Abstract:
A containment flap for an absorbent article, such as an incontinence garment, has elasticity in the long axis and extensibility of the flap with a low modulus of elasticity in its transverse direction. The long axis tension of the flap has a force vector normalized to the transverse direction when the flap is placed in curvature over the body of a wearer, thereby providing a force for extending the flap in the transverse direction to maintain contact with the body of the wearer when the garment begins to sag, such as may happen due to gravity when the garment is loaded with absorbed bodily fluids. Material suitable for constructing such flaps is further disclosed.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    Pant-like absorbent garments, such as diapers and training pants, typically include a pair of leg openings having an elastic portion around each leg opening, and a waist opening having an elastic portion as well. The elastic portions are intended to fit snugly around a wearer&#39;s legs to prevent bodily waste, also sometimes called “exudate” herein, from leaking beyond the garment, yet leakage often persists.  
           [0002]    A number of different approaches have been taken to reduce or eliminate leakage from absorbent garments. For example, physical barriers, such as elasticized containment flaps, have been incorporated into such absorbent garments. The amount and configuration of absorbent material in the zone of the absorbent garment in which liquid surges typically occur (sometimes referred to as a target zone) have also been modified.  
           [0003]    A further approach to decreasing exudate leakage is to increase tension of the elastic portions around each leg opening and the waist opening. The increased tension is often effective, but just as often results in an undesirable red marking on a wearer&#39;s skin due to increased pressure on the wearer&#39;s skin.  
           [0004]    The use of containment flaps has, in the past, been somewhat limited because the flaps are of a finite width in their transverse direction, meaning that as the absorbent garment becomes loaded with absorbed bodily wastes and sags or droops due to gravity, the gasket will pull away from the wearer&#39;s body, sometimes called “a loss of vertical fit”, thereby providing an unwanted leakage path to the exterior of the garment. Providing “oversized” gaskets to try and accommodate a range of sagging is known in the art but results in an undesirable increase of fabric usage from both economical and comfort standpoints.  
           [0005]    There is a need or desire for transversely stretchable material suitable for gaskets or containment flaps in absorbent garments that seal fluid within the absorbent garments and which adjust in the transverse direction to the level of sagging in a loaded garment in order to maintain gasketing.  
         SUMMARY OF THE INVENTION  
         [0006]    The present invention is directed to an improved construction of gaskets in pant-like absorbent garments, and material for those garments, such as, but not limited to, diapers, swim wear, adult incontinence garments, and training pants. The resulting garment may then have extensible gaskets that provide greater leakage protection by maintaining contact with the body of the wearer by extending in their transverse direction when the garment sags away from the body. The present invention provides a material which is at least transversely stretchable in its cross machine direction. The material is suitably light weight and inexpensive. In certain aspects of the invention the material includes thermoplastic fibers of the meltblown or spunbond type, or both. The fibers may be substantially continuous fibers. The nonwoven material made from the thermoplastic fibers may be necked to provide the transverse direction extensibility. A low Young&#39;s modulus of up to about 4.5 psi%, and desirably between about 0.90 psi/% to about 4.5 psi/%, may be suitably achieved in one axis of the material by practice of the present invention.  
           [0007]    Extensible gaskets may be achieved by using flap material which is extensible, and with a low modulus of elasticity, in a transverse direction, or axis, of the containment flap while being tensioned in the long direction, or axis, of the flap. The flap may be provided with different bands of tension through the selective application of elastics, a so-called “targeted elastic” approach which may use various means to achieve a differential elasticity over the material. Such means may include different types or sizes of elastic elements applied to, or made integral with the flap material. The long axis tensioning of the flap provides a force vector normalized to the transverse direction when the flap is placed in curvature over the body of a wearer, thereby providing a force for extending the flap in the transverse direction. Thus less fabric may be used, contributing to economical manufacture and increased wearer comfort since additional gasketing is only provided on demand.  
           [0008]    The transverse direction elastic modulus of the selected flap material should be sufficiently low so that the normal force produced by the long axis elasticity can readily extend the flap material in the transverse direction from, for example, 0% elongation until its point of failure, without a measurable increase in normal force. It will be appreciated that because loss of vertical fit is an irreversible process, the flap material requires very little recovery.  
           [0009]    A disposable garment according to one aspect of the present invention may include gasketing provided by elasticized flap portions which are connected to the interior of the garment along the lower part of each leg opening. Throughout use, the elasticized flap portions fit snugly against the wearer and effectively block most spillage of waste material from the leg openings.  
           [0010]    It will be appreciated that when flap portions are used for the leak guards, a separate manufacturing step can be required to attach the flap material to the garment. Generally, the flaps have been joined via seams. During active use, some separation at the seams can occur, resulting in failure of the flaps to serve as effective leak guards. Providing a seam which is both leakproof and durable has been challenging, and has added to manufacturing costs. To solve this problem, seamless leak guards were disclosed in co-pending U.S. application Ser. No. 09/290,414, of common ownership herewith. The present invention is also applicable to the integral, or seamless, method of providing gasketing.  
           [0011]    As described in the co-pending application, instead of using flaps, seamless leak guards may be provided by extending the liquid-impermeable outer cover layer substantially beyond the absorbent layer on both sides, and to a higher location on the garment and on the wearer. The outer cover extensions on both sides can be reinforced at their edges by elastic leg bands which pull the outer cover extensions upward and away from the absorbent layer, and against the wearer&#39;s body. The lateral extensions of the outer cover material, combined with the upward pulling of the elastic leg bands, may provide the garment with seamless leak guards not requiring separately attached flaps. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 is a vector diagram of tension and pressure at a point along a curved surface;  
         [0013]    [0013]FIG. 2 is a front perspective view of a known absorbent garment given as an environment of the present invention;  
         [0014]    [0014]FIG. 3 is a top plan view of an absorbent garment assembly;  
         [0015]    [0015]FIG. 4 is a simplified top plan view of the garment indicating tensioning of the flaps in their long axis and extensibility of the flaps in their transverse axis;  
         [0016]    [0016]FIG. 5 is a cross-sectional view of the absorbent garment assembly, taken along line  5 — 5  in FIG. 4, and illustrating transverse extensibility of the gasket;  
         [0017]    [0017]FIG. 6 is a schematic side view of the garment, and a wearer thereof, illustrating the extensible flap material gasketing in response to a loading of the garment with absorbed fluids.  
         [0018]    [0018]FIG. 7 is a schematic top view of another embodiment wherein the flap is integral with the chassis.  
         [0019]    [0019]FIG. 8 is a schematic side view of another embodiment wherein the flap has a folded construction.  
         [0020]    [0020]FIG. 9 is a schematic top view of garment with the flap of FIG. 8.  
         [0021]    [0021]FIG. 10 is an end view of the folded flap construction taken along line  10 - 10  of FIG. 9.  
         [0022]    [0022]FIGS. 11 and 12 illustrate alternative placement of the folds in garment construction.  
         [0023]    [0023]FIG. 13 is a schematic of the wire weave pattern of thermal bond for the laminate of FIG. 13. 
     
    
     DEFINITIONS  
       [0024]    Within the context of this specification, each term or phrase below will include the following meaning or meanings.  
         [0025]    “Article” refers to a garment or other end-use article of manufacture, including but not limited to absorbent articles such as diapers, training pants, swim wear, absorbent underpants, adult incontinence articles, feminine hygiene articles, and medical garments and wraps.  
         [0026]    “Attached” can refer to either an integral part or a part joined by a separate joining process.  
         [0027]    A “barrier” material is a material with no measurable transmission of a selected substance through that material over the expected term of use of the material.  
         [0028]    “Bicomponent” nonwoven filaments are known in the art generally as thermoplastic filaments which employ at least two different polymers combined together in a heterogeneous fashion. Instead of being homogeneously blended, two polymers may, for instance, be combined in a side-by-side configuration, so that a first side of a filament is composed of a first polymer “A” and a second side of the filament is composed of a second polymer “B.” Alternatively, the polymers may be combined in a sheath-core configuration, so that an outer sheath layer of a filament is composed of a first polymer “A,” and the inner core is composed of a second polymer “B.” Other heterogeneous configurations are also possible.  
         [0029]    “Bonded” refers to the joining, adhering, connecting, attaching, or the like, of two elements. Two elements will be considered to be bonded together when they are bonded directly to one another or indirectly to one another, such as when each is directly bonded to intermediate elements.  
         [0030]    The term “cloth” includes, but is not limited to, a fabric made of fibrous material, commonly a woven fabric of, for example, cotton. Furthermore, the term “cloth” shall also include all nonwoven materials exhibiting a cloth-like feel.  
         [0031]    “Connected” refers to the joining, adhering, bonding, attaching, or the like, of two elements. Two elements will be considered to be connected together when they are connected directly to one another or indirectly to one another, such as when each is directly connected to intermediate elements.  
         [0032]    “Disposable” refers to articles which are designed to be discarded after a limited use rather than being laundered or otherwise restored for reuse.  
         [0033]    “Disposed”, “disposed on”, and variations thereof are intended to mean that one element can be integral with another element, or that one element can be a separate structure bonded to or placed with or placed near another element.  
         [0034]    “Elastic”, “elasticized”, “elastomeric” and “elasticity” mean that property of a material or composite by virtue of which it tends to recover its original size and shape after removal of a force causing a deformation.  
         [0035]    “Extensible” or “extendible” implies extension under a deformation force with little or no recovery of the original size or shape after the deformation force is removed. A “low modulus of elasticity” with respect to an extensible material implies that little force is required to extend the material and is not meant to imply that the extensible material exhibits elasticity.  
         [0036]    “Fabrics” is used to refer to all of the woven, knitted and nonwoven fibrous webs.  
         [0037]    “Film” refers to a thermoplastic film made using a film extrusion and/or foaming process, such as a cast film or blown film extrusion process.  
         [0038]    “Gaskets”, also called “cuffs” or “containment flaps”, in some instances, are structures within, or on, the personal care product serving as barriers to the escape of bodily exudates. The terms “gaskets”, “flaps” and “containment flaps” will be used interchangeably throughout the application.  
         [0039]    “Integral” or “integrally” is used to refer to various portions of a single unitary element rather than separate structures bonded to or placed with or placed near one another.  
         [0040]    “Layer” when used in the singular can have the dual meaning of a single element or a plurality of elements.  
         [0041]    “Liquid impermeable”, when used in describing a layer or multi-layer laminate, means that a liquid, such as urine, will not pass through the layer or laminate, under ordinary use conditions, in a direction generally perpendicular to the plane of the layer or laminate at the point of liquid contact. Liquid, or urine, may spread or be transported parallel to the plane of the liquid impermeable layer or laminate, but this is not considered to be within the meaning of “liquid impermeable” when used herein.  
         [0042]    “Longitudinal” and “transverse” have their customary meaning, as indicated by the longitudinal and transverse directions depicted in FIG. 4 at arrows  62  and  66 , respectively. The longitudinal, or long, axis lies in the plane of the article and is generally parallel to a vertical plane that bisects a standing wearer into left and right body halves, when the article is worn. The transverse axis lies in the plane of the article generally perpendicular to the longitudinal axis. The article and its parts, although illustrated as longer in the longitudinal direction than in the transverse direction, need not be so.  
         [0043]    “Machine direction”, or MD, refers to the length of a fabric in the direction in which it is produced, as opposed to “cross direction”, or CD, which refers to the width of a fabric in a direction generally perpendicular to the machine direction.  
         [0044]    “Meltblown fiber” means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity heated gas (e.g., air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed for example, in U.S. Pat. No. 3,849,241 to Butin et al. Meltblown fibers are microfibers which may be continuous or discontinuous, are generally smaller than about 0.6 denier, and are generally self bonding when deposited onto a collecting surface. Meltblown fibers used in the present invention are desirably substantially continuous in length.  
         [0045]    “Member” when used in the singular can have the dual meaning of a single element or a plurality of elements.  
         [0046]    As used herein, the term “necked material” refers to any material which has been drawn in at least one dimension, (e.g. lengthwise), reducing the transverse dimension, (e.g. width), such that when the drawing force is removed, the material can be pulled back, or relax, to, or near, its original width. The necked material typically has a higher basis weight per unit area than the un-necked material. When the necked material returns to its original un-necked width, it should have about the same basis weight as the un-necked material. This differs from stretching/orienting a material layer, such as a film, during which the layer is thinned and the basis weight is permanently reduced.  
         [0047]    The term “nonwoven fabric” or “nonwoven web” means a web having a structure of individual fibers or threads which are interlaid, but not in a regular or identifiable manner as in a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as, for example, meltblowing processes, spunbonding processes, air-laying processes, and bonded carded web processes. The basis weight of nonwoven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and the fiber diameters are usually expressed in microns. (Note that to convert from osy to gsm, multiply osy by 33.91).  
         [0048]    “Permanently bonded” refers to the joining, adhering, connecting, attaching, or the like, of two elements of an absorbent garment such that the elements tend to be and remain bonded during normal use conditions of the absorbent garment.  
         [0049]    The term “personal care absorbent product” includes without limitation diapers, training pants, swim wear, absorbent underpants, baby wipes, adult incontinence products, and feminine hygiene products.  
         [0050]    Words of degree, such as “About”, “Substantially”, and the like are used herein in the sense of “at, or nearly at, when given the manufacturing and material tolerances inherent in the stated circumstances” and are used to prevent the unscrupulous infringer from unfairly taking advantage of the invention disclosure where exact or absolute figures are stated as an aid to understanding the invention.  
         [0051]    “Spunbond fiber” refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinnerette having a circular or other configuration, with the diameter of the extruded filaments then being rapidly reduced as by, for example, in U.S. Pat. No. 4,340,563 to Appel et al., and U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No. 3,502,538 to Petersen, and U.S. Pat. No. 3,542,615 to Dobo et al. Spunbond fibers are quenched and generally not tacky when they are deposited onto a collecting surface. Spunbond fibers are generally continuous and often have average deniers larger than about 0.3, more particularly, between about 0.6 and about 10.  
         [0052]    As used herein, the term “substantially continuous fibers” refers to fibers, including without limitation, spunbond and meltblown fibers, which are not cut from their original length prior to being formed into a nonwoven web or fabric. Substantially continuous fibers may have average lengths ranging from greater than about 15 centimeters to more than one meter, and up to the length of the web or fabric being formed. The definition of “substantially continuous fibers” includes fibers which are not cut prior to being formed into a nonwoven web or fabric, but which are later cut when the nonwoven web or fabric is cut, and fibers which are substantially linear or crimped.  
         [0053]    “Thermoplastic” describes a material that softens when exposed to heat and which substantially returns to a nonsoftened condition when cooled to room temperature.  
         [0054]    A “transversely” stretchable, or extendible, material is one which extends more easily along a first axis than along a second axis. “Transversely” extendible is not necessarily meant to imply that there is no extendibility in the second axis.  
         [0055]    These terms may be defined with additional language in the remaining portions of the specification.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0056]    It is well known that pressure exerted from elastic tension at a given body contact point is proportional to the curvature at the point as well as to the amount of tension, as demonstrated by the LaPlace equation: 
           Pg=σ   1   /R   1   (1) 
         [0057]    where Pg is the normal force or gasket pressure, R 1  is the radius of curvature along a wearer&#39;s body  5 , and σ 1  is the tension in the tangential direction (see FIG. 1). Thus, it can be appreciated that pressure Pg is generated under a given tension σ 1 . Pg is a force aligned in the transverse direction of the containment flap providing a force to extend the flap as further explained below.  
         [0058]    In pant-like absorbent garments having elasticized leg openings and/or an elasticized waist opening, the elastic tension σ 1  should be high enough so that sufficient pressure Pg is exerted at all points around the perimeter of the opening, to seal the garment against the wearer&#39;s body. This force in the present invention should also be in an amount to easily achieve fall extension of the flap material towards the wearer.  
         [0059]    Referring to FIG. 2, a conventional pant-like absorbent garment  2  for use in conjunction with the present invention includes a waste containment section  4  and two side portions  6  and  8  defining a waist opening  10  and a pair of leg openings  12  and  14 . The side portion  6  includes stretchable panels  18  and  20  joined together at seam  30 . The side portion  8  includes stretchable panels  24  and  26  joined together at seam  33 . Seams  30  and  33  extend longitudinally from the waist opening  10  to the leg openings  12  and  14  of the garment  2 .  
         [0060]    The waste containment section  4  includes multiple layers, as shown in FIG. 3, including, for instance, a liquid-permeable body side liner  42 , an absorbent core layer  44 , a surge layer  46 , and a liquid-impermeable outer cover  48  which faces away from the wearer. The waste containment section  4  includes waist elastics  22  on the front and back of the garment  2 . The leg openings  12  and  14  also include leg elastics  36  which extend substantially around the portion of the leg openings defined by the waste containment section  4 .  
         [0061]    The stretchable side portions  6  and  8  can be constructed of conventional woven or nonwoven materials, formed from a wide variety of elastic and stretchable polymers. Suitable polymers include without limitation block copolymers of polystyrene, polyisoprene and polybutadiene; copolymers of ethylene, natural rubbers and urethanes; and combinations of the foregoing. Particularly suitable are styrene-butadiene block copolymers which have been sold by Shell Chemical Co. under the trade name KRATON®. Other suitable polymers include copolymers of ethylene, including without limitation ethylene vinyl acetate, ethylene methyl acrylate, ethylene ethyl acrylate, ethylene acrylic acid, stretchable ethylene-propylene copolymers, and combinations thereof. Also suitable are coextruded composites of the foregoing, and elastomeric staple integrated composites where staple fibers of polypropylene, polyester, cotton and other materials are integrated into an elastomeric meltblown web. Certain elastomeric ultra-low density olefin polymers such as single-site or metallocene-catalyzed olefin polymers and copolymers are also suitable for the side portions  6  and  8 . Referencing FIGS. 2 and 3, the stretchable side portions  6  and  8  are desirably rectangular in shape, and desirably, as shown in FIG. 2, extend from the top of the waist opening  10  to the leg openings  12  and  14 . The side portions  6  and  8  may also be laminates of multiple layers, and are desirably breathable to water vapor but impervious to liquids.  
         [0062]    When a laid open absorbent garment as shown in FIG. 3 is assembled into the absorbent garment shown in FIG. 2, the longitudinal seams  30  and  33  may be formed by conventional methods including, without limitation, ultrasonic welding, thermal bonding, adhesive bonding, stitch bonding and the like. Ultrasonic welding is a presently desirable technique. The various bonding techniques are conventional, and are neither critical nor limiting as to the present invention.  
         [0063]    The leg elastics  36  may be attached to the outer cover  48  by a variety of techniques including adhesive bonding, ultrasonic bonding, thermal bonding, stitch bonding or other conventional techniques. Suitable adhesives include spray adhesives, hot melt adhesives, self-adhering elastomeric materials and the like. Often, the leg elastics  36  will be applied in the stretched condition to the outer cover  48 , and then allowed to retract, causing gathering of the outer cover  48  when the leg elastics  36  are retracted. The leg elastics  36  desirably comprise at least two elastic bands, more desirably at least four elastic bands.  
         [0064]    In the vicinity of the waist opening  10 , the waist elastics  22  may be attached to or embedded within the garment  2 . The waist elastics  22  may include single or multiple elastic bands constructed from any of the same materials as the leg elastics  36 . The waist elastics  22  in the front and back of the garment  2  desirably have lengths which are nearly the same, or slightly shorter than the width of the outer cover  48 . The waist elastics  22  may be attached to the outer cover  48  using the same techniques as for attaching leg elastics  36 .  
         [0065]    A wide variety of elastic materials may be employed for the leg elastics  36  and the waist elastics  22 . Examples include a film or meltblown web formed using block or graft copolymers of butadiene, isoprene, styrene, ethylene-methyl acrylate, ethylene-vinyl acetate, ethylene-ethyl acrylate or blends thereof. One desirable elastomer is a block copolymer of styrene-ethylbutadiene-styrene. Polyester elastomeric materials, polyurethane elastomeric materials and polyamide elastomeric materials can be used as well. Elastomeric ultra-low density olefin polymers such as single-site or metallocene-catalyzed olefin polymers and copolymers can also be employed. Also, the leg elastics  36  and the waist elastics  22  can be made of an activatable material applied in an unstretched condition, and activated by heat, light or moisture or radiation to cause shrinkage and elasticity.  
         [0066]    As previously indicated, the outer cover  48  may include a single layer, or may include multiple layers joined together. The outer cover  48 , as shown in FIG. 3, may include two layers, a cloth layer and a polymer layer, joined by an outer cover adhesive layer. The cloth layer of the outer cover  48  can be made from a wide variety of woven or nonwoven material, films, or a film-coated nonwoven material, including, for instance, cast or blown films of polyethylene, polypropylene, polyester or blends thereof. The cloth layer may also be a composite of a bonded carded or spunbond or meltblown material, for example, a spunbond-meltblown composite of thermoplastic material or a spunbond-meltblown-spunbond thermoplastic material, wherein the spunbond layer can provide a cloth-like texture and the meltblown layer can provide liquid impermeability. Materials of which the cloth layer can be made include nonwovens having a basis weight of about 0.4 ounces per square yard (13.6 gsm) or greater. The polymer layer of the outer cover  48  can include extruded films of polyolefin polymers or copolymers, or other thermoplastic materials.  
         [0067]    The outer cover  48 , absorbent core layer  44 , surge layer  46  and body side liner  42  may also be joined together using ultrasonic bonding, thermal bonding, stitch bonding, or any of the adhesive materials described above for the attachment of the leg elastics  36  and the waist elastics  22 .  
         [0068]    The absorbent core layer  44  can, without limitation, be made of wood pulp fluff or a mixture of wood pulp fluff and a superabsorbent material, or a wood pulp fluff integrated with a thermoplastic absorbent material treated with a surfactant, or absorbent foams. Thermal binders, such as Pulpex® can be used in blends or layering with the fluff and superabsorbent material. The absorbent core layer  44  can also include a batt of meltblown synthetic fibers, a bonded carded web of synthetic or natural fibers or blends thereof, a composite of meltblown fibers and the like. The synthetic fibers can be, but are not limited to, polypropylene, polyethylene, polyester and copolymers of these or other polyolefins.  
         [0069]    Examples of synthetic superabsorbent material polymers include the alkali metal and ammonium salts of poly(acrylic acid) and poly(methacrylic acid), poly(acrylamides), poly(vinyl ethers), maleic anhydride copolymers with vinyl ethers and alpha-olefins, poly(vinyl pyrrolidone), poly(vinylmorpholinone), poly(vinyl alcohol), and mixtures and copolymers thereof. Further superabsorbent materials include natural and modified natural polymers, such as hydrolyzed acrylonitrile-grafted starch, acrylic acid grafted starch, methyl cellulose, chitosan, carboxymethyl cellulose, hydroxypropyl cellulose, and the natural gums, such as alginates, xanthum gum, locust bean gum and the like. Mixtures of natural and wholly or partially synthetic superabsorbent polymers can also be useful in the present invention. Other suitable absorbent gelling materials are disclosed by Assarsson et al. in U.S. Pat. No. 3,901,236 issued Aug. 26, 1975. Processes for preparing synthetic absorbent gelling polymers are disclosed in U.S. Pat. No. 4,076,663 issued Feb. 28, 1978 to Masuda et al. and U.S. Pat. No. 4,286,082 issued Aug. 25, 1981 to Tsubakimoto et al.  
         [0070]    Both the surge layer  46  and the body side liner  42  are constructed from liquid pervious materials. These layers function to transfer liquid to the absorbent core layer  44 . Suitable materials include porous woven materials, porous nonwoven materials, open-celled foams, and apertured films. Examples include, without limitation, any flexible porous sheets of polyolefin fibers, such as polypropylene, polyethylene or polyester fibers; webs of spunbond polypropylene, polyethylene or polyester fibers; webs of rayon fibers; bonded carded webs of synthetic or natural fibers or combinations thereof. Either layer may also be an apertured plastic film. The various layers of the garment  2  have dimensions which vary depending on the size and shape of the wearer.  
         [0071]    As seen in FIGS.  4 - 6 , the garment  2  according to the present invention will have the flaps  50 , hereinafter described in the singular, extending in a long axis, or direction, corresponding to the longitudinal axis or direction  62  of the garment  2 . The flap  50  will have an attached edge  52  attached, i.e. affixed to, or integral with, the garment, and a free edge  64  for contacting the body of the wearer  5  (FIGS. 5 and 6). The flap  50  will have a transverse direction  66  perpendicular to its long direction  62 . Arrows  68  indicate the long axis tensioning force σ 1  achieved through addition of elastics  70  extending in the long direction of the flap  50 .  
         [0072]    As seen in FIG. 5, the gasket  50 , in its functional position, extends largely perpendicularly to the garment chassis  3 , with chassis  3  defined for present purposes as including all parts of the absorbent article exclusive of the flaps  50 . Extension of the gasket is indicated by dotted, or phantom, portion  65 . Elastic members  70 , or elasticity, may be provided such as discussed above or in any known manner sufficient to provide a normalizing force adequate to extend the flap in the transverse direction  66 .  
         [0073]    Materials suitable for use in constructing a gasket according to the present invention will satisfy the criteria of being easily extensible and with a low recovery, or modulus of elasticity, in a first direction and readily accepting of elastics, e.g. Lycra (TM) strands or otherwise providing a tensioning force, in a second direction perpendicular to the first as discussed above. The material should further provide suitable liquid barrier properties to function as a gasket. Additionally a soft feel and other esthetic properties are desirable. Among the materials contemplated for use are spunbond/meltblown/spunbond (SMS) multilayer laminates, spunbond nonwoven webs, and film/nonwoven web laminates, including neck stretched microporous film/nonwoven web laminates such as found in co-pending application Ser. No. 60/201,830 and further discussed below. Indeed many of the list materials, or parts thereof, may be suitably neck stretched in the machine direction during their manufacture to thereby provide an extensibility in their cross machine directions, which will ultimately become the transverse direction of the flap. Films meeting the above criteria may also be used alone or in conjunction with nonwoven webs of crimped fibers. Highly oriented nonwoven fabric such as certain types of bonded carded web may also be used in the context of the present invention.  
         [0074]    Referencing especially FIG. 6, it is seen that an absorbent garment  2 , upon becoming loaded with absorbent fluid, will sag under the force of gravity  77  away from the body of the wearer  5 . This loss of vertical fit ordinarily creates a gap  79  between the gasket  50  and the wearer  5  leading to leakage. However, through provision of the flaps  50  of the present invention, as the garment  2  sags, the flap  50  extends toward the body  5  as indicated at line  81  in order to maintain contact with the body  5  thereby providing gasketing and preventing leakage to the exterior of the garment.  
         [0075]    Referencing FIG. 7, in an embodiment wherein portions  54  of the outer cover  48  extend beyond the absorbent layer  44 , the extended portions  54  may serve as seamless leak guards. By “seamless”, it is meant that the leak guards are not separately attached and, thus, do not require a seam for attachment to the waste containment section  4 . To effectively serve as leak guards, the difference in width between the absorbent layer and the outer cover must be substantial in the central region  15  between the leg openings. Generally, the outer cover  48  is at least about 40% wider than the absorbent layer  44  in the central region  15 . Desirably, the outer cover  48  is at least about 60% wider than the absorbent layer  44  in the central region  15 . The outer cover  48  in this embodiment would be constructed and arranged from materials including elastics  70 , selected according to the above discussed criteria, at least in so far as the gasketing area is concerned.  
         [0076]    Referencing FIGS.  8 - 12 , another embodiment of the present invention is shown. This embodiment comprises the construction of non-woven and elastic materials to form a flap-like gasket  150  running in the longitudinal direction of an absorbent article  2  and having a fold  148  therein. This flap construction comprises a transversely extensible facing material, a number of lower tension elastic strands  152  to hold the flap  150  next to the skin, and a number of higher tension elastic strands  154  to lift the flap construction to maintain intimate contact with the body surface  5  of the user.  
         [0077]    Referencing FIGS. 9 and 10, the gasket  150  is constructed so that the outside face  156  of the gasket portion between the higher tension elastic strands  154  and the garment is glued at its ends  160 ,  162  to the garment chassis  3 . Likewise, the inside faces  158  of the gasket  150  are attached to each other at the ends of the gasket.  
         [0078]    Between the longitudinal ends of the garment chassis, the gasket  150  is only attached to the chassis at its attached edge  164 , leaving both the inner and outer faces  166 ,  168  respectively, of the gasket free to move. The material extensibility in the transverse direction between the garment  2  and the higher tension elastic strands  148  allows the region at the loose edge of the flap containing the lower tension strands  152  to continuously interface with the wearer&#39;s body  5  throughout the product life.  
         [0079]    The extensible gasket material requires a very low elastic modulus in the transverse direction. The higher tension elastics  154  must have sufficient tangential force against the user&#39;s body  5  surface to create a normal force in the transverse direction of the flap construction that can readily extend the gasket material from 0% elongation until its point of failure. The extensibility in this portion of the gasket construction keeps the free portion of the gasket between the higher tension elastic and the loose edge firmly against the body surface  5 . The lower tension strands  152  further provide extensibility and conformance along the user&#39;s body surface.  
         [0080]    Referencing FIGS. 11 and 12, it can be seen that the gasket  150  may be attached to the garment chassis  3  so that the fold  148  of the gasket is either on the inside of the garment (FIG. 12) or out from the garment (FIG. 11). By placing the fold  148  out from the garment, i.e. the loose flap edge  170  adjacent the chassis edge  172  (in the folded position), as in FIG. 11, pressure against the gasket forms a shearing force at the interface of the flap and the body surface  5  which is difficult to overcome due to friction. Conversely, placing the fold  148  in toward the garment the loose flap edge  170  adjacent the chassis center-line  174 , as in FIG. 12, would create a peel force at the same interface in the same circumstances. Therefore, it is desirable to place the gasket fold outward to help guard against gasket failure and leakage.  
         [0081]    With current flap construction, a secure gasket depends on the interface of the flap tip and the body surface for containment. This particular embodiment improves on the known design by increasing the area of interface between the gasket and the body surface and by providing a transverse directional extensibility to maintain a secure gasket between the product and the user&#39;s body surface.  
         [0082]    Thermal bonding of two material layers together can be accomplished by at least two methods. The first is using heat and pressure as with heated, patterned bonding rolls. Both rolls may be patterned or one may be patterned and the other may be smooth. One or both of the rolls may be heated or a secondary heat source may be used. If conditions dictate, one of the rolls may be cooled. In any event, the heat should be adjusted so that the bonding agent in the film becomes tacky to bond the two layers together while still maintaining the temperature at least about 5° C. cooler than the melting point of the primary predominately linear polyolefin polymer in the film. By “primary” it is meant that predominately linear polyolefin polymer having the highest weight percent of the total weight of the film if there is more than one predominately linear polyolefin polymer in the film polymer blend.  
         [0083]    Bond patterns and area may be varied depending upon the particular end-use. Suitable bond patterns can include point bonds, continuous lines, decorative patterns and combinations of the foregoing and may include the wire weave bond pattern illustrated in FIG. 13. Bond area will depend upon the degree of lamination desired. For personal care absorbent article applications, bonding should be sufficient to require at least a 5 gram load to delaminate the two layers.  
         [0084]    The second method of bonding is ultrasonic bonding which also is well known to those having ordinary skill in the art. The anvil roll of an ultrasonic bonder can be designed with any of several bond patterns.  
         [0085]    Transversely stretchable, or extendible, materials suitable for use with the present invention are presented below. The exemplary materials are presented as contemplated means of accomplishing certain aspects of the invention and are not intended to limit the scope of the invention. Cross direction, or CD, Young&#39;s modulus and machine direction, or MD, Young&#39;s modulus, were measured to indicate extendibility in those axes. The CD and MD Young&#39;s moduli are then reported as a ratio to indicate strength and flexibility of the sample materials. Hydrohead is also reported as an indication of the absolute liquid barrier properties of the materials.  
         [0086]    Material Examples  
       EXAMPLE 1  
       [0087]    A necked spunbond comprising of a 0.4 osy layer of PRISM bicomponent spunbond fibers, as taught in U.S. Pat. No. 5,382,400 to Pike et al., and necked to about 45% of its original width, was tested according to the below listed test procedures and found to have a CD Young&#39;s modulus of 2.97 psi/%, an MD Young&#39;s modulus of 87.73 psi/%, an MD/CD Young&#39;s modulus ratio of 29.54, and a hydrohead of 3.67 mbar.  
       EXAMPLE 2  
       [0088]    A spunbond/meltblown/spunbond laminate comprising two spunbond layers of a 0.4 osy layer of PRISM bicomponent spunbond fibers, as taught in U.S. Pat. No. 5,382,400 to Pike et al., and necked to about 45% of their original width, with a 0.2 osy layer of meltblown Kraton G filaments between the spunbond layers, was tested according to the below listed test procedures and found to have a CD Young&#39;s modulus of 3.70 psi/%, an MD Young&#39;s modulus of 91.02 psi/%, an MD/CD Young&#39;s modulus ratio of 24.60, and a hydrohead of 11.33 mbar.  
       EXAMPLE 3  
       [0089]    A spunbond/meltblown laminate comprising a single spunbond layer of a 0.4 osy un-necked layer of PRISM bicomponent spunbond fibers, as taught in U.S. Pat. No. 5,382,400 to Pike et al., with a 0.2 osy layer of meltblown KRATON G filaments laminated to the spunbond layer, was tested according to the below listed test procedures and found to have a CD Young&#39;s modulus of 28.89 psi/%, an MD Young&#39;s modulus of 0.90 psi/%, an CD/MD Young&#39;s modulus ratio of 32.10, and a hydrohead of 14.50 mbar. It will be appreciated that the low Young&#39;s modulus direction of this material example is ninety degrees different from the previous examples, but the material may still be suitable for use with certain aspects of the present invention.  
         [0090]    Test Methods  
         [0091]    Elongation Testing:  
         [0092]    A one inch strip of each material was evaluated on an Instron automated stress-strain tester. Specifically, the gap size between clamps on each side of the material during the stress-strain test was set at 0.25 inches. A cross-head, or clamp separation, speed of 20 in/min was used. A maximum elongation of 200%, i.e. specifically from ¼ inch to ¾ inch where samples did not break. A maximum load: of 30 pounds was permitted. This procedure was used to measure the CD Young&#39;s modulus as well as the MD Young&#39;s modulus of the materials. Hydrohead testing:  
         [0093]    In this test, water pressure is measured to determine how much water pressure is required to induce leakage in three separate areas of a test material. The water pressure is reported in millibars (mbars) at the first sign of leakage in three separate areas of the test specimen. The pressure in millibars can be converted to hydrostatic head height in inches of water by multiplying millibars by 0.402. Pressure measured in terms of inches refers to pressure exerted by a number of inches of water. Hydrostatic pressure is pressure exerted by water at rest.  
         [0094]    Apparatus used to carry out the procedure includes a hydrostatic head tester, such as TEXTEST FX-3000 available from ATI Advanced Testing Instruments Corp. of Spartenburg, S.C., a 25.7 cm 2  test head such as part number FX3000-26 also available from ATI Advanced Testing Instruments Corp., purified water such as distilled, deionized, or purified by reverse osmosis, a stopwatch accurate to 0.1 second, a one-inch circular level, and a cutting device, such as scissors, a paper cutter, or a die-cutter.  
         [0095]    Prior to carrying out this procedure, any calibration routines recommended by manufacturers of the apparatus being used should be performed. Using the cutting device, the specimen is cut to the appropriate size. Each specimen has a minimum size that is sufficient to allow material to extend beyond the outer diameter of the test head. For example, the 25.7 cm 2  test head requires a 6-inch by 6-inch, or 6-inch diameter specimen. Specimens should be free of unusual holes, tears, folds, wrinkles, or other distortions.  
         [0096]    First, make sure the hydrostatic head tester is level. Close the drain faucet at the front of the instrument and pull the upper test head clamp to the left side of the instrument. Pour approximately 0.5 liter of purified water into the test head until the head is filled to the rim. Push the upper test head clamp back onto the dovetail and make sure the plug is inserted into the socket at the left side of the instrument. Turn the instrument on and allow the sensor to stabilize for 15 minutes. Make sure the Pressure Gradient thumbwheel switch is set to 60 mbar/min. Make sure the drain faucet is closed. The water temperature should be maintained at about 75° Fahrenheit±10° Fahrenheit. Use the Light Intensity adjustment to set the test head illumination for best visibility of water droplets passing through the specimen.  
         [0097]    Once the set-up is complete, slide the specimen onto the surface of the water in the test head, from the front side of the tester. Make sure there are no air bubbles under the specimen and that the specimen extends beyond the outer diameter of the test head on all sides. If the upper test head clamp was removed for loading the specimen, push the clamp back onto the dovetail. Pull down the lever to clamp the specimen to the test head and push the lever until it comes to a stop. Press the Reset button to reset the pressure sensor to ZERO. Press the Start/Pause button to start the test. Observe the specimen surface and watch for water passing through the specimen. When water droplets form in three separate areas of the specimen, the test is complete. Any drops that form within approximately 0.13 inch (3.25 mm) of the edge of the clamp should be ignored. If numerous drops or a leak forms at the edge of the clamp, repeat the test with another specimen. Once the test is complete, read the water pressure from the display and record. Press the Reset button to release the pressure from the specimen for removal. Repeat procedure for desired number of specimen repeats.  
         [0098]    While the embodiments of the invention described herein are presently considered desirable, various modifications and improvements can be made without departing from the spirit and scope of the invention. The scope of the invention is indicated by the appended claims, and all changes that fall within the meaning and range of equivalents are intended to be embraced therein.