIGS. 20,20A,21and22. Alternatively, the absorbent structure may have a three-dimensional shape other that a relatively flat shape. The absorbent structure may have an anatomically correct shape such that the absorbent structure fits within the labia of the user. Anatomically correct shapes of absorbent are generally know to those skilled in the art and are generally found in the interlabial art field. The absorbent structure may be designed to be partially or fully interlabial. Alternatively, a three-dimensional shaped absorbent structure may also be used in the absorbent article10which is designed not to fit within the labia majora of the user. That is, the absorbent structure21is positioned completely outside the labia during use. The size, location and shape of the absorbent structure21may also be selected for an intended use. For example, in an overnight use, the absorbent may be located further back on the user towards the perinea region of the user. In an overnight use, the absorbent structure may be larger than in a product intended for daytime use. In a daytime use, the absorbent structure will generally be centrally located of the vulva region.

In an alternative embodiment of the present invention, the absorbent structure21is contained within the shell material. That is, the absorbent structure21is an integral part of the shell14and a separate absorbent structure is not present. One way to achieve an integral absorbent structure is to have a shell which is prepared from a material which is a laminate of two or more materials. The first side15of the shell14contains an absorbent material within the body facing side of the laminate. For example, superabsorbent particles or materials may be incorporated into the material making up the body facing layer of the laminate. Another way is to place a very light coating onto the first side12of the shell material, wherein the coating contains a superabsorbent particles or materials. Of course other absorbent materials, other than superabsorbent materials may be used in place of or in addition to the superabsorbent materials.

The absorbent structure21may be located entirely over the shell14, as is shown inFIGS. 19A,19B,20,20A,21,22, and23, meaning at the shell14material is located beneath the absorbent structure14. Alternatively, the absorbent structure21may be positioned over the shell14, such that only a portion of the absorbent structure21is over the shell14. This configuration is shown inFIGS. 24A,24B and24C.FIG. 24Ais a bottom view andFIG. 24Bis a top view of an absorbent article10within the present invention. As can be seen only a portion of the absorbent structure21is positioned over the shell14.FIG. 24Cshows a cross-sectional view of the absorbent article10taken along line6C-6C inFIG. 24B. As with the other embodiments of the present invention, the portion of the first side15of the shell14in which the absorbent structure is attached is the second area12of the shell14. Surrounding the second area12is the first area11of the shell14. The second side17of the shell14is the side of the absorbent article which faces the user during use. By having an absorbent article with the structure shown inFIG. 24C, it is also beneficial for the absorbent structure to have an additional layer23. This additional layer will serve to provide liquid impermeability to the absorbent structure, such that any fluids entering the absorbent core will not flow through the core to clothing of a user.

This additional layer23may be prepared from a variety of materials and is generally, this additional layer constructed of any material which will function to be operatively liquid impermeable. The additional layer, may be a polymeric film, a woven fabric, a nonwoven fabric or the like, as well as combinations or composites thereof. For example, the shell14may include a polymer film laminated to a woven or nonwoven fabric. In a particular feature, the polymer film can be composed of polyethylene, polypropylene, polyester, silicone or the like, as well as combinations thereof. Additionally, the polymer film may be micro-embossed, have a printed design, have a printed message to the consumer, and/or may be at least partially colored. Suitably, the additional layer can operatively permit a sufficient passage of air and moisture vapor out of the absorbent article10, particularly out of an absorbent structure21while blocking the passage of bodily fluids and odors often associated with bodily fluids. Examples of suitable materials for the additional layer23include a breathable, microporous film, such as those described in, for example, U.S. Pat. No. 6,045,900 to Haffner et al., the entire disclosure of which is incorporated herein by reference and made a part hereof.

As is stated above, the first area11of the shell14serves either directly or indirectly attaches to the body of a user. Stated another way, the shell is the body attachment member and the first area11is the portion of the shell14which is attached to the body of the user. Depending on the material selected for the shell, the shell may actively attach to the body of the user using electrostatic means; suction means or a body adhesive may be placed on the first area11of the shell14to attach the absorbent article to the body of a user. Electrostatic means which can be used is by selecting the shell material to be a material which has an affinity for the body of a user, such that the shell material “clings” to the body of the user. Examples of such materials include ethylene vinyl acetate, low density polyethylene and other similar materials know to those skilled in the art. Suction means may be achieved by shaping the shell to conform to the body of the user, much like a contact lens fits to the eye. Generally, suction means can be achieved by forming the shell14into a three-dimensional shape. The easiest way to achieve body attachment is to place a body adhesive in the first area11of the shell14.

The body adhesive44is positioned on the first area11of the first side15of the shell14. The body adhesive44contacts the skin and hair, if present, in the vulva region and possibly the pubic region and/or the perinea region of the wearer's body, thereby supporting and holding the absorbent article10against the body of the wearer during use. The body adhesive44can overlie a portion of the first area11or can overlie the entire first area11of the shell14. Generally, the body adhesive44will be present on a least the outer portion or near the circumference11C of the first area near the edge20of the absorbent article. As is shown inFIGS. 19A,19B,20,20A,22,23B and24B and24C, the adhesive may cover the entire first area11of the absorbent article. Alternatively, the body adhesive44may be placed on a portion of the first area11, as is shown inFIGS. 23 and 23A. The body adhesive44may also be placed in a pattern of the first area11. The body adhesive44can be applied to the first area11of the shell14of using any known process including, inkjet printing, screen printing or extruding the body adhesive44from one or more nozzles, slot coating and the like.

Generally, any pressure sensitive adhesive known to those skilled in the art may be used, provided that the pressure sensitive adhesive is not a known irritant to human skin or that the adhesive is so aggressive that it causes pain to the user when the absorbent article is removed from the skin. It is also desirable that the adhesive is selected such that the adhesive does not leave a substantial amount of an adhesive residue on the surface of the skin of the user, when the absorbent article10is removed by the user after use. Particularly suitable pressure sensitive adhesive materials are disclosed in the commonly assigned U.S. Pat. No. 6,213,993 to Zacharias et al., U.S. Pat. No. 6,620,143 to Zacharias et al., the entire disclosure of each is incorporated herein by reference and made a part hereof. Other suitable adhesives are disclosed in U.S. Pat. No. 5,618,281 to Batrabet et al., the entire disclosure of which is incorporated herein by reference and made a part hereof. Other known body adhesives, such as those described in U.S. Pat. No. 6,316,524 to Corzani et al. which is hereby incorporated in its entirety, may also be used. Other examples of pressure sensitive adhesives include, Hydrogels, Hydrocolloids, Acrylics based adhesives, rubber based adhesives, such as Kraton based adhesives.

The body adhesive44may be positioned on the first area11of the shell14in an open pattern or a closed pattern. By “open pattern” is meant that the adhesive can have an intermittent or discontinuous pattern which does not substantially encircle the entire first area11. For example, there are breaks in the body adhesive at certain portions of the first area11. An open pattern of adhesive is shown inFIG. 23. “Closed pattern” means the adhesive44would encircle the entire second area12of the shell. Preferably, the pattern of the body adhesive44will substantially surround the absorbent structure located in or on the second area12of the shell14. As shown inFIGS. 19A,19B,20,20A,22,23B,24B and24C, the body adhesive44is applied in a closed pattern, since the entire body adhesive is applied in a continuous fashion around the first area. An “open” pattern of the adhesive is shown inFIG. 25, which shows the adhesive applied in a discontinuous fashion. Additionally, the adhesive may be applied in portions of the first area11, as is shown inFIGS. 23 and 23A. In the present invention, the closed pattern can be advantageous since the body adhesive44may form a seal with the body of the user which will assist in preventing leaks from the absorbent article10. The body adhesive may form a dam, which may prevent leaks from the entire perimeter of the absorbent article.

In one embodiment of the present invention, as is shown inFIGS. 19A,19B,20,20A,22,23B,24B and24C, the body adhesive44may be placed on the entire first area11, just outside of the absorbent structure21. In another alternative embodiment of the present invention, as is shown inFIG. 23, the body adhesive44may placed along the outer portions of the first area11near the periphery of the shell14. The body adhesive44may also be placed on the absorbent structure21. Generally, however, the body adhesive44is confined to being placed on the first area11of the shell14, since placing the body adhesive on an area of the absorbent product10which contacts the female genitalia such as the labia majora may cause discomfort to the wearer of the absorbent product.

The adhesive may be applied in a pattern of small discrete dots so as to leave numerous areas free from adhesive. Alternatively, the adhesive may be applied as a continuous bead, or may be applied as a series of semi-continuous beads. Other suitable adhesive patterns may be selected for applying the body adhesive44to the body-contacting first area11of the absorbent article10. For example, adhesive patterns can be oval, swirls, various linear or non-linear arrays of adhesive longitudinally, and/or transversely oriented and reticulated webs having unobstructed interstices between the adhesive fibers or combinations thereof. As stated above, the adhesive patterns may be open or closed. The weights of adhesives are limited to less than about 800 g/m2, and generally less than about 400 g/m2. Generally, the weight of the adhesive is at least 20 g/m2. Typically, the adhesive is applied in an amount of about 100 to about 400 g/m2. The limitations on the basis weight of the adhesive are important to provide the correct adhesive characteristics for applying directly to the wearer's vulva region and optionally the pubic and perinea regions of the wearer's body. If the basis weight is too high, the absorbent article will have a sticky feeling or otherwise uncomfortable feeling. If the basis weight of the adhesive is too low, there may be insufficient adhesion to the body of the user.

Generally, the body adhesive44is applied in a manner which is symmetrical about the longitudinal axis1which bisects the absorbent article10and divides the absorbent article10into substantially equal portions. This symmetrical pattern provides the wearer a balanced feel when wearing the absorbent article10. The symmetrical pattern also reduces the perception of any associated discomfort when the absorbent article10is removed from the body.

As is shown inFIGS. 26A and 26B, to protect the body adhesive44, a peel sheet or release sheet46may be used to prevent the body adhesive44from becoming contaminated, thus loosing its ability to stick to the body of an user and/or prematurely adhering to an unintended surface. Suitable materials for use as a peel strip46are well known in the art and are commercially available. Examples of suitable peel sheets or release sheets include, a silicone coated Kraft paper, a silicone coated film or the like. Other release coating includes coating containing polytetrafluoroethylene. The peel sheet or release sheet46may extend beyond one or both of the ends and/or sides of the shell, as shown inFIG. 26B. Alternatively, the release sheet46may be sized to only cover the body adhesive on the first area11of the shell14, as is shown inFIG. 26A. In yet another embodiment of the present invention, release sheet may extend beyond the adhesive at one or more locations, such as one of the ends or one of the sides of the shell as is shown inFIG. 26Cby providing the release sheet46with a tab47for the user to grasp to remove the release sheet46from the absorbent article10and the body adhesive44on the absorbent article. When the release sheet46extends beyond the adhesive, it is generally easier for the user to remove the release sheet46to place the absorbent article10for use.

Alternatively, the release sheet46may be provided with a pressure sensitive adhesive to hold the release sheet46in place when the absorbent article is devoid of an adhesive for body attachment. In this configuration, the release sheet serves to protect the absorbent structure and first side of the shell from dirt and damage prior to use.

In another alternative, a release sheet may not be necessary. For example, the absorbent article may be rolled, folded onto itself or stacked upon each other. In these configurations, a release sheet is not needed. If rolled, the body adhesive44will generally contact the second side17of the shell14. The body adhesive44should releasably stick to one second side of the shell by readily releasing when unrolled by the user or wearer. In addition, the body adhesive44should not leave a residue on the second side17of the shell. This should similarly occur when the absorbent articles10are stacked upon each other such that the body adhesive44of one article will attach the second side of the shell of a second article. In another possible configuration, the absorbent article may10be folded along the longitudinal axis1of the lateral axis such that the body adhesive44in one area comes into contact with body adhesive in another area. In the folded configuration, the body adhesive should be selected such that the body adhesive will release from itself when manipulated by a user.

The dimensions and shape of the shell14should be such that it is appropriately sized for its intended use. The same is true for the size and shape of the absorbent structure. Generally, the size and shape of the absorbent structure21will dictate the size of the shell14. The shape of the shell14is selected so that the absorbent article will have a comfortable feeling for the user, which providing protection against leaks and preventing the absorbent article from becoming dislodged from the body of the user during user. Generally, the shell will be curved to fit the body of a user. The shell14also generally gives the absorbent article10its overall size and shape in the longitudinal1and lateral2directions.

When the absorbent article is intended for use as a pantiliner, a sanitary napkin or a feminine incontinence article, the shell14should be wider and longer than the absorbent structure21attached to the second area12of the shell14. The absorbent structure should be at least as wide and as long as the labia majora of the user. As a result, to fit most women, the absorbent structure is longer in the longitudinal direction than it is wide in the lateral direction of the absorbent structure. Generally, for most women, the labia majora are generally between about 40 mm and about 70 mm in width and between about 80 mm and 150 mm in length. Ideally, the absorbent structure should be wider than the labia majora and slightly longer than the labia minora and slightly longer than or equal to the labia majora. Generally, the absorbent should be between about 40 mm and 90 mm in width in the lateral direction and between about 95 mm and about 150 mm in length the longitudinal direction. The shape of the absorbent structure21will generally tend to be oblong and may be an oval, a rectangle, tear drop shaped, hourglass shaped or racetrack shaped. As can be seen inFIGS. 19A,23,23B,24B,25and27, the absorbent structure21has a generally elliptical or oval shape to match the size and shape of the vaginal area of most women. An example of a teardrop shaped absorbent is shown inFIG. 19A.

Generally, the shape of the shell14may vary from a generally oval shape, as shown inFIGS. 19A and 19Bto a shape which is a generally hourglass-like shape, shown inFIG. 23A. By generally hourglass shape, it is meant a shape in which the sides19of the shell14converge towards one another at a point away along the longitudinal axis1of the shell14to form a narrowest portion33of the absorbent article. Generally, the hourglass-like shape provides a cut-out for the user's legs. By having an hourglass-like shape, the shell14will not be attached to the legs of a user during use. This will provide more comfort for the user of the absorbent article10. The shape of the shell14should be selected such that the absorbent article10will be comfortable to wear, while providing very effective leakage protection to the user. The shell14and the absorbent structure21should be able to adapt to the curvature of a users body during use. Other possible shapes for the shell14are also shown inFIGS. 23,23A,23B, and24A. Other shapes not specifically shown may also be used, provided that the shape will provide comfort to the user of the absorbent article.

To obtain an effective attachment of the absorbent article to the user, when the absorbent article is used as a sanitary napkin or an incontinence article, generally the width of the of the shell should be at least 10 mm on either side of the labia majora. Generally, the shell14of the absorbent article10will have a width, in the lateral direction2, between about 50 mm up to 200 mm or more. Typically, the shell will be between about 60 and 120 mm at its narrowest point. This will allow the shell14to have a first area11that can be effectively attached to the skin of a user on either side of the labia majora.

In addition, the absorbent article10may also be configured to have an anterior region64, a central region65and a posterior region66, as is shown inFIG. 27. A particular embodiment is shown inFIG. 26of an absorbent article having a configuration designed to fit specific areas of the vulva region of a user. By providing specific portions for attachment to specific areas of the body of the user, the absorbent article may be configured to better fit the body of the user. The anterior region64of the absorbent article will be the portion of the absorbent article between the absorbent structure21and the first end61of the absorbent article10. The posterior region66of the absorbent article10will be the portion of the absorbent article between the absorbent structure21and the second end62of the absorbent article10. Generally, the posterior region66will be designed to be placed between the vagina area and the anal area of the user. The anterior region64is designed to be placed on the mons Veneris region of a female user. The central region65of the absorbent article10is designed to cover the vagina area of the user and the skin area surround the lateral sides of the labia majora, when the absorbent article is used as a pantiliner, sanitary napkin or an incontinence article. In an alternative use, the absorbent article of the present invention may also be used as an underwear replacement, or a guard for a swimming suit.

To obtain an effective attachment to the body of the user, the shell14can be configured to be anatomically correct for a user. As is shown inFIGS. 27 and 28, the shape of the absorbent article10is such that it will correctly and securely fit in the vulva region of a user. The general shape of the absorbent article shown inFIG. 28has been found to effectively attach to the vulva region of female users of the absorbent article. Additional features may be included to ensure an anatomically correct shape. For example, in the posterior region of the absorbent article10, more particularly, the posterior region of the shell on the first side15, the shell14may be imparted with a three-dimensional protrusion67, as shown inFIGS. 27 and 28. The protrusion67acts to fit comfortably in the perinea region of the user. The protrusion67may be formed from the shell material of may be formed from the body adhesive44. By providing the three-dimensional protrusion67, the absorbent article can effective fit to the typical body shape of the female user, thereby preventing leaks form the posterior region of the absorbent article. The protrusion67may also serve as a guide to the user in placement of the absorbent article10on the body prior to use.

The absorbent article of the present invention may have other features which aid the user to place and remove the absorbent article from the body. As is shown inFIGS. 29A and 29B, the second side12of the shell14may be provided with positioning aids, such as a finger pocket99, or finger grooves in the shell material. The finger pocket99has an opening98toward the anterior region64or first end61of the absorbent article10. The pocket99gives the user a location to place her fingers during placement of the absorbent article10onto the user's body. The pocket99may be an opening wide enough for the user to place at least two fingers in the pocket. Alternatively, there may be two or more openings which allows the user to place only one finger in each opening. Other similar positioning aids may be used to help guide a user to properly place the absorbent article for use. For example, grooves may be placed in the second side12of the shell14opposite the absorbent structure. This may allow the user to feel the location of the absorbent structure relative to the vulva region during application of the absorbent article10to the vulva region of the body. The pocket99may also assist the user in removing the absorbent article from their body.

The absorbent article10may also be provided with a removal aid which provides the user with an easy way to grasp and remove the absorbent article applied to the body. One particular removal aid is shown inFIG. 29Bincluding a tab92located on the first end61of the shell which is not adhered to the body or is devoid of adhesive. Alternatively, other removal aids, such as having an area of the first end61being devoid of the body attaching adhesive44. Other types of removal aid which may be present include loops, and pull strings. The removal aid allows the user to effectively begin the process of gentling removing the absorbent article from the body of the user, without the need of having to find a portion of the shell which may not be completely attached.

Other features or additives may be incorporated into the absorbent article of the present invention. For example, the absorbent article may contain an odor control agent, or a fragrance, skin wellness agents and other similar additives currently used in currently available absorbent articles. Any odor control agent or, fragrance known to those skilled in the art may be used in the absorbent article of the present invention. The odor control agent or fragrance may be added in various components of the absorbent article, including the shell14, the absorbent structure21of the body adhesive44. Skin wellness additives may be added onto the absorbent structure, any portion of the first area15of the shell not attached to the user or in the body adhesive44.

Generally, to apply the absorbent article10to the body of a user, the release sheet46, protecting the absorbent structure and adhesive, if present, is removed from first surface of the shell. Next, the user positions the absorbent structure of the portion of the body in which absorbency is needed. If positioning pockets or other positioning aids are present on the absorbent structure, the user may optionally use these positioning aids to properly place the absorbent article for use. In the case of sanitary napkins and incontinence absorbent articles for females, the absorbent is positioned over the vagina area such that the absorbent structure will absorb body fluids. The user then checks to ensure that the first area11of the shell or the adhesive44, if present, is contacting the skin around the vagina area.

If the absorbent article is intended to have a front and a back portion, the user first identifies the anterior region64and/or the posterior region66of the absorbent article. To aid in identification of the anterior and posterior regions, indicia located on the release sheet, shell or absorbent to indicate the anterior region and/or posterior region of the absorbent article may be present. Indicia can be simply lettering or a picture to indicate the front or back of the absorbent article. Once anterior region and posterior region are identified by the user, the user places the absorbent article in the same manner described above.

In each case, the absorbent structure, which is designed to cover the labia majora of the user, may be positioned with the aid of the absorbent structure. More specifically, the absorbent structure, when sized and shaped to the approximate size of the labia majora, can serve to guide the placement of the absorbent structure over the labia majora. Once properly placed, pressure is applied by the user to the second surface of the shell which will allow the first surface of the shell to contact the skin of the user, or to allow any adhesive applied to the first surface to be applied to the skin of the user.

By having the absorbent article10attached to the body of a user, the absorbent article10will tend to move with the skin of the user. This results in a comfortable to wear absorbent article which will be less likely to leak than conventional absorbent articles. The absorbent article has a very close to the body fit which may provide improved discretion for the user.

Other benefits of the absorbent article10of the present invention may also be provided. For example, when the first side of the shell has an adhesive applied thereto, upon removal of the absorbent article after user, the user may fold the first side of the shell onto itself to dispose of the used absorbent article. An effective seal may be formed around the perimeter of the shell, thereby effectively encapsulating the absorbent structure within a closure. As a result, any odors associated with the absorbed fluids will be contained within the shell material.

FIGS. 30-32illustrate one suitable embodiment for packaging any of the absorbent articles described above, e.g., the absorbent article200ofFIG. 11. As illustrated, the absorbent article200can be placed in a packaged configuration suitable for packaging, stowing, or transporting the absorbent article. In the packaged configuration of this embodiment, the absorbent article200is rolled up onto itself. More particularly, in the illustrated configuration, the absorbent article200is rolled starting at its first end261and ending with its distal end204′,204. As a result, the first end261is disposed in the center of packaged configuration and the distal end204′,204is disposed on the exterior thereby making the distal end accessible to the wearer. In this configuration, the body adhesive244applied to the first side215of the shell214is used to hold the absorbent article200in its packaged configuration. It is understood that the absorbent article200can be rolled in the opposite direction. That is, the absorbent article200can be rolled starting with the distal end204,204′ and ending with the first end261.

A closure in the form of an adhesive tab1001is also used to secure the absorbent article200in its packaged configuration. In addition, the tab1001provides a grip for gripping by the wearer to unroll the absorbent article as described in greater detail below. It is understood, however, the any suitable closure can be used (e.g., hook and loop, snaps, adhesive tape, rubber band) or that the closure can be omitted.

In another suitable embodiment, the absorbent article200can include a peel sheet (such as peel strip146illustrated inFIG. 8A) and rolled to a packaged configuration similar to that of the embodiment illustrated inFIG. 30. In this embodiment, the absorbent article200can be held in the packaged configuration by any suitable closure, such as the tab1001illustrated inFIG. 30or other suitable means.

In its packaged configuration, the absorbent article200can be wrapped individually, as illustrated inFIG. 33, or along with a plurality of absorbent articles200. As illustrated inFIG. 33, the absorbent article200can be placed individually into a frangible wrapper, indicated generally at1003. The illustrated wrapper1003suitably has a front panel1005and a back panel1007sealingly engaged with the front panel to define an interior space1009sized and shaped for receiving the absorbent article200in its packaged configuration. Thus, the wrapped absorbent article200can be carried as a single unit by the user (e.g., in a purse, backpack, or a pocket) in a sealed, hygienic condition.

The wrapper1003can be selectively opened to permit removal of the absorbent article200from the wrapper by the wearer. In one example, the wearer can tear the wrapper opening. Notches or cuts can be provided to assist the wearer in tearing the wrapper. In another example, the wrapper1003can be provided with a line of weakness (not shown) formed thereon to provide a path along which the wrapper is more readily torn to open the wrapper. The line of weakness can suitably comprises a plurality of aligned perforations, a plurality of separation points, a score line, a breakaway line or areas, a chain stitch, a thinning of the wrapper material or other suitable line of weakness. The line of weakness may be suitably formed by partial pressure cutting, partial ultrasonic cutting, partial thermal deformation, mechanical thinning, or other suitable techniques.

The wrapper1003may suitably be formed from woven material, non-woven material, films, laminates, or a combination thereof. For example, in one suitable embodiment, the wrapper1003may be made of paper, polyethylene, polypropylene, oriented polypropylene materials, or the like. Suitable examples include, without limitation, a low density polyethylene (LDPE) film; a LDPE/LLDPE (linear low density polyethylene) film laminate; a LDPE/MDPE (medium density polyethylene) film laminate; and a LDPE/HDPE (high density polyethylene) film laminate or the like. One particular material suitable for making the wrapper1003is available from Pliant Corporation under the tradename XP3-999-1459.0.

In another suitable embodiment, which is illustrated inFIGS. 34 and 35, the absorbent article200can be rolled to its packaged configuration about a cylindrical member and, more specifically, a tube, indicated generally at1011. In the illustrated configuration, the tube1011includes bulbous ends1013and a recessed center portion1015disposed between the ends. The absorbent article200is rolled about the recessed center portion. The tube1011can be made from any suitable material, e.g., cardboard, plastic. It is understood that the tube1011can have other configurations (i.e., cylindrical) than that illustrated and described herein.

In one suitable embodiment, the tube1011defines an interior chamber1017, which can be used to stow one or more other products, for example, a tampon and tampon applicator assembly1019as illustrated inFIGS. 36A and 36B. Additional products including a wipe, a glove, a cleansing lotion, a disposal bag, and a cleansing pillow can be stow with or instead of the tampon and tampon applicator assembly1019. One or both of the ends1013of the tube1011may include a suitable closure, such as a foil or plastic cover (not shown), for enclosing the interior chamber1017of the tube and thereby any products stored within the tube. It is contemplated that the tube can be permeable or impermeable. It is also contemplated that the tube may contain a liner (not shown), which may or may not be removeable.

In still another embodiment, the absorbent article200can be rolled to its packaged configuration about one or more products. For example, as illustrated inFIG. 37, the article200can be rolled up directly around the tampon and tampon applicator assembly1019. It is understood that the article200can be rolled directly around one or more other products including, without limitation, a wipe, a glove, a cleansing lotion, a disposal bag and a cleansing pillow. It is also understood that the products about which the absorbent article200is rolled can be wrapped or unwrapped.

Besides being rolled, the absorbent article200can also be folded to a packaged configuration as illustrated inFIGS. 38-41. In one suitable embodiment, the absorbent article200is folded generally in half about the transverse axis of the absorbent article. In another suitable embodiment, which is illustrated inFIG. 42, the absorbent article200is folded in generally Z-fold. It is understood that the absorbent article200can be folded in any suitable manner, e.g., a W-fold.

As previously mentioned, other products including, without limitation, a wipe, a glove, a cleansing lotion, a disposal bag and a cleansing pillow can be provided in combination with the absorbent article200. In one suitable embodiment, the product can be placed between the absorbent article200in its folded configuration. For example, a tampon and tampon assembly1019(or any other suitable product) can be disposed in a pocket1025formed by folding the absorbent article as illustrated inFIG. 43. It is contemplated that the absorbent article200and the other product(s) can have other relative arrangements (e.g., the product can be place on top of, beneath, adjacent the absorbent article). The products can be individually wrapped, unwrapped, or separated from the absorbent article200using a suitable barrier.

It is contemplated that the article200can be held in its folded packaged configuration using the body adhesive244of the article or using a suitable closure, such as, an adhesive tab1021. It is understood that the article may also include a peel sheet246as illustrated inFIG. 43. As seen inFIG. 41, the article200can be placed in a wrapper1023in its packaged configuration. The wrapper1023ofFIG. 41is substantially the same the wrapper1003ofFIG. 33varying only in size and shape.

In another packaged configuration, which is illustrated inFIG. 44, the absorbent article200is generally flat and sealed within a wrapper, indicated generally at1033. In one suitable embodiment, the wrapper1033includes in upper layer1035for overlying the absorbent article and a bottom layer1037for underlying the absorbent article. In the illustrated configuration, longitudinal sides of the wrapper1033are open thereby not fully enclosing the absorbent article200. It is understood, however, that the wrapper1033can be sealed along its longitudinal sides to fully enclosing the absorbent article200.

In one suitable embodiment of use, the wearer removes the absorbent article200from a sealed or partially sealed wrapper by tearing or otherwise opening the wrapper. It is understood that the absorbent article200can be provided to the wearer in an unwrapped configuration. Once unwrapped, the wearer converts the absorbent article200from a packaged configuration to a use configuration, as illustrated inFIG. 11. The absorbent article200can be converted by unrolling or unfolding the absorbent article depending on the specific package configuration of the article. As mentioned above, the absorbent article200can be rolled about itself, about a tube, or about another product (e.g., a tampon, a wipe, a glove, a cleansing lotion a disposal bag, and a cleansing pillow) in the packaged configuration. Thus, in these embodiments, the absorbent article200is converted from the packaged configuration to the use configuration by unrolling the absorbent article. As also mentioned above, the absorbent article200can be folded in half, z-folded, or W-folded in its packaged configuration. In these embodiments, the absorbent article200is converted from the packaged configuration to the use configuration by unfolding the absorbent article.

The wearer can apply the absorbent article200by adhering the posterior region266of the absorbent article to the gluteal region of the wearer, the central region265of the absorbent article adjacent the wearer's vaginal region, and the anterior region264of the article200adjacent the wearer's lower abdomen region using the body adhesive244located on the shell214. If the absorbent article200includes a peel sheet (e.g., peel sheet246ofFIG. 43), the wearer removes the peel sheet before adhering the absorbent article in place. In one suitable embodiment, the peal strip246has a rigidity that is greater than the rigidity of the shell214to provide a greater degree of stiffness to the absorbent article200. The increase in stiffness improves the handling properties of the absorbent article200.

It is contemplated that the absorbent article200can be converted between the packaged configuration and the use configuration before or simultaneously with the applying step. For example, as illustrated inFIGS. 45-47, the distal end204,204′ of the absorbent article200can be released from the tube1011by the wearer using the adhesive tab1001(FIG. 45). The wearer can then adhere the distal end204,204′ to her glutal region. With the distal end204,204′ secured to the wearer, the wearer unrolls the absorbent article200from the tube1001while adhering the absorbent article to herself using the body adhesive244. The central region265of the absorbent article200is unrolled next and adhere to the wearer adjacent her vaginal region. That is, the central region is adhered between the wearer's upper thighs. Next, the anterior region of the absorbent article200is unrolled and adhered adjacent the wearer's lower abdomen.

In the illustrated embodiment, the anterior region of the article200is adhered to the wearer after the central region and the posterior region of the absorbent article. It is understood, however, that the absorbent article200can be applied to the wearer in the opposite direction. In other words, the anterior region of the absorbent article200can be applied first and the posterior region last.

The absorbent article200can be removed by pulling the article away from her body thereby releasing the body adhesive244. It is contemplated that the absorbent article200can be refolded or re-rolled to its packaged configuration after use to thereby place the article in suitable form for disposal.