Patent Publication Number: US-2021161734-A1

Title: Absorbent Article With Low Profile Closure

Description:
BACKGROUND 
     Training pants are particularly useful in the toilet training process because children can associate the transition from diapers to training pants with “growing up” or progression toward the goal of wearing underwear. Furthermore, pant style diapers allow the child to be able to pull the diaper down before using the toilet and to pull them back up when finished, therefore allowing the child the independence and confidence to successfully toilet train. 
     Many traditional training pants are provided with permanent side seams requiring the pant to be pulled on and off like a regular undergarment. Some training pants are provided with refastenable side seams, allowing the pant to be applied like a pant or like a diaper, the latter conferring the ability to apply the pant in a manner of diaper or a pull-up. 
     SUMMARY OF THE INVENTION 
     The present invention relates, in part, to an absorbent article, comprising an absorbent chassis having a front portion, back portion, and crotch portion the crotch portion extending between and connecting the front portion and back portion, the absorbent chassis having first and second major longitudinal edges, first and second laterally opposed side panels, connecting the front portion to the back portion along a length of the first and second major longitudinal edges, to define first and second leg openings in the absorbent article, wherein the first and second side panels comprise a front side panel having a distal edge, a rear side panel having a distal edge, and a bridging component releasably coupling the front and rear side panels in a non-overlapping configuration. 
     Other aspects of the invention, relate, in part to a method of making an absorbent article, the method comprising: coupling first and second side panels to an absorbent chassis, the absorbent chassis having a front portion, back portion, and crotch portion, the crotch portion extending between and connecting the front portion and back portion, and having first and second major longitudinal edges, and wherein the first and second side panels are coupled to absorbent chassis along lengths of the first and second major longitudinal edges, to define first and second leg openings in the absorbent article; wherein the first and second side panels comprise a front side panel having a distal edge, a rear side panel having a distal edge, and a bridging component coupling the front and rear side panels in a non-overlapping configuration. 
     In yet other aspects, the present invention relates, in part, to a side panel for a pull-up type absorbent article, comprising a first panel having first and second major surfaces and distal edge, a second panel having first and second major surfaces and a distal edge, a bridging component coupled to the first major surface of the first panel and the first major surface of the second panel—wherein the bridging component holds the distal edges of the first and second panels together in a butt-joint configuration. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a side view of a typical prior art disposable absorbent article with side seams. 
         FIG. 2  is a plan view of the absorbent article shown in  FIG. 1  in an unfastened, open, laid out condition. 
         FIG. 3  is a plan view of an embodiment of the bridging component of the invention. 
         FIG. 4A  is a schematic of one embodiment of an improved side seam pant closure. 
         FIG. 4B  is a schematic of one embodiment of an improved side seam pant closure. 
         FIG. 4C  is a schematic of one embodiment of an improved side seam pant closure. 
         FIG. 4D  is a schematic of one embodiment of an improved side seam pant closure. 
         FIG. 4E  is a schematic of one embodiment of an improved side seam pant closure. 
         FIG. 5  is a schematic of an embodiment of the bridging component. 
         FIG. 6A  is a schematic of a prior art side seam. 
         FIG. 6B  is a schematic of a side seam achieved employing an embodiment an improved bridging component. 
         FIG. 7  is perspective view of an embodiment of an improved bridging component shown in a folded orientation. 
         FIG. 8  is side view of a pant type diaper employing an embodiment of the bridging component of the invention. 
         FIG. 9  is a plan view of the absorbent article shown in  FIG. 8  in an unfastened, open, laid out condition. 
         FIG. 10  is a side view schematic of an embodiment of a side seam according to an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Traditional training pants are used by toddlers when transitioning between diapers and knit underwear. They have absorbent capabilities along the lines of diapers, but whereas a diaper is traditionally constructed to wrap around the underside of an infant and then be secured with the use of lateral side closure fasteners of some sort (for example adhesive tabs or the like), training pants are structured more like underwear and do not include side closure fasteners. However, to facilitate easy removal of traditional training pants, a removal seam is typically disposed on either side of the training pant, allowing a user to rip the training pant away from the wearer, thus splitting the sides of the training pant along the removal seam. 
     A problem associated with some training pants of the prior art is that the removal seams are an overlap design, giving traditional training pants a more diaper-like appearance resembling closure tabs, thereby potentially frustrating toilet training efforts due to the child&#39;s perception that he or she is wearing a diaper. It would be desirable to have a disposable absorbent article that provides the garment-like or underwear-like look of a traditional training pant yet affords the option of being applied either like a diaper or like a pant. 
     The principles of the present invention can be incorporated into any suitable disposable absorbent article. Examples of such suitable articles include diapers, training pants, feminine hygiene products, incontinence products, other personal care or health care garments, or the like. For ease of explanation, the description hereafter will be in terms of a child&#39;s training pant. 
       FIG. 1  and  FIG. 2  illustrate a training pant  520  of the prior art,  FIG. 1  shown in partially fastened, three dimensional view,  FIG. 2  shown in plan view (unfastened). Reference elements are interchangeable between the two figures. Referring to  FIG. 2 , training pant  520  has a longitudinal direction  12  and a lateral direction  14 . In the longitudinal direction  12 , the training pant  520  defines an absorbent chassis  511  that can be divided into a front portion  516 , a back portion  518 , and a crotch portion  526  extending between and connecting the front portion  516  and the back portion  518 . Training pant  520  includes a bodyside liner  530  (facing away from the view depicted in  FIG. 2 ) and an absorbent core  535  located between the bodyside liner and the outer cover  532 . The training pant  520  has a pair of opposite longitudinal side edges  528  and  528 ′ that extend between a back waist edge  538  and a front waist edge  540 . Training pant  520  also includes a pair of longitudinally-extending leg cuffs  536  and  536 ′. Leg cuffs  536  and  536 ′ may be adapted to fit about the legs of a wearer in use and serve as a mechanical barrier to the lateral flow of body exudates. 
     The training pant  520  includes a pair of side panels  510 . The side panels  510  comprise front side panels  534  and  534 ′ and back side panels  534   a  and  534   a ′. The pairs of front side and back side panels  534 ,  534 ′,  534   a ,  534   a ′ may be formed integrally with the back and front portions or alternately may be formed separately and subsequently attached. Front side and back side panels  534 ,  534 ′,  534   a ,  534   a ′ comprise a distal edge  568  extending along a length of each respective panel, that can be seen in the prior art pant to form an overlapping seam when fastened. Front side and back side panels have a first major (inner) surface  545 , which contacts the wearer and an opposing second major surface  547  that faces outward, away from the wearer. 
     In typical prior art training pants, front side and back side panels are releasably attached to one another by means of a prior art fastening system  544  and  544 ′. The prior art fastening system is used to secure the training pant  520  around the waist of a wearer. The fastening system may comprise a pressure sensitive adhesive, or a hook-type material with corresponding loop material for either fastening system  544  or  544 ′, for example. The front portion  516  would include an outer cover  532  suitably selected to form a receptive fastening component to the fastening system  544 . For example, if fastening system  544  comprises a hook-type material, the training pant front portion  516  would comprise a suitable nonwoven material selected to suitably engage with and couple to the selected hook-type material. 
     To increase comfort and wearability, front side and back side panels  534 ,  534 ′,  534   a ,  534   a ′ may be formed of an elastic material that stretches in a direction parallel to the lateral direction  14  of the training pant  520 . 
     The overlapping nature of the closure system used in training pant  520  results in a prominent overlap region where the fastening system overlaps with its counterpart. It also creates a flap, along for example distal edge  568 , which makes the training pant feel and look a bit like diapers. Ideally, a more streamlined pants side seam closure system would be more discreet, and would not have overlap of the diaper components, so as to present as thin, without noticeable flaps of distal edges. 
     Improved Pant Side Seam Closure 
     In reference to  FIGS. 8 and 9 , a training pant  20  according to embodiments of the present invention includes an improved lateral fastening system  80  for securing the training pant about the waist of the wearer, one on each lateral side of the wearer. In some embodiments, the improved fastening system may be thinner than pant-type lateral fastening systems of the prior art, and may resemble traditional underwear more than diapers in look and feel. 
     The improved fastening system comprises a bridging component  86  or  87  that is adapted to refastenably connect to fastening components  82 ,  83 ,  84 ,  85  provided on the front side and back side panels  34 ,  34 ′  134 , and  134 ′ respectively. The illustrated fastening system  80  includes first and second back side panel fastening components  82  and  83  and first and second front side panel fastening components  84  and  85  that are adapted to refastenably connect to the first and second bridging components  86  and  87 . In some embodiments one or all of the fastening components  82 ,  83 ,  84 , and  85  may be distinct from the front side and back side panels and attached by means of adhesive and/or thermal or ultrasonic bonding as is well known in the art. In other embodiments, the front side and back side panels themselves act as fastening components, as they may be made out of a material, such as a loop-type material, amenable to coupling with a hook-type fastening system on the bridging component. In such embodiments, the training pant  20  would include an outer cover  32  suitably selected to form a receptive fastening component to the bridging components  86  and  87 . For example if bridging components  86  and  87  comprises a hook-type material, the side panels  34 ,  34 ′,  134 , and  134 ′ might comprise a nonwoven material selected to suitably engage with and couple to the selected hook-type material. 
     In some embodiments, one surface of each of the first and second back side panel include discreet fastening components  82  and  83  ( FIG. 9 ) and first and second front side panel fastening components  84  and  85 . These fastening components comprise a plurality of engaging elements that are adapted to releasably engage and disengage the engaging elements of the bridging components  86  and  87 . 
     An embodiment of a bridging component  86  is depicted in  FIG. 3 . Bridging component  87 , which would be used on the opposite lateral side of a pant, is in most embodiments of identical construction, so only bridging component  86  will be described herein. Bridging component  86  is generally rectangular, having a length € and a width, w, but may comprise any variety of shapes and features, including elliptical, clipped corners, and the like. Bridging components on the same pant may have the same, substantially same, or different dimensions and shape. Bridging component  86  comprises a pair of longitudinally opposed first and second edges,  88  and  89  and a pair of transversely opposed third and fourth edges  90  and  91 . For ease of description of various aspects of the invention, bridging component  86  can be divided into four hypothetical quadrant lanes ( 92 - 95 ) that extend across the width between the opposed first and second edges  88  and  89  with a centerline  96  being defined at the boundary between the second and third quadrant lane  93  and  94 , respectively. 
     Bridging component  86  includes fastening members  105  for releasably fastening the first and second front side panels  34  and  34 ′ to first and second back side panels  134 ,  134 ′, respectively. In some embodiments, fastening members  105  may comprise hook-type fasteners. In such case, the surface of the side panels on the pant (side panels side panels  34 ,  34 ′,  134 , and  134 ′) would be provided with suitable complementary fastening components, e.g., loop material. In another embodiment, bridging component  86  may comprise loop type fasteners and the mating fastening components  82 - 85  (in reference to  FIG. 9 ) each comprise complementary hook type fasteners. Loop type fasteners typically comprise a fabric or material having a base or backing structure and a plurality of loop members extending upwardly from at least one surface of the backing structure. The loop material can be formed of any suitable material, such as acrylic, nylon or polyester, and can be formed by methods such as warp knitting, stitch bonding or needle punching. 
       FIG. 4A-E  shows various profile views various embodiments of bridging component  86 . Bridging component  86  may comprise a bridging component backing  97  to which the material carrying the fastening members may attached. Since a body side surface  140  of bridging component backing  97  contacts the skin of the wearer when in use, it may be comprised of a soft material such as non-woven, such materials are well known in the art. To increase comfort, bridging component backing  97  may be formed of a breathable material. Bridging component backing  97  may be provided as a laminate and/or may optionally be elastic. Backing  97  may be the same or substantially the same size of as backing  104  that is carrying the fastening members  105 . Alternately, bridging component backing  97  may be larger than the backing  104  carrying the fastening members  105 , extending beyond the edges such that no portion of backing  104  is in contact with a wearer of a pant. 
     Backing  104  and the hook projections  105  may be of a construction known in the art. Hook type fasteners typically comprise a fabric or material having a base or backing structure and a plurality of hook members extending upwardly from at least one surface of the backing structure. Suitable hook material can be molded or extruded of nylon, polypropylene or another suitable material. Suitable single-sided hook materials for the bridging component  86  or the mating fastening components  82 - 85  are available from 3M Company of St. Paul, Minn. under product name CHK-05810. In some embodiments, hook backing material is sufficiently soft to eliminate need for bridging component backing. 
     To increase comfort, hook backing  97  may be breathable. Breathable hook backing coupled with breathable bridging component backing  104  would confer excellent overall breathability to the bridging components, improving air circulation and heat transfer. Examples of breathable hook tape include reticulated type fasteners such as those described by Chandrasekaran et al. in U.S. Pat. No. 9,649,824, the entire contents of which are incorporated herein. Other breathable hook tapes may be employed as is known to those of skill in the art. 
     To improve aesthetics and/or comfort, bridging components can have a minimal thickness, thereby reducing bulk, which could be uncomfortable to a wearer and/or could diminish the underwear look of the pant. In some embodiments the thickness of bridging component  86  ranges from about 30μ to about 900μ. 
       FIGS. 4B through 4E  depict various embodiments alternative constructions of bridging component  86 , each comprising hook type fastening members  105 . Hook type members  105  are shown projecting outward from backing  104 . Backing  104  is attached to a soft bridging component backing  97  (already described) with adhesive and/or ultrasonic or thermal bonding as is known in the art. Hook type members  105  may be provided in a variety of patterns across the backing  97 . In the embodiment shown in  FIG. 4A , hook type members  105  are distributed over substantially all the surface area of the bridging component backing  97  and extend across all four hypothetical quadrant lanes ( 92 - 95 , depicted as dashed lines). In an alternate embodiment, depicted in  FIG. 4E , hook type members  105  are provided in rows across all four hypothetical quadrant lanes. In alternate embodiments, hook type members  105  may be distributed over less than substantially all surface area of the bridging component backing  97 . For example, as depicted in  FIG. 4B , fastening members  105  may be provided on one side of the bridging component  86  and  87  thereby creating a flange  108  that may be used to attach the bridging component to any of the first or second front or back side panels  34 ,  34 ′,  134 ,  134 ′ with adhesive and/or ultrasonic or thermal bonding as is well known in the art. For example, fastening members, shown as hook type members  105 , may be provided in quadrant lanes three and four only, alternately in quadrant lane three exclusively and further alternatively in quadrant lane four exclusively. In some embodiments, keeping quadrant free of hook creates an effective flange  108  that may be attached to the pant as described above (ultrasonic, adhesive, etc.). Alternatively, a flange is not provided and the bridging component attachment to the side panels occurs in regions comprising fastening members. In these embodiments, attachment may be achieved through the mating of the complementary fastening components and bridging component fastening members alone or a combination with adhesive and/or thermal or ultrasonic bonding as is well known in the art. 
     In other alternative embodiments, hook type members  105  may be provided at exterior edges of bridging component  86  such as in quadrant lanes one and four and two and three as depicted in  FIGS. 4C and 4D , respectively. The embodiment shown in in  FIG. 4C  may be beneficial in the event that the front side and back side panel do not abut (described below) adequately to cover hooks provided on the bridging component  86  thus exposing potentially irritating textures to the wearer or the wearer&#39;s caregiver. 
     Soft bridging component backing  97  can be seen extending slightly beyond the perimeter of the backing  104  carrying the fastening members  105  ( FIGS. 4A-4E ). In some embodiments bridging component backing  97  is substantially the same size as the backing  104  carrying the fastening members  105 . In other embodiments bridging component backing  97  is larger than the backing  104  carrying the fastener members  105 . 
     The overall dimension of the bridging components  86  is not strictly limited. However, for ease of use and aesthetics, bridging component  86  is desirably sized to be concealed behind the front side and back side panels  34 ,  34 ′,  134 , and  134 ′ when in use. As shown in  FIG. 8 , bridging components  86  and  87  may have a length l that is less than the length of the distal edges  68  of the front side and back side panels  34 ,  34 ′,  134 , and  134 ′ so as to be concealed when fastened to a wearer. As will be appreciated, bridging components may have any length l that is less than the distal edges  68 . Alternately, the length l may be greater than the distal edges  68 . Bridging components  86  and  87  should be of a size adequate to remain secured to the wearer during normal physical activity. 
       FIG. 5  illustrates an alternate embodiment of the bridging component  86  wherein the fastening members  105  comprises a loop type fastener. Such fasteners are known in the art. In these embodiments, front side and back side panels  34 ,  34 ′,  134 , and  134 ′ may be provided with complementary mating fastening components, such as, e.g., hooks, as fastening components  82 - 84  (in reference to  FIG. 9 ). Such fastening mechanisms are described in U.S. Pat. No. 5,888,607 to Seth et. al issued Mar. 3, 1998, the entire contents of which are herein incorporated by reference. 
     Seams formed utilizing embodiments of the bridging components described herein desirably eliminate the overlapping flaps that the fastening systems of prior art training pants typically include. A prior art fastening system  99  is illustrated in  FIG. 6A  where front side and back side panels  34 , and  134  are shown coupled together via a releasable connection formed between a fastening component  84  provided on the back side panel  134  and a fastening component  82  provided on the front side panel  34 . The nature of the prior art fastening systems creates an overlap  98  with a portion of the back side panel  134  undesirably overlapping a portion of the front (also shown in  FIG. 1 ) thereby imparting a diaper-like look to the training pant. 
     In contrast, as depicted in  FIG. 6B , embodiments of the bridging components of the present invention can be employed to produce low profile seams and aesthetically pleasing butt-joints  100 , with the distal edges  68  of front side and back side panels  34 ,  34 ′,  134 , and  134 ′ (only one side shown) abutted up next to each other 100 so that very little or no overlap is formed between the front side and back side panels  34 ,  34 ′,  134 , and  134 ′. In this embodiments&#39; configuration, the outer surface  110  of front side and back side panels  34 ,  34 ′,  134 , and  134 ′ remain in the same plane even when engaged with the bridging component  86 . In the embodiment shown, bridging component  86  includes a flange  108 , a portion of which is adhered to a portion of the front side panel  34  near the distal edge  68  by adhesive and/or thermal or ultrasonic bonding  101 . A portion of the bridging component  86  bearing fastening members  105  extends past the distal edge  68  of the front side panel  34  for engagement with a fastening component  84  provided on the back side panel  134 . In the embodiment shown, back side panel  134  itself functions as fastening component  84  and is configured to releasably engage the hook type members  105  of the bridging component  86 , for example, with loops (not shown). It will be appreciated that  FIG. 6B  depicts one side of a training pant, a second bridging component and second fastening component would be provided on the opposite side to enclose the training pant around the waist of the wearer. 
       FIG. 8  depicts a training pant  20  with the first and second front side and back side panels  34 ,  34 ′,  134 , and  134 ′ fastened utilizing an embodiment of the bridging component  86  (and  87 ). First and second bridging components  86  and  87  are seen fastened on the inner surface (body side)  28  of the training pant  20 . The majority of the surface area of the bridging components  86  and  87  is concealed (as viewed from outside the pant, if worn by a wearer) by the front side and back side panels  34 ,  34 ′,  134 , and  134 ′. The distal edges  68  of the front and back side panels  34 ,  34 ′,  134 , and  134 ′ are seen to be held in close proximity to each other forming a butt joint. In the embodiment shown, the distal edges  68  do not overlap. However, it should be appreciated that a small amount of overlap may occur without diminishing the low profile seam appearance achieved with use of the bridging components described herein. Even with a small overlap, training pant  20  still resembles underwear, unlike the prior art flap described previously. 
     Training pant  20  can be applied to a child in diaper or pant fashion. To apply in diaper fashion, the side panels are unfastened from the bridging components, which allows the training pant to be opened and laid flat out and the training pant applied to the child in a manner similar to a diaper. To apply in a training pant fashion, i.e., with side panels fastened to bridging components, the child&#39;s legs are placed through the leg openings  52  and the entire pant pulled up around the waist. It will be appreciated that once the training pant  20  is applied to the child, it can be pulled down and up without need for unfastening the front and back side panels  34 ,  34 ′,  134 , and  134 ′. In this regard, the training pant  20  functions like underwear. With the low-profile butt joint achieved with use of the inventive fastening system, the pant also has the appearance of underwear. 
     First and second bridging components  86  and  87  may have sufficient pliability in the transverse and/or longitudinal axes to allow folding and/or bending (shown in  FIG. 7 ) to facilitate automated production of pre-sealed training pants. In  FIG. 7 , bridging component  86  is folded along the longitudinal axis at approximately the centerline  96  (in reference to  FIG. 3 ) such that the fastening members  105  face outward and the bridging component backing  97  faces inward. This creates a first fastening surface  102  and a second fastening surface  103  that are positioned to make fastening connection with the first or second front side or back side panels  34 ,  34 ′,  134 ,  134 ′. It will be appreciated that the way the bridging component is folded is not limiting. The only requirement is that the first and second fastening surfaces  102  and  103  are available to make fastening contact with the front side and back side panels  34 ,  34 ′  134 ,  134 ′. Alternatively, bridging component can be provided pre-fastened to only one of the front side and back side panels  34 ,  34 ′  134 ,  134 ′ or unfastened to any surface of the absorbent articles and instead provided as a discrete component. In these embodiments, the user would seal the training pant  20  prior to placing on a child or could apply the training pant  20  in a fashion like that of a traditional diaper. 
     The folding of bridging component  86  can advantageously be employed in a manufacturing process to provide pre-fastened training pants  20 . The manufacture of diapers and training pants is well known in the art. Briefly, and in reference to  FIG. 8 , training pants are typically start as a continuous web connecting the front waist edge  40  of one pant to the back-waist edge  38  of the adjacent pant. The crotch portion of individual pants are cut, then folded at centerline (shown as dashed line in  FIG. 9 ) in the crotch portion  26 . Bridging components can be provided as a continuous roll, folded, and subsequently cut into the desired dimension at the time of manufacture of the pant. 
     Individual bridging components can be introduced while the training pants are in the unfolded state as shown in  FIG. 9 . Bridging components  86  and  87  should be oriented so that at least one of the first or second fastening surfaces  102  or  103  (in reference to  FIG. 7 ) makes fastening contact with its corresponding mating surface of fastening component  82 ,  83 ,  84 , or  85  on the first or second front side or back side panel  34 ,  34 ′,  134 ,  134 ′. In one embodiment, webbing and/or individual training pant  20  and bridging components  86  and  87  are brought into proximity of each other such the first fastening surface  102  of each of the bridging components  86  and  87  align with the mating surfaces of fastening components  84  and  85  of the front side panels  34  and  34 ′. In the embodiment shown, first surface  102  includes hook type fastening members  105 . In this embodiment, first fastening surface  102  may be releasably attached via hook and loop type fastening. Alternately, first surface  102  may be secured by additional means such as adhesive and/or thermal or ultrasonic bonding. In other embodiments, first surface is provided as a flange  108  (shown in  FIG. 4B ). In these embodiments, flange  108  may be provided without fastening members and be non-releasably attached to mating surfaces by means of adhesive alone or in combination with thermal and/or ultrasonic bonding. 
     With first surfaces  102  thus attached to first and second front side panels  34  and  34 ′, second surfaces  103  of first and second bridging components  86  and  87  are exposed and available for releasable fastening engagement with fastening components  82  and  83  of back side panels  134  and  134 ′. As shown in  FIG. 10 , when training pant  20  is folded at centerline (shown as dashed line in  FIG. 9 ) in crotch portion  26 , fastening components  82  and  83  come into contact with second surfaces  103  of bridging components  86  and  87  and engage to form a pant with two non-overlapping side seams at both sides. At this point, fastened training pants  20  may be packaged. 
     Thus, embodiments of the Absorbent Article With Refastenable Fastening System are disclosed. One skilled in the art will appreciate that the present invention can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation, and the present invention is limited only by the claims that follow.