REVERSIBLE AND CONFIGURABLE ABSORBENT ARTICLES

The present disclosure is directed, in part, to an absorbent article comprising a chassis comprising a topsheet, a backsheet, and an absorbent core positioned at least partially intermediate the topsheet and the backsheet. The absorbent article comprises a central lateral axis, a central longitudinal axis, a first waist edge comprising a first curvilinear portion, a second waist edge comprising a second curvilinear portion, a first side edge comprising a third curvilinear portion, and a second side edge comprising a fourth curvilinear portion, and a core wrap. A masking material may be positioned at least partially intermediate the absorbent core and the backsheet. The chassis has an outer perimeter. About 50% to about 95% of the outer perimeter is curvilinear and about 5% to about 30% of the outer perimeter comprises linear portions.

FIELD

The present disclosure is generally directed to reversible and configurable absorbent articles. The absorbent articles may be used with one or more inserts.

BACKGROUND

Absorbent articles are used to contain and absorb bodily exudates (i.e., urine, bowel movements, and menses) in infants, children, and adults. Absorbent articles may be used in hospitals for diapering infants, premature babies, and/or Neonatal Abstinence Syndrome (“NAS”) babies. Premature babies, NAS babies, or other small infants may require special care by nurses and other hospital staff. These babies are oftentimes on ventilators, feeding tubes, or other life support or monitoring systems. In some instances, the babies may be positioned within incubators, also known as isolettes. The babies are typically kept in high humidity, sterile environments as they have very delicate skin that needs to be protected. It is important to the health of these premature babies that they not be handled too much and that they are maintained in a very sterile environment. Handling the babies too much may cause them stress. Some current absorbent articles for premature or NAS babies are somewhat difficult to use and are too large for very premature babies, especially in the crotch region. When the current absorbent articles are folded about their lateral axis, they typically take on a rectangular or substantially rectangular shape, thereby providing a wide crotch region with a bulky core upon loading. Additionally, some current absorbent articles for premature and NAS babies may not provide superior containment of bodily exudates and skin protection from the bodily exudates. Furthermore, some current absorbent articles do not provide full flexibility with fastener systems. Premature or NAS babies may benefit from unconventional fastening system requirements. Further, some current absorbent articles do not provide all of the features that premature or NAS baby caregivers may view as beneficial. As such, absorbent articles for premature babies, NAS babies, other babies, and other wearers should be improved.

SUMMARY

The present disclosure provides reversible and configurable absorbent articles suitable for premature and NAS babies (and other small infants, other babies, or other wearers), while not being limited to any certain sizes or uses. As discussed above, one issue with some current absorbent articles is that they are not configured for the specific needs of premature or NAS babies, in some instances, forcing nurses to handle these babies more than the nurses' desire. The configurable and reversible absorbent articles of the present disclosure overcome the disadvantages of some current premature and/or NAS baby absorbent articles by providing very narrow crotch regions, small overall dimensions, discrete and fully removable fastening members, soft skin-contacting surfaces, waist and/or side edges having curvilinear portions, gradually sloped front and back umbilical cord or surgical site notches, and optionally one or more wetness guards. In some forms, the configurable and reversible absorbent articles of the present disclosure may allow for use without any fastening members, owing to the discrete and removable fastening members. This may be desired by nurses in some instances and may reduce the need to touch or move the baby. Absorbent materials in absorbent cores of the absorbent articles may be homogeneous to allow for reversible use. Further, the absorbent cores may have an extended hourglass shape to help narrow the crotch region and provide for more fit options and leg placements.

The fully removable fastening members may allow caregivers to attach and remove the fasteners as desired at any orientation and/or at any angle. For example, the fully removable fastening members may attach to themselves (or to each other—overlapping fasteners) or may be attached to any portion of a garment-facing surface of the configurable and reversible absorbent articles and to any other portion of the garment-facing surface of the reversible configurable absorbent articles. This provides caregivers with great flexibility for various scenarios of how an absorbent article would be fastened on a premature or NAS infant, in various positions, which may be quite different than conventional taped diapers.

The absorbent articles of the present disclosure may have waist and/or side edges (or outer perimeters) that comprise curvilinear portions. Babies have complex curvilinear surfaces. As such, absorbent articles with linear waist and/or side edges (or outer perimeters) may be not always be appropriate for the best fit and leakage protection, especially in the case of premature babies. Providing curvilinear portions on waist edges gradually leading to a surgical site or umbilical cord notch on the lateral midpoint, allows nurses a wider range of adjustment options on the baby. By providing waist and/or side edges (or outer perimeters) with curvilinear portions, the absorbent articles may have improved fit, improved leakage protection, and convey the impression of quality/intentionality to consumers.

The absorbent cores of the present disclosure may comprise multiple layers positioned within a core wrap or at least partially within a core wrap. The core wrap may comprise a first layer comprising a superabsorbent material (e.g., superabsorbent polymers) and optionally cellulosic fibers, a hydrophilic nonwoven material or hydrophilic material, a second layer comprising a superabsorbent material and optionally cellulosic fibers, and a masking material or a masking nonwoven material. The layers may be organized in the listed order from most proximal to the topsheet to most proximal to the backsheet. The masking material may form a portion of the core wrap most proximate to the backsheet. This multi-layer absorbent core design may be configured to deliver the absorbency and fit requirements for premature babies by enabling capacity without bulk, superabsorbent material presence for dryness, and improved urine visualization and softness optimization. The first layer may have enough superabsorbent material to enable topsheet dryness, but still may have enough cellulosic fibers to provide fast bodily exudate acquisition and a soft wearer-facing surface feel. The second layer may have more superabsorbent material than the first layer to provide a high storage capacity for bodily exudates, while also being thin and, thereby, less bulky. The hydrophilic nonwoven material or hydrophilic material between the first and second layers may provide capillary continuity between the first and second layers so that bodily exudates may easily transfer from the first layer to the second layer. The masking material may aid in the softness of the absorbent article from the garment-facing side by masking the potentially gritty feel of the superabsorbent material in the first and/or second layers. The masking material may be a nonwoven material, a film, a foam, or other suitable material. Any of the first layer, the hydrophilic material, the second layer, and the masking material may be formed of more than one layer.

The absorbent articles of the present disclosure may be used with one or more inserts. Inserts may lessen the need for a full change of an absorbent article which leads to less movement of the baby. This is highly desired in a premature or NAS baby context. Nurses may position one or more inserts on a wearer-facing surface of an absorbent article. If more than one insert is used, the inserts may form a stack of inserts on the wearer-facing surface of the absorbent article. At least some of, or all of the inserts may comprise a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core positioned therebetween. An optional acquisition material and/or distribution material may be positioned intermediate the topsheet and the absorbent core. When the baby discharges bodily exudates, a nurse may remove the most wearer-facing insert without changing the entire absorbent article.

The present disclosure is directed, in part, to an absorbent article comprising a chassis comprising a topsheet, a backsheet, and an absorbent core comprising a core wrap and positioned at least partially intermediate the topsheet and the backsheet. The absorbent article may comprise a central lateral axis, a central longitudinal axis, a first waist edge comprising a first curvilinear portion, a second waist edge comprising a second curvilinear portion, a first side edge comprising a third curvilinear portion, and a second side edge comprising a fourth curvilinear portion. The first side edge may be positioned on a first side of the central longitudinal axis with the second side edge positioned on a second side of the central longitudinal axis. The first waist edge may be positioned on a first side of the central lateral axis with the second side edge positioned on a second side of the central longitudinal axis. The core wrap may at least partially or fully encapsulate: a first layer comprising a superabsorbent material and optionally a fibrous material, a hydrophilic material or a hydrophilic nonwoven material, a second layer comprising a superabsorbent material and optionally a fibrous material, and a masking material. The materials may be in the order listed within the core wrap, with the first layer being most proximal to the topsheet, and the masking material being most proximal to the backsheet. The masking material may form a portion of the core wrap most proximate to the backsheet.

The various absorbent articles may be placed in packages. The packages may be sold in arrays or on-line arrays.

DETAILED DESCRIPTION

Various non-limiting forms of the present disclosure will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the reversible and configurable absorbent articles disclosed herein. One or more examples of these non-limiting forms are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the reversible and configurable absorbent articles described herein and illustrated in the accompanying drawings are non-limiting example forms and that the scope of the various non-limiting forms of the present disclosure are defined solely by the claims. The features illustrated or described in connection with one non-limiting form may be combined with the features of other non-limiting forms. Such modifications and variations are intended to be included within the scope of the present disclosure.

The absorbent articles of the present disclosure may have waist and/or side edges each having one or more curvilinear or arcuate portions. This enables the absorbent articles to better fit smaller infants or other wearers, due to their curvilinear surfaces. The curvilinear portions also aid in the consumer perception of softness and intentionality/customization of the absorbent articles.FIG. 1is a front perspective view photograph of an absorbent article of the present disclosure in an in-use configuration.FIG. 2is a side view photograph of the absorbent article ofFIG. 1in the in-use configuration.FIG. 3is a plan view of an absorbent article of the present disclosure, garment-facing surface facing the viewer, and with removable fastening members attached to an outer cover nonwoven material.FIG. 4is a plan view of an absorbent article chassis of the present disclosure, wearer-facing surface facing the viewer, and without the removable fastening members attached thereto.

Referring toFIGS. 3 and 4, an absorbent article10of the present disclosure may comprise a chassis12and one or more, such as two, fully removable fastening members14. The removable fastening members will be discussed in further detail below. The chassis12may comprise a central lateral axis16and a central longitudinal axis18. The chassis12may comprise a liquid permeable topsheet20(FIG. 4) forming a portion of a wearer-facing surface of the chassis12, a liquid impermeable backsheet21, an outer cover nonwoven material22forming a portion of a garment-facing surface of the chassis12, and an absorbent core24. The absorbent core24may comprise a core wrap and may have a first outer surface configured to face toward a wearer-facing surface in an absorbent article and a second outer surface configured to face toward a garment-facing surface in an absorbent article. The topsheet may be apertured or non-apertured and may or may not comprise three-dimensional elements, patterns, and/or embossing. The backsheet21may comprise a breathable or a non-breathable film. The outer cover nonwoven material22may or may not comprise apertures, three-dimensional elements, patterns, and/or embossing. The chassis12may comprise an acquisition material26positioned at least partially intermediate the topsheet20and the absorbent core24. The chassis12may comprise a first side edge28, a second side edge30, a first waist edge32, and a second waist edge34. The first side edge28may be positioned on a first side of the central longitudinal axis18with the second side edge30positioned on a second side of the central longitudinal axis. The first waist edge32may be positioned on a first side of the central lateral axis16with the second waist edge34positioned on a second side of the central longitudinal axis. The first side edge28may comprise one or more first curvilinear portions36. The second side edge30may comprise one or more second curvilinear portions38. The first waist edge32may comprise one or more first curvilinear portions40. The second waist edge34may comprise one or more second curvilinear portions42. The first side edge28may comprise one or more linear portions44. The second side edge30may comprise one or more linear portions46. The linear portions44and/or46may be folded over material. Stated another way, the linear portions44and/or46may have two or more layers of material. The folding over of the edges of the linear portions and/or46results in clean, smooth edges that are visually and tactilely appealing. The first and second waist edges32,34may each comprise one or more linear portions or may not comprise any linear portions.

The entire perimeter of the chassis12may be either cut or folded over. In some instances, the linear portions may be folded over with the remainder of the perimeter of the chassis12being cut. This results in clean, smooth edges that are visually and tactilely appealing. The entire perimeter of the chassis12, whether cut or folded over, may comprise 2 or more layers. In other instances, the entire perimeter of the chassis12may not comprise 2 or more layers or only portions of the perimeter of the chassis12may comprise 2 or more layers. In this instance, the perimeter, or a portion thereof, may have 1 layer or 3 or more layers. The folded edges may be linear and the cut edges may be curvilinear or non-linear.

The chassis12may be substantially symmetrical about the central lateral axis16and/or may be substantially symmetrical about the central longitudinal axis18to provide reversibility. Likewise, the first side edge28may be substantially symmetrical to the second side edge30about the central longitudinal axis18and the first waist edge32may be substantially symmetrical to the second waist edge34about the central lateral axis16again to provide reversibility. “Substantially symmetrical” means planned to be symmetrical, but allowing for manufacturing tolerances. In addition to the side and/or waist edges, the absorbent core24, the optional acquisition material26, the backsheet21, the outer cover nonwoven material22(or other materials, such as a distribution layer) may be substantially symmetrical about the central lateral axis16and/or the central longitudinal axis18. By having the chassis12and its components be substantially symmetrical about the central lateral and longitudinal axes16,18, the absorbent article may be fully reversible, thereby allowing a caregiver or nurse the ability to apply the absorbent article with either of the first or second waist edge on a front waist of a wearer. This reversibility is especially helpful in the context of premature infants as they may be positioned in various positions and it is desired to move them as little as possible. In some instances, the chassis12may not be substantially symmetrical about the central lateral axis16and/or the central longitudinal axis18. In this instance, the chassis12may or may not still be reversible.

Referring again toFIGS. 3 and 4, the first curvilinear portion40of the first waist edge32may comprise one or more first concave portions and one or more first convex portions with respect to the central lateral axis16. Likewise, the second curvilinear portion42of the second waist edge34may comprise one or more first concave portions and one or more first convex portions. In some instances, the entire first and second waist edges32,34may have a single concave portion and two convex portions with respect to the central lateral axis16. The concave portions of the first and second waist edges, or portions thereof, may form umbilical cord or surgical site notches or recesses48in the first and second waist edges. The gradual slopes into the umbilical cord or surgical site notches or recesses48may be important in a premature baby context. These gradual slopes may allow nurses to easily adjust the absorbent article (i.e., pull toward the front or back) depending on the size of the infant and/or the location of a surgical site or belly button. Instead of umbilical cord or surgical site notches or recesses, the chassis12may have umbilical cord or surgical site projections (shown in dash) to cover the belly button or surgical site.

In some instances, the first waist edge and/or the second waist edge of an absorbent article may be provided with optional umbilical cord notches or foldable areas so that a nurse may decide whether to remove/fold over a portion of the absorbent article or not depending on the diapering situation he or she may be encountering. Referring toFIG. 3A, an absorbent article10′ may comprise one or more lines of perforations31proximate to a first waist edge32′ and/or a second waist edge34′. The lines of perforations31may extend through the thickness of the absorbent article10′ so that a nurse may tear along one of the lines of perforations31to create an umbilical cord notch of varying desired size. A removable area33of the chassis is positioned intermediate the lines of perforations31and the first waist edge32′. The removable area33may comprise one or more of the lines of perforations31depending on which line of perforations31the nurse chooses to tear. The lines of perforations31may also be provided proximate to the second waist edge34′. The lines of perforations31may comprise arcuate or curvilinear portions. Referring toFIG. 3B, an absorbent article10″ may comprise two or more lines of perforations31″ proximate to the first waist edge32″ or the second waist edge34″. The lines of perforations31″ may extend through the thickness of the absorbent article10″ so that a nurse may tear along two of the lines of perforations31″ to create an umbilical cord notch of varying desired size (in both the lateral direction and the longitudinal direction). This tearing along the two lines of perforation31″ leaves behind a foldable area35of the chassis between the first and second lines of perforation31″. The foldable area35of the chassis may comprise one or more lines of perforations31″ depending on what two lines of perforations31″ the nurse tears. In such a configuration, the nurse may fold at least a portion of the foldable area35over the wearer-facing surface or the garment-facing surface of the absorbent article to create the umbilical cord notch. The nurse may optionally tape or otherwise attach a portion of the foldable area35to the wearer-facing surface or to the garment-facing surface or cut away the material with scissors, for example. The lines of perforations31″ may also be provided proximate to the second waist edge34″.

The chassis12may be a uni-body chassis or may have protrusions50(shown with dashes) attached thereto. The protrusions50may be attached to a main body of chassis (i.e., chassis12without the protrusions50) much like ears are attached to commercially available absorbent articles, such as through the use of adhesives and/or bonding. In a non-uni-body configuration, first and second protrusions50may be attached proximate to the first side edge28and third and fourth protrusions50may be attached proximate to the second side edge30. In a uni-body configuration, a first protrusion50may be formed in the first side edge28, a second protrusion may be formed in the second side edge30, a third protrusion may be formed in the first side edge, and a fourth protrusion may be formed in the second side edge30. Each of the first, second, third, and fourth protrusions, in the uni-body configuration, are not separate elements from the chassis12. In either configuration, at least one of, two of, three of, or all of the protrusions50may each have one or more additional curvilinear portions (separate from curvilinear portions in the side edges). A uni-body configuration may be desired because the absorbent article would not have seams (where components are joined to each other), thereby leading to improved softness and improved leakage protection.

The first and second side edges28,30and the first and second waist edges32,34may together form an outer perimeter of the chassis12. In the context of the uni-body chassis and the non-uni-body chassis, the protrusions50form portions of the first and second side edges and, thereby, the outer perimeter. About 40% to about 95%, about 50% to about 95%, about 60% to about 95%, or about 60% to about 90%, of the outer perimeter may be curvilinear, specifically reciting all 1% increments within the specified ranges and all ranges formed therein or thereby. Only about 5% to about 50%, about 5% to about 40%, about 5% to about 30%, or about 5% to about 25%, of the outer perimeter may be linear (i.e., straight), specifically reciting all 1% increments within the specified ranges and all ranges formed therein or thereby.

On an absorbent article manufacturing line, a web having an infinite length is typically conveyed in a machine direction. These webs typically have linear side edges and are cut in a cross-machine direction to an absorbent article pitch. The one or more linear portions44and the one or more linear portions46may be portions of the linear side edges of the webs, while the curvilinear portions36,38,40,42may be formed by additional cutting and removal of the cut portions (i.e., trim removal).

FIG. 5is a plan view of a second surface of a removable fastening member.FIG. 6is a plan view of a first surface of the removable fastening member ofFIG. 5.FIG. 7is a cross-sectional view of the removable fastening member taken about line7-7ofFIG. 6. The fully removable fastening members14may be stretch panels that may be discrete elements from the chassis12. Referring toFIGS. 5 and 6, the fastening members14may each comprise a first surface52, a second surface54, a first end56, and a second end58. The first surface52may be opposite to the second surface54and the first end56may be opposite to the second end58. The fastening members14may comprise a first fastener60that may be configured to engage a first portion of the outer cover nonwoven material22or a first portion of a landing zone (if provided) and be positioned on the first surface52. The first fastener60may be configured to engage a portion of the chassis12on a first side of the central lateral axis16. The chassis12may be free of a landing zone and any portion of the outer cover nonwoven material22may function as the landing zone. The fastening members14may comprise a second fastener62that may be configured to engage a second, different portion of the outer cover nonwoven material22and positioned on the first surface52. The second fastener62may be configured to engage a portion of the chassis12on a second side of the central lateral axis16. In some instances, only one fully removable fastening member14may be provided with a chassis12. In this scenario, the first fastener60may engage a portion of the outer cover nonwoven material22of the chassis12and the second fastener62may engage another portion of the outer cover nonwoven material22or may engage a portion of the second surface54of the fastening member14. The fastening members14may be provided in a package with one of the fasteners60,62attached to portions of the outer cover nonwoven material and with the other fastener60,62engaged with the topsheet20(or other portion of the chassis) or not engaged to any portion of the chassis12. The other fastener60,62may also be engaged with a surface52,54of the fastening members to at least inhibit the fasteners60,62from catching on other absorbent articles or other items. In still other instances, the fastening members14may be provided in a package with the chassis12, but be separate from the chassis12. In other instances, the fastening member14and the chassis12may be provided in separate packages.

Since the fastening members14are fully removable from the absorbent article10, they can be fastened as desired by a nurse or caregiver. In some instances, the nurse or caregiver may remove the fastening members14from the chassis12and not use them if the infant is in a certain position, for example. In other instances, the nurse or caregiver may only use one of the fastening members14if the infant is in another certain position, for example.

Referring toFIGS. 5 and 6, the first fastener60and the second fastener62may not extend to the outer perimeter of the fastening members14. This may help prevent, or at least inhibit, rough fastener material (e.g., hooks) from contacting or irritating a wearer's skin. The fasteners60and62are illustrated as rectangular but may be any other suitable shape, such as circular or ovate, for example. In some instances, it may be desirable to have fasteners without corners to again prevent, or at least inhibit the fasteners from irritating a wearer's skin.

Referring toFIGS. 3 and 4, the first fastener60may be attached to the garment-facing surface of the chassis12in an area that overlaps, or partially overlaps, the absorbent core24, inboard, or partially inboard, of the protrusions50. By attaching the first fastener60in an area that overlaps the absorbent core24, the first fastener60is positioned in a low motion force zone on the chassis12to minimize unintended separation of, for example, hooks64of the first fastener60. As a result, a nurse or caregiver may apply the absorbent article without unattaching the first fastener60or re-securing the first fastener60. This can be quite desirable in a hospital setting, especially if the baby is premature. This concept may apply to both of first fasteners60of the fastening members14.

In addition, the first fasteners60or areas of the fully removable fastening members14proximate to the first fasteners60may be additionally secured to the garment-facing surface of the chassis12by additional mechanical bonds, thermal bonds, ultrasonic bonds, and/or glue (together referred to as “bonds” and numbered61inFIG. 3), for example. Any suitable number, shape, and/or size of bonds61may be provided on the first fastener60or on areas around the first fastener. The bonds61may provide the first fasteners60or areas of the fully removable fastening members14proximate to the first fastener60with additional strength beyond merely the hooks64for additional resistance to disengagement. In such an instance though, the first fastener60may still be removable from the chassis12. The bonds61may be positioned on leading and trailing edges of the hooks64, for example, and/or on the left and right side of the hooks64. In other instances, the bonds61may be positioned in corners of the first fasteners or outboard of corners of the first fasteners. The bonds61not only aid in securing the first fasteners60to the garment-facing surface of the chassis12, but also prevent, or at least inhibit, the first fasteners60from partially peeling off and exposing a portion of the hooks64, which could cause the hooks64to undesirably engage clothing, blankets, and/or other items. The first fastener may be positioned and attached as discussed in in this paragraph when in a package or when presented to a caregiver. The first fasteners may be fastened to the first waist region or the second waist region in this fashion. The second fasteners62may also comprise the bonds to prevent, or at least inhibit, unintentional opening of the second fasteners62.

When packaged, the second fasteners62may engage a wearer-facing surface of the chassis12in the protrusions50. Typically, the second fasteners62may not have the bonds61in that the second fasteners are intended to be opened and repositioned on the chassis12. By initially attaching the second fasteners62to the wearer-facing surface of the chassis12in the protrusions50, a nurse or caregiver is able to grasp an absorbent article, slide the absorbent article under an infant or premature baby without having to move the baby to unattach the second fastener62. Stated differently, the second fastener62may not be underneath the infant or premature baby so that the baby does not need to be moved, rolled, and/or lifted, to remove and reattach the second fasteners62in an appropriate location.

Referring toFIG. 7, the fastening members14may comprise a first nonwoven or other substrate64, a second nonwoven or other substrate66, and an elastic material68positioned at least partially intermediate the first and second substrates64and66. The elastic material68may comprise an elastic nonwoven material, an elastic film, and/or elastic strands, for example. The elastic material may be apertured or micro-apertured to promote breathability. In other instances, the fastening members may comprise one or more substrates and may not comprise an elastic material. In still other instances the fastening member may comprise one or more elastic nonwoven substrates.

FIG. 8is a plan view of an example absorbent article chassis12of the present disclosure with wetness guards and leg cuffs, wearer-facing surface facing the viewer. The fully removable fastening members14may be used with the absorbent article chassis12, much like illustrated inFIG. 3and discussed herein. The example absorbent article chassis12is not illustrated with the curvilinear portions on the waist and side edges32,34,28,30for simplicity in illustration, although it will be understood that the chassis may have the same or similar shape as the chassis ofFIGS. 3 and 4. The absorbent article chassis12may comprise one or more pairs of leg cuffs70and one or more wetness guards72. The leg cuffs70may have one or more elastic strands74positioned therein. The elastic stands74may be attached to the cuffs only in a central zone76proximate to the central lateral axis16. As an example, the central zone may76extend between about 0.5 inches and about 2.5 inches in a smaller sized absorbent article. In the central zone76, the elastic strand74may be glued or bonded to a portion of the leg cuff. In some instances, only one pair of leg cuffs may be provided. Additional features of the leg cuffs are disclosed in U.S. Patent Application Publication No. 2017/0246052, to Ludwig et al., published on Aug. 31, 2017.

One or more wetness guards72may be provided on a wearer-facing surface of the chassis12. In some instances, only one wetness guard may be provided on a longitudinally end region of the chassis12. In other instances, two wetness guards may be provided on longitudinally opposite end regions of the chassis12. When bodily exudates, especially urine, enter an absorbent article they may initially be absorbed in a central longitudinal region of the absorbent article or the crotch region. By design, and to inhibit the crotch region from becoming overloaded, the bodily exudates are wicked towards the longitudinal end region of the absorbent article by the acquisition material and the absorbent core. This allows the crotch region to be able to accept additional insults of bodily exudates without overloading. This also potentially makes the longitudinal end regions wet. In order to protect an infant's skin in contact with the longitudinally end regions, such as the lower back and the front waist of a wearer, wetness guards may be provided in one or both of the longitudinally end regions. The wetness guards72may each overlap a portion of the topsheet20to inhibit topsheet to skin contact and thereby reduce moisture on the skin of a wearer.

The wetness guards72may comprise one or more layers of material. In an instance, the wetness guards may comprise a film facing the topsheet20and one or more nonwoven materials facing the wearer. In other instances, the wetness guards72may comprise a hydrophobic nonwoven material without a film. By providing a film or a hydrophobic nonwoven material, wetness from the absorbent core or acquisition material may be shielded from contacting the lower back or the front waist of a wearer, thereby improving skin health and dryness.

In some instances, the wetness guards72may be formed of portions of the backsheet film21and outer cover nonwoven22folded over the waist edges32,34. In other instances, the wetness guards may be discrete components attached to the chassis12.FIG. 9illustrates a photograph of a wetness guard72attached to a chassis12, wearer-facing surface facing the viewer. The wetness guards72may have a free, unattached end78most proximate to the central lateral axis16. The free, unattached end78is illustrated as linear inFIG. 9, but may comprise curvilinear portions. The wetness guards may be fully removable from the chassis12, if desired, by providing hooks or other attachment features on the topsheet facing side of the wetness guards and/or on the topsheet. In other instances, the wetness guards72may be permanently bonded, adhesively attached, or otherwise attached, to the chassis12, for example along attachment area79. Additional features of the wetness guards are disclosed in U.S. Patent Application Publication No. 2017/0246052, to Ludwig et al., published on Aug. 31, 2017.

FIG. 10is an example cross-sectional schematic illustration of an absorbent core24and optional acquisition material26of the absorbent articles herein, taken about a central lateral axis16of a chassis12.FIG. 11is another example cross-sectional schematic illustration of an absorbent core24and an optional acquisition material26of the absorbent articles disclosed herein, taken about a central lateral axis16of a chassis12. The absorbent cores24of the present disclosure are designed to provide superior absorbency and storage with reduced bulk and improved softness from both the garment-facing side and the wearer-facing side. Further benefits of such an absorbent core are discussed above.

The optional acquisition material26may be positioned outside of a core wrap80. The acquisition material26may be wider (direction along the central lateral axis16) than the core wrap80or not as wide as the core wrap80. The acquisition material26may be longer (direction along the central longitudinal axis18) than the core wrap or shorter than the core wrap80. A distribution material may or may not be provided intermediate the acquisition material26and the core wrap80, or otherwise located. The acquisition material26and/or a distribution material may be rectangular or shaped, such as hourglass shaped, with a narrower crotch region and wider longitudinal end regions. The shape may be similar to that illustrated inFIG. 12.

The core wrap80may be formed of a single material (FIG. 10) or may be formed of two or more materials (FIG. 11). The core wrap80may also take on a C-wrap design where a first upper (closest to topsheet) material is partially wrapped around a lower material. The lower material, as discussed below, may be formed by a portion of the masking material. The core wrap may also be configured to any other suitable configurations known in the art. The core wrap80may have a first outer surface81facing a wearer-facing surface of an absorbent article and a second outer surface83facing a garment-facing surface of an absorbent article. The core wrap80may be at least partially overlapped with itself on the second outer surface83(seeFIG. 10) or the first outer surface81. The masking material may form a portion of the second outer surface83. Various components may be at least partially or fully encapsulated within the core wrap80. The core wrap80may comprise a nonwoven material, a tissue material, a portion of the masking material, or other suitable material. Starting on the topsheet side of the absorbent core24, a first layer82may be provided. The first layer82may comprise a superabsorbent material84and/or a fibrous material, such as cellulosic fibers86. In some instances, the first layer82may only comprise the superabsorbent material84or may only comprise the fibrous material86. If fibrous material8686is provided in the first layer82, it may help make the wearer-facing side of the absorbent core26softer and mask any grittiness caused by the superabsorbent material particles. The first layer82may have enough superabsorbent material84to enable topsheet dryness, but still may have enough of the fibrous material86, such as cellulosic fibers, to provide fast bodily exudate acquisition and a soft wearer-facing surface feel.

A hydrophilic nonwoven material or hydrophilic material88may be positioned under the first layer82. A second layer90that may comprise a superabsorbent material84and/or a fibrous material86, such as cellulosic fibers, may be positioned under the hydrophilic material88. In some instances, the second layer90may only comprise the superabsorbent material84or may only comprise the fibrous material86. The second layer90may have more superabsorbent material than the first layer82to provide high storage capacity of bodily exudates while also being thin and, therefore, less bulky. Stated another way, the second layer90may have a higher concentration of the superabsorbent material84than the first layer82. The first layer82may have a higher concentration of the fibrous material86than the second layer90. The hydrophilic material88between the first and second layers82,90may provide capillary continuity between the first and second layers so that bodily exudates may easily transfer from the first layer82to the second layer90. A masking material92may be positioned under the second layer90. The masking material92may aid in the softness of the absorbent article from the garment-facing side by masking the potentially gritty feel of the superabsorbent material in the first and/or second layers82,90. The masking material92may comprise a nonwoven material, a woven material, a fibrous material, such as cellulosic fibers, a film, a foam, a tissue, a high-loft tissue, a fibrous superabsorbent web, and/or any other suitable material. In some configurations, the masking material92may form a portion of an outer perimeter of the absorbent core.

Any or all of the first and second layers82,90, the hydrophilic material88, the core wrap80, and the masking material92may have the shape94illustrated inFIG. 12or a similar shape. This shape is considered an extended hourglass shape and allows the crotch region of the absorbent articles to be quite narrow. In the premature infant context, a wide crotch region may not be desired as it may push the infant's legs apart and potentially create issues with hips. Instead of having the extended hourglass shape, notches or recesses may be created in the various components to create a narrow crotch region.

The first layer82may have a first width (direction along central lateral axis16) proximate to its longitudinal end and a second width at its longitudinal midpoint. The first width may be greater than the second width. Likewise, the second layer may have a first width proximate to its longitudinal end and a second width at its longitudinal midpoint. The first width may be greater than the second width. This feature may also apply to the core wrap, the hydrophilic material and/or the masking material. In such instances, any or all of the layers or materials may not be rectangular and may instead be shaped (i.e., not rectangular or square).

The hydrophilic material may be wider than or not as wide (direction along the central lateral axis16) as the first layer82, the second layer90, and/or the masking material92.

The first layer82may comprise the superabsorbent material in the range of about 5% to about 60%, about 5% to about 55%, about 15% to about 55%, or about 20% to about 50%, by weight of the first layer, specifically reciting all 0.5% increments within the specified ranges and all ranges formed therein or thereby. The second layer82may comprise the superabsorbent material in the range of about 30% to about 100%, about 40% to about 90%, about 40% to about 80%, about 40% to about 70%, or about 40% to about 60%, by weight of the second layer, specifically reciting all 0.5% increments within the specified ranges and all ranges formed therein or thereby.

The first layer82may comprise the fibrous material, such as cellulosic fibers, in the range of about 30% to about 100%, about 40% to about 95%, about 50% to about 90%, or about 50% to about 80%, by weight of the first layer, specifically reciting all 0.5% increments within the specified ranges and all ranges formed therein or thereby. The second layer82may comprise the fibrous material, such as cellulosic fibers, in the range of about 30% to about 80%, about 30% to about 70%, about 35% to about 65%, or about 40% to about 60%, by weight of the second layer, specifically reciting all 0.5% increments within the specified ranges and all ranges formed therein or thereby.

The masking material92may have a higher basis weight than a basis weight of each of the hydrophilic material88and the core wrap80. The masking material may be formed of one or more layers. A single layer may be folded over itself or multiple individual layers may be provided. The masking material may have a basis weight in the range of about 8 gsm to about 100 gsm, about 10 gsm to about 90 gsm, about 10 gsm to about 60 gsm, about 10 gsm to about 40 gsm, about 10 gsm to about 30 gsm, about 13 gsm to about 25 gsm, or about 13 gsm to about 20 gsm, specifically reciting all 0.5 gsm increments within the specified ranges and all ranges formed therein or thereby.

The masking materials of the present disclosure may have a thickness in the range of about 0.25 mm to about 20 mm, about 0.25 mm to about 15 mm, about 0.5 mm to about 12 mm, about 0.5 mm to about 11 mm, about 1 mm to about 10 mm, about 1 mm to about 8 mm, about 2 mm to about 6 mm, about 3 mm to about 5 mm, or about 4 mm, specifically reciting all 0.01 mm increments within the specified ranges and all ranges formed therein or thereby. Thickness is measured according to the Thickness Test herein.

The masking materials of the present disclosure may have a stiffness in the range of about 50 mN to about 3,500 mN, 100 mN to about 3,500 mN, about 100 mN to about 3,200 mN, about 100 mN to about 2,500 mN, about 100 mN to about 2,000 mN, about 100 mN to about 1,500 mN, or about 100 mN to about 1,000 mN, about 100 mN to about 750 mN, about 200 mN to about 600 mN, about 300 mN to about 500 mN, or about 400 mN, specifically reciting all 1 mN increments within the specified ranges and all ranges formed therein or thereby. Stiffness is measured according to the Stiffness Test herein.

In an example, a masking material may have a thickness in the range of about 1 mm to about 8 mm and a stiffness of about 100 mN to about 1,000 mN. Typically, the thickness should be large enough to mask any gritty feeling of superabsorbent polymers in the absorbent core, while having a low enough of a stiffness to allow the absorbent article to remain flexible and conform to a wearer.

In an example, the masking material may have a basis weight in the range of about 5 gsm to about 75 gsm, about 10 gsm to about 65 gsm, about 10 gsm to about 60 gsm, about 10 gsm to about 50 gsm, about 10 gsm to about 45 gsm, about 10 gsm to about 40 gsm, about 15 gsm to about 35 gsm, about 15 gsm to about 30 gsm, about 15 gsm to about 25 gsm, or about 20 gsm, specifically reciting all 0.1 gsm increments within the specified ranges and all ranges formed therein or thereby. Basis weight is measured according to the Basis Weight Test herein.

Referring toFIGS. 10 and 11, adhesives may or may not be positioned intermediate the various components. Adhesives may be positioned only between some components and not other components.

At least two of, or at least three of, the core wrap80(one or two layers), the hydrophilic material, the masking material92, and/or other nonwoven materials in the absorbent core24may have the same or different properties. These properties may be surface energy, pore size, basis weight, caliper, and/or other nonwoven properties. This may apply in a single material core wrap context (e.g.,FIG. 10) or a dual material core wrap context (e.g.,FIG. 11).

FIG. 13is an example cross-sectional schematic illustration of an absorbent core24and optional acquisition material26of the absorbent articles herein, taken about a central lateral axis16of a chassis12.FIG. 14is another example cross-sectional schematic illustration of an absorbent core24and an optional acquisition material26of the absorbent articles disclosed herein, taken about a central lateral axis16of a chassis12. InFIGS. 13 and 14, the masking material92may form a portion of the second outer surface83or outer perimeter of the core wrap80. Stated another way, the core wrap80may only partially encapsulate the various components with the masking material92completing the encapsulation. Thus, portions of the masking material92may be considered a portion of the core wrap. InFIGS. 13 and 14, the various components having the same references numbers asFIGS. 10-12may be the same as described above with respect toFIGS. 10-12. InFIG. 14, the second layer90may not be present.

Referring toFIGS. 15-20, one or more inserts100may be provided for use with an absorbent article110(or absorbent article10discussed herein). The one or more inserts may be packaged together with one or more absorbent articles or packaged and sold separately. One or more inserts and one or more absorbent articles may be in a kit. The one or more inserts may be positioned within the absorbent article after the absorbent article is donned on the wearer or before the absorbent article is donned on the wearer. The inserts essentially provide an additional absorbent containment element that may be used prior to soiling of the absorbent article or after soiling of the absorbent article. The inserts may be advantageous in that the baby or wearer may not need to be fully changed and, thereby, moved, lifted, or handled less, compared to if only the absorbent article was used. Multiple inserts may be used at one time, so that once soiled the most wearer-facing insert may be removed. In some instances, the inserts may be fastening or joined to the wearer-facing surface of the absorbent article or to a wearer-facing surface of another insert using any suitable joining techniques. In other instances, the inserts may merely be placed on the wearer-facing surface of the absorbent article or the wearer-facing surface without some separate attachment or joining mechanism. In these instances, the inserts may remain in place by friction or merely by weight of the baby. In some instances, at least portion of the inserts may have low coefficients of friction to allow them to slide over a portion of a wearer-facing surface of the absorbent article, when being inserted into the absorbent article while it is on a wearer. The inserts are helpful as full absorbent article changes may be reduced, thereby leading to less stress on (i.e., less movement/lifting of) a baby or premature baby.

FIG. 16is a plan view of an insert100positioned on a wearer-facing surface of an example absorbent article110, although the absorbent article may have the outer perimeter and/or other features of the absorbent article10discussed herein.FIG. 17is a plan view of the insert100.FIG. 18is an example cross-sectional illustration of the insert100ofFIG. 17, taken about line18-18.FIG. 19is another example cross-sectional illustration of the insert100ofFIG. 17, taken about line19-19.FIG. 20is a plan view of another insert100′.FIG. 21is a plan view of another insert100″.

The inserts100may comprise a topsheet142, an optional acquisition material and/or distribution material144, an absorbent core146, a backsheet148, and optionally an outer cover nonwoven material150. The topsheet142may be formed of one or more nonwoven materials, one or more films, or a laminate formed of one or more nonwoven materials and one or more films. The topsheet142may comprise a liquid permeable material or apertures152defined in the topsheet142. The topsheet142may also comprise three-dimensional features, embossments, bond patterns, graphics, lotions, and/or surfactants, for example. The acquisition material and/or distribution material144may be formed of nonwoven materials, foams, or other suitable materials. Optionally, a layer of cross-linked cellulosic fibers may also be present intermediate the topsheet142and the acquisition material and/or distribution material144. The absorbent core146may comprise an absorbent material. The absorbent material may comprise a mixture of airfelt and superabsorbent polymers, mostly or only airfelt, or mostly or only superabsorbent polymers. The absorbent core146may have areas that are free of the absorbent material (e.g., channels that are free of the absorbent material) or may have areas where the absorbent material is densified (e.g., channels that are formed by densified areas in the absorbent material). The backsheet148may be liquid impermeable, and may or may not be air permeable (or “breathable”). In some instances, the backsheet148may not be provided and bodily exudates that are not absorbed by the absorbent core146may pass through the insert100and into the absorbent article100. The outer cover nonwoven material150may or may not be provided and may be formed of a nonwoven material, for example.

Referring toFIG. 19, the insert100may have the cross-section illustrated when taken about line19-19ofFIG. 17. In such an instance, the topsheet142may form a C-wrap around end regions of the backsheet148and be joined to the backsheet148using adhesive bonds149, or other types of joining. In such an instance, a portion of the backsheet148may face the topsheet of an absorbent article in use. Stated another way, a portion of the backsheet148may form a garment-facing surface of the insert. An optional acquisition material and/or distribution material144may be provided. The insert ofFIG. 19may, in some instances, have an outer cover nonwoven material as well.

Referring toFIG. 20, an insert100′ is illustrated. This example insert100′ has a grasp tab154on one end and a cut out156on the other end. The grasp tab154may be used by a caregiver to easily grasp and remove the insert100′ from an absorbent article after being soiled. The grasp tab154, in an example, may be formed only of a backsheet material, or other liquid impermeable material, so that bodily exudates cannot wick to the grasp tab154. In other instances, the grasp tab154may be formed of a portion of the topsheet142, a portion of the backsheet148, and/or a portion of the outer cover nonwoven material150. By providing the grasp tab154on one end and the cut out156on the other end, a material savings may be achieved when the inserts are manufactured in a strip of a plurality of the inserts100′. Any of the inserts described herein may be manufactured in a strip of a plurality of the inserts and may be packaged as a roll of inserts, for example. Lines of weakness158may be formed intermediate the various inserts. In such an instance, a roll of a plurality of inserts may be provided to a caregiver or nurse and the caregiver or nurse can then tear off any suitable number of inserts for use on a particular wearer. The inserts may also be packaged in stacks, for example, or in other forms.

Referring toFIG. 21, the insert100″ is illustrated. The example insert100″ may have a grasp tab154on both ends to allow for easier caregiver or nurse placement and removal of the inserts100″.

In some instances, the various inserts may comprise stiffening members or stiffened portions (e.g., foams, densified regions) to aid in application of the inserts into a donned absorbent article.

FIG. 22is an example side view of a leg cuff system200with an outer cuff202and an inner cuff204that may be used in the absorbent articles described herein. The outer cuff202may comprise one or more elastic strands206and the inner cuff204may comprise one or more elastic strands208. The leg cuff system200may be formed of a single piece of nonwoven material or multiple pieces of nonwoven material. If formed of a single piece of nonwoven material, ends or portions of the nonwoven material may be joined together by hem bonds (represented by X's inFIG. 22). It is noted that the overlap at the ends of the nonwoven material proximate to the hem bonds may be reversed. The inner cuff204and the outer cuff202may each form finished edges owing to the fold over of the nonwoven material. Finished cuff edges are desired for softness and premium visual appearance.

Although the nonwoven material of the leg cuffs herein may be formed of a single piece, it may comprise multiple layers. The layers may comprise one or more spunbond high loft nonwoven layers, one or more melt blown nonwoven layers, and/or one or more spunbond nonwoven layers. Spunbond high loft nonwoven layers typically comprise bicomponent fibers with two different polymers having different melting temperatures. When the polymers cool, one of the polymers cools faster than the other polymer resulting in the fibers curling or “crimping”. Spunbond high loft nonwoven layers are also known as crimped nonwoven layers to those of skill in the art.

A nonwoven material for the leg cuffs herein may comprise, in order from the wearer facing surface outward, a first spunbond high loft nonwoven layer, a first meltblown nonwoven layer, a second meltblown nonwoven layer, and a second spunbond high loft nonwoven layer. A cuff, such as the inner or outer cuff202,204, for example, may have two of these nonwoven materials folded over themselves. Another nonwoven material for the leg cuffs herein may comprise, in order from the wearer facing surface outward, a spunbond high loft nonwoven layer, a first meltblown nonwoven layer, a second meltblown nonwoven layer, and a spunbond nonwoven layer. A cuff, such as the inner or outer cuff202,204, for example, may have two of these nonwoven materials folded over themselves. Yet another nonwoven material for the leg cuffs herein may comprise, in order from the wearer facing surface outward, a first spunbond high loft nonwoven layer, a first meltblown nonwoven layer, a second meltblown nonwoven layer, a second spunbond high loft nonwoven layer, and a spunbond nonwoven layer. A cuff, such as the inner or outer cuff202,204, for example, may have two of these nonwoven materials folded over themselves. Still another nonwoven material for the leg cuffs herein may comprise, in order from the wearer facing surface outward, a first spunbond nonwoven layer, a first meltblown nonwoven layer, a second meltblown nonwoven layer, a second spunbond nonwoven layer, and optionally another spunbond nonwoven layer. A cuff, such as the inner or outer cuff202,204, for example, may have two of these nonwoven materials folded over themselves.

The spunbond high loft nonwoven layers described above may have a basis weight in the range of about 5 gsm to about 20 gsm, about 7 gsm to about 15 gsm, about 8 gsm to about 13 gsm, about 8 gsm to about 11 gsm, about 9 gsm to about 10.5 gsm, or about 9.9 gsm, specifically reciting all 0.1 gsm increments within the specified ranges and all ranges formed therein or thereby. The meltblown nonwoven layers described above may have a basis weight in the range of about 0.5 gsm to about 5 gsm, about 0.5 gsm to about 3 gsm, about 0.5 gsm to about 2 gsm, about 1 gsm to about 1.5 gsm, or about 1.1 gsm, specifically reciting all 0.1 gsm increments within the specified ranges and all ranges formed therein or thereby. The spunbond nonwoven layers described above may have a basis weight in the range of about 3 gsm to about 20 gsm, about 3 gsm to about 15 gsm, about 4 gsm to about 12 gsm, or about 5 gsm to about 10 gsm, specifically reciting all 0.1 gsm increments within the specified ranges and all ranges formed therein or thereby. Basis Weight is measured according to the Basis Weight Test herein.

FIGS. 23 and 24are example cross-sectional illustrations (without an outer cover nonwoven material and the fastening members14illustrated) of a chassis configuration.FIG. 23is taken about the central longitudinal axis18ofFIG. 3andFIG. 24is taken about the central lateral axis16ofFIG. 3. The illustrated components include a topsheet20, a backsheet21, an acquisition material26, an absorbent core24, and a masking material92. The absorbent core24may comprise a blend of superabsorbent polymers 84 and a fibrous material, such as cellulosic fibers86. The absorbent core24may be wrapped in a core wrap80that may be configured as a C-wrap. Side portions of the materials forming the C-wrap may be joined by a bond or adhesives (represented inFIG. 24by an “X”). End seals81of the absorbent core24may be joined together by bond or adhesives. The masking material92may be positioned outside of the core wrap80and at least partially intermediate the absorbent core24and the backsheet21.

Test Methods

Thickness Test

The thickness of a test sample is measured as the distance between a reference platform on which the sample rests and a pressure foot that exerts a specified amount of pressure onto the sample over a specified amount of time. All measurements are performed in a laboratory maintained at 23° C.±2 C.° and 50%±2% relative humidity.

Thickness is measured with a manually-operated micrometer equipped with a pressure foot capable of exerting a steady pressure of 0.5 kPa±0.01 kPa onto the test sample. The manually-operated micrometer is a dead-weight type instrument with readings accurate to 0.001 mm. A suitable instrument is Mitutoyo Series 543 ID-C Digimatic, available from VWR International, or equivalent. The pressure foot is a flat ground circular movable face with a diameter of 50 mm. The test sample is supported by a horizontal flat reference platform that is larger than and parallel to the surface of the pressure foot. The system is calibrated and operated per the manufacturer's instructions.

Obtain a test sample by removing it from an absorbent article, if necessary. When excising the test sample from an absorbent article, use care to not impart any contamination or distortion to the test sample layer during the process. Test samples are conditioned at 23° C.±2 C.° and 50%±2% relative humidity for 2 hours prior to testing. To measure thickness, first zero the micrometer against the horizontal flat reference platform. Place the test sample on the platform with the test location centered below the pressure foot. Gently lower the pressure foot with a descent rate of 1.0 mm±0.1 mm per second until the full pressure is exerted onto the test sample. Wait 5 seconds and then record the thickness of the test sample to the nearest 0.01 mm. In like fashion, repeat for a total of five replicate test samples. Calculate the arithmetic mean for the Thickness and report to the nearest 0.01 mm.

Stiffness Test

The stiffness or “hand” of a test sample is determined using NWSP 090.3.R0 (15) with a slot width of 6.0 mm and a 100 gram force load cell. Test samples are ideally 200×200 mm in size. Smaller samples can be tested by correcting the results as outlined in the NWSP method (i.e., doubling the results obtained for a 100×100 mm sample). All measurements are performed in a laboratory maintained at 23° C.±2 C.° and 50%±2% relative humidity. Test samples are conditioned under these same climatic conditions for 2 hours prior to testing. When excising the test sample from an absorbent article, use care to not impart any contamination or distortion to the test sample layer during the process. A total of 5 replicate samples are tested and the arithmetic mean for Stiffness is reported to the nearest 0.1 mN.

Basis Weight Test

Basis weight of the materials described herein may be determined by several available techniques, but a simple representative technique involves taking an absorbent article or other consumer product, removing any elastic which may be present and stretching the absorbent article or other consumer product to its full length. A punch die having an area of 45.6 cm2is then used to cut a piece of the material being measured from the approximate center of the absorbent article or other consumer product in a location which avoids to the greatest extent possible any adhesive which may be used to fasten the material to any other layers which may be present and removing the material from other layers (using cryogenic spray, such as Cyto-Freeze, Control Company, Houston, Tex., if needed). The sample is then weighed and dividing by the area of the punch die yields the basis weight of the material. Results are reported as a mean of 5 samples to the nearest 0.1 gram per square meter (gsm).

While particular forms of the present disclosure have been illustrated and described, those of skill in the art will recognize that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of the present disclosure.